Fule Booster Module 11.64310-0485 en

Documentation

Fuel Oil Booster Module
Documentation

PROJECT DATA
0B

Customer:
1B MAN Diesel & Turbo SE
Order‐No.:
2B 4500949723
Material‐No.:
3B 11.64310‐0485
Project:
4B 5301770 Kodda, Bangladesh
Manufacturer Project:
5B 131M083‐01_09
Module‐type:
6B FM‐B‐18.0‐B‐50‐1S‐C‐S

CONTENTS
7B

 Operation manual
8B Fuel Oil Booster Module 38 pages
 Appendix A
9B Drawings 62 pages
 Appendix B
10B Documentation of sub‐suppliers 538 pages
Prepared by :
1B O. Wascher
Checked by
12B : M. Lampe
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Documentation
Table of contents

Declaration of Incorporation 5
Residual risks 16
REACh‐Declaration 17
Operating Manual 19
Appendix A 59
A.1 General drawing 61
A.2 Flow diagram 62
A.3 Electrical drawings and list of electrical material 63
A.4 Automation instruction Siemens S7‐1200 / KTP600 95
Appendix B 121
B.1 Manufacturers documentation of main components
 Change over valve, electrically operated END56 AA010 / AA030 123
 Flowmeter END56 CF900 135
 Mixing tank END56 BB010 175
 Booster pumps END56 AP011 / AP012 187
 Heater END56 AC010 239
 Heating medium control valve LBA81 AA010 251
 Viscosity sensor END56 CV010 263
 Indication filter END56 AT040 305
 Pulsation damper END56 BB021 / BB022 355
 DO cooler EGD53 AC020 365
 Change over valve, manually operated END56 AA020 405
 Strainer END56 AT900 / AT910 / AT920 415
B.2 Manufacturers documentation of other components
 Vibration limit switch VEGASWINGS 61 417
 Temperature transmitter PT1000 type MBT 3560 469
 Pressure switch type 900 473
 Steam trap type FT14 481
 Strainer type 23.050 497
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Documentation
 Ball valves
‐ Automatic ball valve with pneumatic actuator type AKP 87E 509
‐ Ball valve type V3NBC, V1 517
‐ Ball valve type 79 523
‐ Ball valve type 020002040002 527
 Non‐return valves
‐ Non‐return valve type SR 20.40‐St 529
‐ Non‐return valve type RK76 559
‐ Non‐return valve type RHDI 573
 Safety valve type SAFE TCP 577
 Globe valve type STOBU 509
 Butterfly valve type GESA 615
 Needle valve type 2221 635
 Sight glass type 880 637
 Thermometer 639
 Pressure gauge 645
 Pressure gauge shock absorber 647
 Pressure gauge and test valve 649
 Pressure gauge valve 651
 Pressure measuring connection 655
 Check valve 657

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Anlage zur Einbauerklärung | Annex to Declaration of Incorporation
gemäß EG-Richtlinie 2006/42/EG, Anhang II, Nr. 1 B | according to EC Directive 2006/42/EC, Annex II, No. 1 B
Beschreibung der grundlegenden Sicherheits- und Gesundheitsschutzanforderungen gemäß

2006/42/EG, Anhang I, die zur Anwendung kommen und eingehalten werden:
Description of essential safety and health protection requirements acc. to 2006/42/EC, Annex I that
are applied and fulfilled:
Zutreffend Applicable Erfüllt Fulfilled

Nr. No. Grundlegende Anforderung Essential requirement
Ja Yes Nein No Ja Yes Nein No
1.1 ALLGEMEINES | REMARKS
1.1.1 Begriffsbestimmungen | Definitions

1.1.2 Grundsätze für die Integration der Sicherheit | Principles of safety integration X X
1.1.3 Materialien und Produkte | Materials and products X X
1.1.4 Beleuchtung | Lighting
Konstruktion der Maschine im Hinblick auf die Handhabung | Design of machinery to
1.1.5 X X
facilitate its handling
1.1.6 Ergonomie | Ergonomics X X
1.1.7 Bedienungsplätze | Operating positions
1.1.8 Sitze | Seating X
STEUERUNGEN UND BEFEHLSEINRICHTUNGEN | CONTROL
1.2
SYSTEMS
Sicherheit und Zuverlässigkeit von Steuerungen | Safety and reliability of control
1.2.1 X X
systems
1.2.2 Stellteile | Control devices X X
1.2.3 Ingangsetzen | Starting X X
1.2.4 Stillsetzen | Stopping X X
1.2.4.1 Normales Stillsetzen | Normal stop X X
1.2.4.2 Betriebsbedingtes Stillsetzen | Operational stop X X
1.2.4.3 Stillsetzen im Notfall | Emergency stop X X
1.2.4.4 Gesamtheit von Maschinen | Assembly of machinery
1.2.5 Wahl der Steuerungs- oder Betriebsarten | Selection of control or operating modes
1.2.6 Störung der Energieversorgung | Failure of the power supply
SCHUTZMASSNAHMEN GEGEN MECHANISCHE GEFÄHRDUNGEN |
1.3
PROTECTION AGAINST MECHANICAL HAZARDS
1.3.1 Risiko des Verlusts der Standsicherheit | Risk of loss of stability X X
1.3.2 Bruchrisiko beim Betrieb | Risk of break-up during operation X X
Risiken durch herabfallende oder herausgeschleuderte Gegenstände | Risks due to
1.3.3 X X
falling or ejected objects
Risiken durch Oberflächen, Kanten und Ecken | Risks due to surfaces, edges or
1.3.4 X X
angles
Risiken durch mehrfach kombinierte Maschinen | Risks related to combined
1.3.5
machinery
Risiken durch Änderung der Verwendungsbedingungen | Risks related to variations in
1.3.6
operating conditions
1.3.7 Risiken durch bewegliche Teile | Risks related to moving parts X X
Wahl der Schutzeinrichtungen gegen Risiken durch bewegliche Teile | Choice of
1.3.8
protection against risks arising from moving parts
1.3.8.1 Bewegliche Teile der Kraftübertragung | Moving transmission parts
Bewegliche Teile, die am Arbeitsprozess beteiligt sind | Moving parts involved in the
1.3.8.2
process
1.3.9 Risiko unkontrollierter Bewegungen | Risks of uncontrolled movements
DeclarationOfIncorporation-Annex_131M083_BoosterModule.doc Seite Page 1 / 2

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Zutreffend Applicable Erfüllt Fulfilled
Nr. No. Grundlegende Anforderung Essential requirement
Ja Yes Nein No Ja Yes Nein No
ANFORDERUNGEN AN SCHUTZEINRICHTUNGEN | REQUIRED

1.4
CHARACTERISTICS OF GUARDS AND PROTECTIVE DEVICES
1.4.1 Allgemeine Anforderungen | General requirements
Besondere Anforderungen an trennende Schutzeinrichtungen | Special requirements
1.4.2
for guards
1.4.2.1 Feststehende trennende Schutzeinrichtungen | Fixed guards
Bewegliche trennende Schutzeinrichtungen mit Verriegelung | Interlocking movable
1.4.2.2
guards
Zugangsbeschränkende verstellbare Schutzeinrichtungen | Adjustable guards
1.4.2.3
restricting access
Besondere Anforderungen an nichttrennende Schutzeinrichtungen | Special
1.4.3
requirements for protective devices
RISIKEN DURCH SONSTIGE GEFÄHRDUNGEN | RISKS DUE TO
1.5
OTHER HAZARDS
1.5.1 Elektrische Energieversorgung | Electricity supply X X
1.5.2 Statische Elektrizität | Static electricity X X
1.5.3 Nichtelektrische Energieversorgung | Energy supply other than electricity X X
1.5.4 Montagefehler | Errors of fitting X X
1.5.5 Extreme Temperaturen | Extreme temperatures X X
1.5.6 Brand | Fire X X
1.5.7 Explosion | Explosion X
1.5.8 Lärm | Noise X
1.5.9 Vibrationen | Vibrations X X
1.5.10 Strahlung | Radiation X
1.5.11 Strahlung von außen | External radiation
1.5.12 Laserstrahlung | Laser radiation X
Emission gefährlicher Werkstoffe und Substanzen | Emissions of hazardous materials
1.5.13 X X
and substances
Risiko, in einer Maschine eingeschlossen zu werden | Risk of being trapped in a
1.5.14 X
machine
1.5.15 Ausrutsch-, Stolper- und Sturzrisiko | Risk of slipping, tripping or falling X X
1.5.16 Blitzschlag | Lightning X X
1.6 INSTANDHALTUNG | MAINTENANCE
1.6.1 Wartung der Maschine | Machinery maintenance X X

Zugang zu den Bedienungsständen und den Eingriffspunkten für die Instandhaltung |
1.6.2 X X
Access to operating positions and servicing points
1.6.3 Trennung von den Energiequellen | Isolation of energy sources X X
1.6.4 Eingriffe des Bedienungspersonals | Operator intervention X X
1.6.5 Reinigung innen liegender Maschinenteile | Cleaning of internal parts X X
1.7 INFORMATIONEN | INFORMATION
Informationen und Warnhinweise an der Maschine | Information and warnings on the

1.7.1 X X
machinery
1.7.1.1 Informationen und Informationseinrichtungen | Information and information devices X X
1.7.1.2 Warneinrichtungen | Warning devices X X
1.7.2 Warnung vor Restrisiken | Warning of residual risks X X
1.7.3 Kennzeichnung der Maschinen | Marking of machinery
1.7.4 Betriebsanleitung | Instructions X X
Allgemeine Grundsätze für die Abfassung der Betriebsanleitung | General principles
1.7.4.1 X X
for the drafting of instructions
1.7.4.2 Inhalt der Betriebsanleitung | Contents of the instructions X X
1.7.4.3 Verkaufsprospekte | Sales literature X X
DeclarationOfIncorporation-Annex_131M083_BoosterModule.doc Seite Page 2 / 2

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EN - Please also pay attention to the entire documentation and operating manual! Machine's Life Cycle
Dis-
Assembly Mainte- assembly
Commis- nance Decommis-
No. 2006/42/EC - Annex I Residual Risks / Information Transport sioning Operation Repair sioning
1 1.1.2 - Principles of safety integration
* no danger from used materials (acc. to REACh)
2 1.1.3 - Materials and products * remains of oil/anticorrosive could be inside the module X X X X X
* possible heavy weight of module/compontents
* observe instructions / see information
3 1.1.5 - Design of machinery to facilitate its handling
* Risk of falling over while lifting of module/components
X X X X
* observed as known; not included in scope of supply

4 1.1.6 - Ergonomics X X X
5 1.2.1 - Safety and reliability of control systems * observe manual / trained staff X X X
* no danger to staff, but possible danger to materials (module/components)
6 1.2.2 - Control devices * observe manual / trained staff X X X
7 1.2.3 - Starting * observe manual / trained staff X X x
8 1.2.4 - Stopping * observe manual / trained staff X X X
9 1.2.4.1 - Normal stop * observe manual / trained staff X X X
10 1.2.4.2 - Operational stop * observe manual / trained staff X X X
11 1.2.4.3 - Emergency stop * observe manual / trained staff X X X
* possible heavy weight of module/compontents
* observe instructions / see information
12 1.3.1 - Risk of loss of stability * Risk of falling over while lifting of module/components X X X X X
* Fix module to the foundation; bored holes prepared
13 1.3.2 - Risk of break-up during operation * module / piping under possible pressure X X X
14 1.3.3 - Risks due to falling or ejected objects * in case of leakage: risk of emission of media under high pressure X X X
* Risk of bumping on module/components/steel profiles
15 1.3.4 - Risks due to surfaces, edges or angles * personal protective equipment (PPE)!!! X X X X X
* Risk of injury by pump/motor du to moving parts (remove power supply first)
* if applicable: check guards/protective deveives before starting
16 1.3.7 - Risks related to moving parts X X X
* danger of electric shock when working on electrical devices / components or improper

cabling
17 1.5.1 - Electricity supply
* Caution when (dis)connecting from power supply
X X X
* possible danger due to EM fields
* earthing screws exist; need to be connected
18 1.5.2 - Static electricity
* mas not responsible for mounting site
X X X
* steam pipe: improper connecting to energy supply (also see technical specification)
19 1.5.3 - Energy supply other than electricity X X
* inaccurate mounted components (pumps) may lead to defects
20 1.5.4 - Errors of fitting X X X
* hot surfaces; insulation installed at time of delivery
* Pumps and motors may heat up during operation
* cool down before maintenance or repair
21 1.5.5 - Extreme temperatures
* hot media may opt out when leakage
X X X X
* flammable media; fire hazard when leakage

22 1.5.6 - Fire * remains or gases can be ignited by improper maintenance X X X
* mowing parts (pumps) and streaming media may lead to vibrations
23 1.5.9 - Vibrations X X
* leakages may occur (big/small amount of media)
24 1.5.13 - Emissions of hazardous materials and substances
* remains of oil/anticorrosive inside the module
X X X X X
* danger of tripping and falling can not be eliminated due to the design
* leakages may occur (big/small amount of media)
25 1.5.15 - Risk of slipping, tripping or falling * to be checked again after incorportion of partly completed machinery into machinery X X X X X
(adjustment of equipment if needed)
* earthing screws exist; need to be connected

26 1.5.16 - Lightning
* mas not responsible for mounting site
X X X
27 1.6.1 - Machinery maintenance * observe manual / trained staff
* observe manual / trained staff
28 1.6.2 - Access to operating positions and servicing points
29 1.6.3 - Isolation of energy sources * observe manual / trained staff

30 1.6.4 - Operator intervention * observe manual / trained staff
31 1.6.5 - Cleaning of internal parts * observe manual / trained staff
* to be checked again after incorportion of partly completed machinery into machinery
32 1.7.1 - Information and warnings on the machinery
* all components/connections have name(numbers) plates in specified languages acc. to

33 1.7.1.1 - Information and information devices
design drawings at time of delivery
* to be checked again after incorportion of partly completed machinery into machinery
34 1.7.1.2 - Warning devices
35 1.7.2 - Warning of residual risks * see Annex to Declaration of Incorporation

36
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Operation Manual
Fuel Oil Booster Module
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mas‐maritime assembly systems GmbH
Zum Dock 3/4
23966 Wismar
Germany

Phone +49 3841 7125‐0
Fax +49 3841 7125‐23

24‐h‐Service‐Hotline +49 3841 7125 21

http://www.mas‐wismar.com
info@mas‐wismar.com

©maritime assembly systems GmbH Edition 01‐2014/SB
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Operation Manual
PROJECT DATA

Customer: MAN Diesel & Turbo SE
Order‐No.: 4500949723
Material‐No.: 11.64310‐0485
Project: 5301770 Kodda, Bangladesh
Manufacturer Project: 131M083‐01_09
Module‐type: FM‐B‐18.0‐B‐50‐1S‐C‐S

WARNING! DANGER TO LIFE FOR PEOPLE WITH PACEMAKERS

Pumps with magnetic coupling are installed on this module. There is a danger to life for
people with pacemakers.
 Under no circumstances may persons with pacemakers perform installation, removal or
connection work, commissioning work, maintenance or repair work.

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Operation Manual
Table of contents

1. GENERAL INFORMATION 6
1.1 Concerning this documentation 6
1.1.1 Copyright 6
1.2 Symbols used 7
1.3 General safety instructions 7
1.4 Standards and guidelines 8

2. TECHNICAL DATA 9
2.1 Identification 9
2.1.1 Module type code 9
2.1.2 Name plate 10
2.2 Operating data 10
2.2.1 Use of the module 10
2.2.2 Application of the fuel oil booster module 10
2.2.3 Technical specifications of the module 11

3. FUNCTIONAL DESCRIPTION 14
3.1 General drawing of the module 14
3.2 Description of the main components 14
3.3 Component list of the module 16

4. TRANSPORT AND STORAGE OF THE MODULE, DISPOSAL OF CONSERVATION MATERIALS 21
4.1 Transport 21
4.2 Storage 21
4.3 Disposal of conservation materials 21

5. INSTALLATION, CONNECTION AND REMOVAL 22
5.1 Installation of the module 22
5.1.1 Information for the assembly of the module 22
5.1.2 Space requirement of the module 22
5.2 Electrical connection of the module 23
5.3 Removal of the module 24
5.3.1 Dismantling level of the module 24
5.3.2 Information for the dismantling of the module 24

6. OPERATION 26
6.1 Start‐up 26
6.1.1 Preparatory steps and putting into operation 26
6.1.2 Putting into DO operation 27
6.1.3. Mixing Tank Level Automatic 29
6.1.3.1 Layout 29
6.1.3.2 Automatic Air Refilling 30
6.1.3.3 LS+ Function 30
6.1.3.4 LS‐ Function 30
6.1.3.5 LS‐ ‐ Function 30
6.1.3.6 Venting valve function 31
6.1.3.7 Refilling valve function 31
6.1.4 Change over to HFO operation 31
6.2 Putting the module out of service 32
6.3 Measures in case of frost danger 32

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7. SERVICING 34
7.1 Maintenance, inspection and repair work 34
7.1.1 Information on maintenance and inspection 34
7.1.2 Inspection intervals 35
7.1.3 Repair work 39
7.2 Replacement parts and customer service address 39
7.2.1 Replacement parts 39
7.2.2 Customer service address 39

8. TROUBLESHOOTING 40

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Operation Manual
1. General information
1.1 Concerning this documentation

This documentation is to be read and understood by all persons who are responsible for using the module
of the mas GmbH and all its points must be observed.

You should carefully read this documentation before initially putting into service because we cannot be
held responsible for any breakdowns and damage to that result in the case of non observance.
Furthermore, we will not assume liability for any injuries resulting from non observance either.

Operating errors on the module can only be avoided by studying this documentation correctly. For this
reason, the documentation should always be accessible to persons responsible and kept near the
module.

This documentation should help you to become familiar with the components of the module and enable
you to understand them. It will provide you with information describing the sequence of events when
starting the module for the first time and for its subsequent operation. This information is listed and noted
under item 6. Operation.

Maintenance, inspection and repair are dealt with under item 7.1 and important and useful information is
provided. You can find information on replacement parts and customer service address under item 7.2.1
and 7.2.2.
In the case of any difficulties, please contact our customer service and replacement parts department or
one of our agencies.

1.1.1 Copyright

The copyright of this documentation remains in the property of mas GmbH.
The sole purpose of this documentation is to instruct and support the staff responsible for installation,
operation and monitoring of the module.

It is prohibited to pass on, duplicate, utilize or to communicate the contents of this documentation unless it
has been expressly permitted. Any persons contravening this are obliged to pay compensation. All rights
reserved in the case of the patent design, registered utility model or registered design entry.
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Operation Manual
1.2 Symbols used

Symbol Meaning

Warning!

Warning! Danger of explosion

Danger! High voltage

Notice for mechanical / electrical installation

1.3 General safety instructions

The module has only been designed for the area of use specified under item 2.2.3 Technical specifications
of the module. Before you use the module for any other purpose than it was designed for, please seek
advice from our customer service (address and phone number under item 7.2.2), because otherwise the
guarantee for the module is rendered invalid!

Particular attention should be paid to the work safety information below:

 The module has been built according to the state‐of‐the‐art and is safe to operate.
However, there is still the possibility of danger occurring with the module if it is misused or
operated by untrained staff. Therefore, the operating staff should read through this documentation
very carefully.
 The operator is recommended to get written confirmation from his operating staff acknowledging
that they have carefully read and understood this documentation.
 The operating staff must ensure that no unauthorized persons work on the module or carry out any
other activity on it.
 Modifications that impair the safety of the module are not permitted. Any modifications carried out
on the module, which impair the safety, must be reported to the manufacturer immediately.
 The operator and his operating staff are obliged to operate the module in perfect condition.
Cleanliness and neatness should always be ensured.
 The module may only be operated, maintained and repaired by trained and authorized staff. To
ensure this, the operating staff must be specially instructed and familiar with this documentation.
 A clear work organisation must be specified for the assembly, dismantling, initial operation, putting
into service and putting out of service as well as for operation and maintenance.
 Suitable work safety measures are to be met with all work on the module.
 The procedures for putting into service and putting out of service stipulated in this document must
always be complied.
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Operation Manual
 Protective gear may only be removed when the respective aggregate has stopped and must always
be reinstalled again before putting into service. Otherwise, the operating staff and/or module could
be put at risk.
 When working on electrical components such as electric motors, control cabinets, control valves or
similar components, these must be switched to a voltage‐free state and protected against being
switched on again without authorization.
 After installing the electrical system or carrying out repair work, the protective measures must
always be checked (e.g. earthing resistance).
 The local safety and accident prevention regulations apply when operating the module.

1.4 Standards and guidelines

This documentation corresponds to the following standards:

 DIN EN 62079 (Preparing of instructions)
 VDI 4500 Part 1 / 2 (Technical documentation: Definitions and legal basics / Organisation and
management)
 DIN‐Fachbericht 146 (Technical product documentation)
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Operation Manual
2. Technical data
2.1 Identification
2.1.1 Module type code

Different modules, as a rule custom‐designed, are available. The type name indicates the execution of the
module for the operation with respect to the requirements.

FM‐SB‐20‐S‐60‐2S‐MDO‐C‐S
1 2 3 4 5 6 7 8 9

1
FM Heavy fuel oil module
FU Heavy fuel oil unit
BM Bio‐fuel oil module
LM Lubricating oil module
CWM Cooling water module
TCM Turbo charger module
DM Diesel oil module
PH Preheating unit
IG Ignition fuel oil module
2
B Booster module
SB Supply and booster module
S Supply module
HT High temperature
LT Low temperature
BO Boiler
R Replenishing
N Nozzle
HE Heat exchanger
3
Capacity of the module (2.4, 4, 8, 12, 20.... in MW)
4
Automatic filter installed on supply or booster side of the module
5
Frequency of the module (50 or 60 Hz)
6
Heater: Number of heaters (1 or 2) and type of heating (steam –S, electric –E, thermal oil –T, hot
water ‐W)
7
MDO‐pump: Number of MDO‐pump (1 or 2)
8
Cooler
9
Standard type of module for engine maker (MAN –M, Caterpillar –C) or special types
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Operation Manual
2.1.2 Name plate

The name plate includes following information:

1 Article No.
2 Weight (Dry)
3 Pos.
4 Year/ Month of Production
5 Ord. No./ Project
6 KKS‐No.
7 Medium
8 Working Pressure
9 Working Temperature

Fig. 1

2.2 Operating data
2.2.1 Use of the module

The module has been conceived, designed and construct according to the requirements and environmental
conditions.

Please note:
 Pipes and aggregates must not be entered.
 The entering of the pre‐heater has to be avoided.
 Do not pull on electrical wires or attach any loads to them.
 Electrical control cabinet must be kept closed provided that they are not being worked on.
 Proceed with caution when using water and others liquids. Otherwise, electrical components will
get damaged.
 Do not leave pipe connections open for a long period of time. Foreign bodies could fall into the
pipes thereby causing damage to the module and its components.
 Proceed with caution when welding; covering the module so that the module does not become
dirtied or damaged.

2.2.2 Application of the fuel oil booster module

The fuel oil booster module is designed to provide the engine with heavy fuel oil (HFO) or diesel oil (DO).
The module is the tool to regulate the values of pressure and viscosity of the FO demanded from the
engine.
The module ensures that the engine supplied all the time with constant pressure, filtration and degassing
and correct injection viscosity.
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Operation Manual
2.2.3 Technical specifications of the module

PROJECT DATA
Main Diesel Engine MAN Diesel SE
engine type 18V51/60
engine max. output [kW] 18,000
total engine max. output [kW] 18,000
nominal fuel consumption + 5% DO [kg/kW*h] 0.196
total fuel oil consumption app. [l/h] 4,200
fuel oil type HFO [cSt at 50°C] 380
fuel oil type DO‐DMB [cSt at 40°C] 2‐11
HFO‐module inlet temperature [°C] 70 ‐ 98
DO‐daily service tank temp. [°C] 5‐45
injection viscosity [cSt] 12 ‐ 14
max. ambient temp. [°C] 55
max. operating temp. [°C] 149
max. operating / test pressure booster side [MPa] 1.6 / 2.4
voltage [V] 415 / 3 phases
frequency [Hz] 50
Module Dimensions see general arrangement drawing
Change Over Valve, electrical operated END56 AA010 461404‐49ev
maker kfm
kvs value [m³/h] 25
with limit switches 49ev
Flowmeter END56 CF900 SVC 10 A1 F1 F1 S1
maker KRACHT
flow rate [l/min] 1 ‐ 100
indication local indication E1
layout differential pressure [MPa] 98°C 40 cSt 0.06
layout differential pressure [MPa] 70°C 80 cSt 0.09
Mixing Tank END56 BB010 200
maker mas GmbH
capacity [l] 200
limit switch HL, LL, LLL VEGASWING 61
operating pressure/test pressure [MPa] 1.0/1.5
max. operating temp. [°C] 150
calculated mixing tank temp. [°C] 122
thermal lost between engine and return to mixing tank [°C] 3
Change Over Valve, manual operated END56 AA020 126ST50 + Tiny
maker Wehlan
with limit switches Tiny
Change Over Valve, electric operated END56 AA030 462405‐49ev
maker kfm
with limit switches 49ev

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Operation Manual
PROJECT DATA
Booster Pumps END56 AP011/012 /‐M ACG 045N8 NMBP, IEC 132
maker IMO
min. capacity HFO [m³/h] 12.7
min. capacity DO [m³/h] 11.0
operating inlet pressure [MPa] 0.4
operating outlet pressure [MPa] 1.0
layout differential pressure [MPa] 0.6
power absorbed at 1000 cSt [KW] 5.84
electric motor power [kW] 7.5
nominal speed [rpm] 2,900
isolation class F
protection class IP55
efficiency class IE2
DO Cooler, plate type EGD53 AC020 S19A‐IG16‐46‐TL‐LIQUID
maker SONDEX
cooling medium LT cooling water
capacity [kW] 61 (73)
DO flow return, assumed 80 % flow booster pumps [m³/h] 8.48
cooler also suitable for 100 % flow booster pumps 10.6 m³/h with
min. 15 % fouling margin
DO inlet temp. app. [°C] 68.4 (67.76)
DO outlet temp. [°C] 54.0
pressure drop at 100 % DO flow [MPa] 0.016(0.018)
cooling water flow [m³/h] 8
cooling water inlet temp. [°C] 51.0
cooling water outlet temp. [°C] 57.7 (58.97)
pressure drop at 100 % CW flow [MPa] 0.008 (0.009)
Heater END56 AC010 MX20/2P T16 L=800
maker Alfa Laval Aalborg A/S
heating medium steam 80 °C (70°C)
max. capacity [kW] 152 (170)
fuel oil flow [m³/h] 12.7
fuel oil inlet temp. [°C] 120 (117)
fuel oil outlet temp. [°C] 142
pressure drop HFO side [MPa] 0.01
fouling margin [%] 10‐20
heating medium flow (steam [kg/h]) 257
heating medium inlet temp. [°C] 175
Heating Medium Control Valve, electrical operated LBA81 AA010 421403‐49ev‐49srüri32‐49v3
maker kfm
with limit switches and 4–20 mA position indication 49ev and RI32
Viscosity Sensor END56 CV010 / 900 ViscoSense2
maker VAF
measuring method torsion pendulum

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PROJECT DATA
Pulsation Damper END56 BB021 / BB022 SM50P‐3,8WA1/116U‐50FCF‐4
maker Hydac
type metal bellow accumulator
damping medium nitrogen
Indication Filter END56 AT040 2.06.5.4 265.500, DDA 4.36.2
maker Boll & Kirch
indicator/alarm DPI/DPA
mesh size [µm] 34

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3. Functional description
3.1 General drawing of the module

Fig. 2 Fig. 3

3.2 Description of the main components

CHANGE OVER VALVE END56 AA010
3/2‐way change over valve, electric operated. The valve is equipped with end position switches for remote
indication (HFO operation / DO operation).

CONSUMPTION MEASURING SYSTEM END56 CF900
Flowmeter for indicating the fuel oil consumption. The flowmeter measures the fuel oil consumption of the
engine. The flowmeter is equipped with strainer, bypass, spring loaded bypass non‐return valve ∆p 0.1 MPa
and closing valves. In case of commissioning install of flowmeter Promass 83F DN25 is possible.

PRESSURE MIXING TANK WITH ACCESSORIES END56 BB010
The unconsumed fuel oil from the engines is brought back through the return line into the mixing tank,
where it is mixed up with fuel oil coming from the day tank. As a result of engine manoeuvring the return
flow may cause a sudden temperature variation, therefore is the mixing tank designed with a precise
capacity to avoid unstable control system and viscosity measurement. Low level alarms will be generated
by a level switch. Automatic degassing valve and automatic air filling valve controlled by LSL are arranged.

3/2‐way change over valve, manual operated. The valve is equipped with end position switches for remote
indication (return flow to service tank / circulating flow to mixing tank).

DO COOLER EGD53 AC020
The DO cooler of plate type is installed in the return line from the engine to the booster module. The
reduction of the DO temperature is necessary whenever the module runs on DO because the engine heats
up the surplus oil which is going back to the module or day‐tank. The cooler is equipped with safety valve
and closing valves.

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3/2‐way change over valve, electric operated. The valve is equipped with end position switches for remote
indication (DO cooler / bypass cooler).

BOOSTER PUMPS END56 AP011 / 012 / ‐M
Screw pumps complete with safety valves for full capacity, as well as non‐return valves, closing valves and
pressure gauges. One pump is working while the other pump is in stand‐by. The pumps are equipped with
magnetic coupling and e‐motors with efficiency class IE2.

HEATER END56 AC010
The installed heater is a shell and tube heat exchanger. The heat exchanger is a counter flow type; the
heated medium is flowing through the shell and the heating medium through the pipes. The heating
medium is steam. The heater is equipped with safety valve, bypass and closing valves.

HEATING MEDIUM CONTROL VALVE LBA81 AA010
Control valve with built‐on positioning drive. The control valve is driven by the output signal of the viscosity
controller and controls the heating medium flow to the fuel oil heater. The valve is equipped with end
position switches for remote indication, with position indication signal 4‐20 mA, bypass and closing valves.

VISCOSITY / TEMPERATURE SENSOR END56 CV010 / 900
The viscosity system is designed to maintain the desired fuel viscosity by regulating the heating medium
control device. The viscosity is shown in cSt and the temperature in °C. The sensor is factory calibrated and
delivers current output signal, proportional to the measured viscosity (4 ‐ 20 mA). The unit is equipped with
closing and bypass valves.

PULSATION DAMPER END56 BB021 / BB022
The damper contains a metal bellows which is welded to its housing and is therefore completely gas‐proof.
It is able to move up and down without any friction or abrasion and improves the damping efficiency.

INDICATION FILTER END56 AT040
The duplex filter is installed to protect downstream parts of the system. The double‐stage switch‐over
mechanism ensures the switch‐over is performed without pressure surges. The construction of the circuit
prevents both filter chambers from being shut down at the same time. One chamber can be regenerated
without interrupting the filtering process.

CONTROL CABINET E1
Cabinet is equipped with power and control circuits, switches, transformers, contactors, colour touch
panel, signal lamps etc. The cabinet is installed at the module and cabled up to the devices on the module.
Power supply and external cables are to make by customer. Sensors and signals acc. customer requirement.
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3.3 Component list of the module

Q’ty Pos. Description Supplier part no. DN PN Supplier or dealer
END56
1 ball valve, V3NBC‐316‐050 V3NBC‐316‐050 50 25 VALTEC
AA900
END56 motor‐control valve kvs 25, three way form, for
1 461404‐49ev 40 16 KFM
AA010 oil, with end switch
EGD51
AA953
EGD51 non‐return valve, wafer type,
1 9800001728 40 16 RITAG
AA954 SR 20.40‐St, DN 40
EGD51 RHDI 1/4"; 0.5 bar VENTEK
1 non‐return valve RHDI 1/4"; 0.5 bar Viton 1/4" 16
AA955 Viton ARMATUREN
EGD51
1 pressure gauge valve MS 1/4" 1516035 1/4" 125 WIKA
AA956
END56
1 glycerin vac. pressure gauge d=63, 0/+1.6 MPa 7021732 1/4" 16 WIKA
CP090
END56 EMIL‐STELLING/
1 pressure gauge shock absorber MS 1/4" 10088021 1/4" 250
CP090 HTI
END56
1 pressure gauge and test valve MS 1/4" DDE5428 1/4" 250 DODEN
CP090
END56 ball valve with locking device,
1 V1‐316‐299‐015‐LD 1/2" 25 VALTEC
AA904 V1‐316‐299‐015‐LD
END65 straight thermometer, 0‐160°C, L1=63x10 mm,
1 3900843 1/2" 16 WIKA
CT090 long version

END56
AA907
END56 DN40, PN40, special DRW
1 strainer, DN 40, steel, special mesh 40 40
AT900 mesh INDUSTRIETECHNIK
END56
1 flowmeter SVC 10 A1 F1 F1 S1 SVC 10 A1 F1 F1 S1 25 25 KRACHT
CF900
END56 non‐return valve, wafer type,
1 9800001728 40 16 RITAG
AA910 SR 20.40‐St, DN 40
END56
AA908
END56
AA905
END56 non‐return valve RK 76 with spring 1000 mbar,
1 RK7640 40 40 GESTRA
AA903 DN 40
END56
AA906

END56
1 mixing tank 200 l 200 l MAS
BB010
END56
1 vibration limit switch VEGASWING 61 SWING61.CAGBVXPNL 3/4" 40 VEGA
CL090
END56
CL900
END56
CL098
1 switch isolator ‐ NAMUR‐ 2 channel, 24V DC KFD2‐SR2‐EX2.W PEPPERL+FUCHS
1 switch isolator ‐ NAMUR‐ 2 channel, 24V DC KFD2‐SR2‐EX2.W PEPPERL+FUCHS
END56
1 safety valve, TCP, set point 1.0 MPa 679610015G1 1/2" 100 ARI
AA903
END56 angle thermometer, 0‐200°C, L1=100x10mm,
1 3901050 1/2" 16 WIKA
CT094 long version
END56
CP091
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CP091 HTI
END56
CP091
1 V1‐316‐299‐020‐LD 3/4" 25 VALTEC
AA902 V1‐316‐299‐020‐LD
END56 3‐way change over ball valve, type 126ST50,
1 126ST50 + Tiny 50 16 WEHLAN
AA020 manually operated, with end switch
1 9800001729 50 16 RITAG
AA901 SR 20.40‐St, DN 50
END56
AA916

1 V1‐316‐299‐020‐LD 3/4" 25 VALTEC
AA917 V1‐316‐299‐020‐LD
END56 AKP 87 E DVGW 3/4"
1 ball valve type AKP 87 E DVGW 3/4" DAE 63 3/4" 16 G. BEE
AA913 DAE 63
END56
1 ball valve (compressed air), 1/4" 020002040002 1/4" 40 DODEN
AAxxx
END56
1 ball valve, V1‐316‐299‐020 V1‐316‐299‐020 3/4" 25 VALTEC
AA912
END56
1 ball valve, V1‐316‐299‐020 V1‐316‐299‐020 3/4" 25 VALTEC
AA911
END56 DRW
1 needle valve type 2221 05, carbon steel 2221 05 3/4" 16
AA914 INDUSTRIETECHNIK
END56 DRW
1 non‐return valve RHDI 3/4"; 1 bar steel RHDI 3/4"; 1 bar steel 3/4" 16
AA915 INDUSTRIETECHNIK

SCB73
1 ball valve (compressed air) 020002040002 1/4" 40 DODEN
AA901
SCB73
1 ball valve type AKP 87 E DVGW 1/2" DAE 42 STV200072250 1/2" 16 G. BEE
AA900
SCB73
AAxxx
SCB73
AAxxx
SCB73
1 pressure gauge valve MS 1/4" 1516035 1/4" 125 WIKA
AA902
SCB73 RHDI 1/4"; 0.5 bar VENTEK
1 non‐return valve RHDI 1/4"; 0.5 bar Viton 1/4" 16
AA903 Viton ARMATUREN

END56
CP092
CP092 HTI
END56
CP092
END56
1 ball valve, type 79 ‐ 50 ‐ 16 79 ‐ 50 ‐ 16 50 16 G. BEE
AA929
1 strainer, DN 50, steel 50 40
END56 ACG 045N8 NMBP,
1 srew pump ACG 045N8 NMBP, IEC 132 50 16 IMO AB
AP011 IEC 132
END56
1 e‐ motor HMA2 132 S2, 2 poles HMA2 132 S2; 2 pole SVEND HOYER
AP011.1
1 9800001729 50 16 RITAG
AA933 SR 20.40‐St, DN 50
END56
AA930
END56
AA931
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1 strainer, DN 50, steel 50 40
END56 ACG 045N8 NMBP,
1 srew pump ACG 045N8 NMBP, IEC 132 50 16 IMO AB
AP012 IEC 132
END56
1 e‐ motor HMA2 132 S2, 2 poles HMA2 132 S2; 2 pole SVEND HOYER
AP012.1
1 9800001729 50 16 RITAG
AA934 SR 20.40‐St, DN 50
END56
AA932
END56
1 pressure switch, pressostat 2...25 bar 900.2380.907 G1/4" TRAFAG
CP095
END56
1 glycerin vac. pressure gauge d=63, 0/+2.5 MPa 7021740 1/4" WIKA
CP096
CP096 HTI
END56
CP096

END56
1 steam heater MX 20/2P T16 L=0800 MX 20/2P T16 L=0800 16 AALBORG
AC010
END56
AA935
END56
AA936
END56
AA937
LCA86
AA900
LCA86 ball valve with locking device,
1 V1‐316‐299‐015‐LD 1/2" 25 VALTEC
AA902 V1‐316‐299‐015‐LD
LCA86 ball valve with locking device,
1 V1‐316‐299‐015‐LD 1/2" 25 VALTEC
AA901 V1‐316‐299‐015‐LD

LBA81 motor‐control valve kvs 16, two way form, for 421403‐49ev‐
1 32 16 KFM
AA010 water and steam 49srüri32‐49v3
LBA81
1 globe valve, straight type, STOBU, DN 25 2200600251 25 16 ARI
AA900
LBA81
AA902
LBA81
AA901
LBA81
AA904
LBA81
AA905
LBA81
AA906
LBA81 G1/4" DIN 3844,
1 check valve G1/4" DIN 3844, series 1 1/4" 16 DODEN
AA9xx series 1
LBA81
1 strainer, y‐pattern, fine screen 250 µm, DN 25 2305000252 25 25 ARI
AT910
LBA81
1 steam trap, FT14‐10 (L‐R), DN 20 FT14‐10 20 16 SPIRAX SARCO
AA903
LBA81 straight thermometer, 0‐200°C, L1=63x10 mm,
1 3900878 1/2" 16 WIKA
CT090 long version
LBA81 EMIL‐STELLING/
CP090 HTI
LBA81
CP090
LBA81
CP090
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END56
1 viscosity sensor ViscoSense2 DN50 VS2 DN50 50 40 VAF
CV010
1 V1‐316‐299‐015‐LD 1/2" 25 VALTEC
AA938 V1‐316‐299‐015‐LD
END56
AA939
END56
AA940
END56
AA941
END56 angle thermometer, 0‐200 °C, L1=63x10 mm,
1 3676235 1/2" 16 WIKA
CT093 short version
END56 temperature transmitter PT 1000
1 084Z4035 1/4'' 16 DANFOSS
CT900 MBT 3560 l= 50mm
END56
CP097
END56
CP097
CP097 HTI

END56 duplex indicator filter 2.06.5.4 265.500, 34 µm, 2.06.5.4 265.500,
1 50 16 BOLL&KIRCH
AT040 with DDA 4.36.2 DDA 4.36.2

END56 metal bellows accumulators as pulsation damper, SM50P‐3,8WA1/116U‐ SAE
1 50 HYDAC
BB021 SM50P‐3,8WA1/116U‐50FCF‐4 (MAN) 50FCF‐4 (MAN) 2"
pressure measuring connection
2 SMK20‐G1/4‐VC‐C6F 1/4" STAUFF
SMK20‐G1/4‐VC‐C6F
1 V1‐316‐299‐015‐LD 1/2" 25 VALTEC
AA946 V1‐316‐299‐015‐LD
END56
CP093
CP093 HTI
END56
CP093
END56
AA942

END56
AA947
END56 metal bellows accumulators as pulsation damper, SM50P‐3,8WA1/116U‐ SAE
1 50 HYDAC
BB022 SM50P‐3,8WA1/116U‐50FCF‐4 (MAN) 50FCF‐4 (MAN) 2"
pressure measuring connection
2 SMK20‐G1/4‐VC‐C6F 1/4" STAUFF
SMK20‐G1/4‐VC‐C6F
END56
CP094
CP094 HTI
END56
CP094
END56 straight thermometer, 0‐200°C, L1=63x10 mm,
1 3900878 1/2" 16 WIKA
CT096 long version

END56 motor‐control valve kvs 27, three way form, for
1 462405‐49ev 50 16 KFM
AA030 oil, with end switch
EGD53 plate heat exchanger, S19A‐IG16‐46‐TL‐
1 65 10 SONDEX
AC020 type S19A‐IG16‐46‐TL‐LIQUID LIQUID
EGD53
AA911
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EGD53 non‐return valve, wafer type,
1 9800001729 50 16 RITAG
AA912 SR 20.40‐St, DN 50
EGD53
AA916
EGD53 ball valve with locking device,
1 V1‐316‐299‐015‐LD 15 25 VALTEC
AA915 V1‐316‐299‐015‐LD
EGD53 ball valve with locking device,
1 V1‐316‐299‐015‐LD 1/2" 25 VALTEC
AA913 V1‐316‐299‐015‐LD
EGD53
AA914
END56
CP099
CP099 HTI
END56
CP099
END56 angle thermometer, 0‐200 °C, L1=63x10 mm,
1 3676235 1/2" 16 WIKA
CT091 short version
MJG32
1 butterfly valve, lug type, GESA, EPDM, DN65 2201300651911 65 16 ARI
AA905
MJG32 straight thermometer, 0‐100°C, L1=63x10 mm,
1 3502945 1/2" 6 WIKA
CT091 short version
MJG32
CP091
MJG32 EMIL‐STELLING/
CP091 HTI
MJG32
CP091
MJG32 ball valve with locking device,
1 V1‐316‐299‐015‐LD 1/2" 25 VALTEC
AA908 V1‐316‐299‐015‐LD
MJG32 non‐return valve, wafer type,
1 9800001730 65 16 RITAG
AA906 SR 20.40‐St, DN 65
MJG32 ball valve with locking device,
1 V1‐316‐299‐015‐LD 1/2" 25 VALTEC
AA909 V1‐316‐299‐015‐LD
MJG32 VENTEK
1 sight glass, type 880, DN 65, PN 16 880 65 16
AA913 ARMATUREN
MJG32
AA910
MJG32 straight thermometer, 0‐100°C, L1=63x10 mm,
1 3502945 1/2" 16 WIKA
CT092 short version
MJG32
CP092
MJG32 EMIL‐STELLING/
CP092 HTI
MJG32
CP092
MJG32
1 butterfly valve, lug type, GESA, EPDM, DN65 2201300651911 65 16 ARI
AA911

1 E1 control cabinet 25862201 MAS

Spare parts
1 LD safety valve, TCP, set point 1.0 MPa 679610015G1 1/2" 100 ARI
1 LD safety valve, TCP, set point 1.6 MPa 679610015G1 1/2" 100 ARI

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4. Transport and storage of the module, disposal of conservation materials
4.1 Transport

The module is delivered fully assembled. Depending on customer requirements, the packing of the module
varies from unpacked up to seaworthy packing including 12 month conservation. Additional single
components like spare parts are stored additionally (see packing list).

WARNING! RISK OF ACCIDENT FROM FALLING LOADS

During transport of the module, accidents may occur due to sizes and weights
 Use correctly proportioned and intact lifting accessories.
 Attach the separate lifting accessories properly to the module.
 Do not stand and do not work under raised loads.
 Wear the appropriate safety equipment and clothing (helmet, protective gloves, safety
shoes).

4.2 Storage

In some cases it is inevitable that the module must be stored for a certain period of time. In this case make
sure that it is stored somewhere dry and clean. A high humidity, salty air etc. will noticeably reduce the life
time. We recommend not exceeding a storage time of 4 months.

WARNING! MATERIAL DAMAGE DUE TO IMPROPER STORAGE

Improper storage will cause damage to the module
 The transport case should not be stored outdoors.
 Protect the module from moisture and contamination during storage.
 Do not store the module below the frost line.

4.3 Disposal of conservation materials

The module is emptied after the test run and only contains another fine film of hydraulic oil on the insides
of the pipes. During transport, small quantities of oil can accumulate at protection caps and cap plugs of
the pipes. It is therefore required to take corresponding precautions before the line be opened to collect
such remnants and dispose of them professionally.

WARNING! ENVIRONMENT DAMAGE THROUGH OIL

Improper disposal of oil could lead to environmental damage
 The environmental regulations of the respective operator country have to be taken into
account.
 Unscrew the counter‐flanges and remove the metal plates/caps which have sealed the
pipes up and dispose of them professionally.
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5. Installation, connection and removal
5.1 Installation of the module

Before installing and assembling the module, the following points should be taken into account:

 The module should be freely accessible from all sides if possible.
 Sufficient height must be available so that there is enough room for the possible removal of
components.
 The module should be provided with a stable foundation or bearing surface.
 The module should stand horizontally.
 The module should stand on the same level as the service tank if possible.

5.1.1 Information for the assembly of the module

Below we have listed some information about the installation and assembly of the module:

 The module must be firmly connected to the base or foundation.

Depending on the position of the module in power house it should be supported to avoid or

reduce vibrations.

 Pipes leading to and from the module must be installed strain‐free.
 Attention should be paid to the pipe diagrams for the module so that pipes are not installed
incorrectly.
 The module must be covered when welding next to it, on it or above it.
 Only clean pipes that have been cleaned on the inside can be connected to the module.

WARNING! MATERIAL DAMAGE DUE TO DIRT

Dirt can damage components on the module and the engine
 Ensure that the pipe system has been cleaned carefully.
If dirt causes damages to the components, this is not a guarantee case!

5.1.2 Space requirement of the module

The module measures are: Length 3,000 mm
Width 1,800 mm
Total height 2,100 mm
Dry Weight /
Max. Maintenance Weight app. 2,400 kg
Operating Weight app. 2,750 kg
Max. Weight app. 3,250 kg

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Additional space is required on three sides of the module for operating and repair work. The clearance
should be at least 600 mm on these sides.

Fig. 4

If changes become necessary, for example at the steel frame of the module, due to the mounting situation
into power house because of pipes of other systems or similar, the company mas GmbH must be consulted
to judge whether problems can occur due to this, for example vibrations on the module.

Please see under Appendix A for the general drawing and flow diagram.

5.2 Electrical connection of the module

DANGER! HIGH VOLTAGE

Risk of death resulting from electric shock
 Only authorized and qualified personnel are allowed to connect the module.
 Make sure that the power supply is disconnected.

The module is completely cabled up to the terminal strips in the control cabinet which is installed at the
module. Power supply and external cables have to be done by customer.

Connect the control cabinet according to the electrical connection drawings.

Please see under Appendix A for the electrical drawings.

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5.3 Removal of the module
5.3.1 Dismantling level of the module

The base frame of the module consists of steel profiles that are welded together and thereby forming a
stable construction. Several vertical steel posts are welded onto this base frame. They support the
mountings for the components.
The individual components are screwed down to their mountings and fastening points by means of bolts
and nuts and are thus easy to dismantle. Supply and drainage pipes are connected to the components by
means of screwed flanges. Each shut‐off device can be disassembled easily because it is located between
two flanges or screwed connections.
The mixing tank together with its floor stand is screwed to the base frame and can also be dismantled. After
this, it is no longer possible to operate the module.

5.3.2 Information for the dismantling of the module

Before starting to dismantle the module, the entire module must be rendered voltage‐free and protected
against being unintentionally switched on.
All pipes leading to and from the module must be shut off. The module must be cooled down and drained.
All module pipes and components must be depressurized.



WARNING! BURNING DANGER BY HOT LIQUIDS

Hot liquids can cause severe burns
 Cool down the system before draining the module.

WARNING! RISK OF PERSONAL INJURY AND PROPERTY DAMAGE

To avoid personal injury and property damage caused by compressed air:
 Wear proper eye protection when disconnect the compressed air supply.
 Disconnect air supply and depressurize all air lines before starting to dismantle the
module.

WARNING! DANGER OF EXPLOSION

Danger of explosion due to combustible residue and its vapours in the pipes and
components
 Do not use gas‐burning equipment or other parting‐off tools that have a thermal effect
during the dismantling on the module.

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When dismantling the components always be aware that these have a heavy deadweight
 Attach the separate lifting accessories properly to the components.
shoes).

WARNING! DANGER OF ENVIRONMENT DAMAGE THROUGH OIL

account.
 When dismantling the module and disposing of the old parts, pay particular attention
that the components that have come into contact with fuels and oils are disposed of
professionally.

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6. Operation
6.1 Start‐up



The module is completely mounted and cabled up to the terminal strips in the control cabinet which is
installed at the module. Power supply and external cables have to be done by customer.
The module is equipped with a PLC which is integrated into the control cabinet. The PLC takes over all
automatic system and rule functions. For the change of parameters, reading operation data and the listing
of alarms this PLC is provided with a display Siemens KTP600 which is installed in the door of the control
cabinet. Please see under Appendix A.

Fig. 5

6.1.1 Preparatory steps and putting into operation

Preparatory steps on electrical parts of the module:

 Put all switches, fuse and motor protection to off or zero.
 Check the internal parts of the electrical cabinet and make sure that there are no foreign objects,
dust and leftovers from the cable mounting.
 Switch on and check the voltage supply for right rotating field, voltage and frequency.
 Check the voltage transformers and the power supply units on the primary and secondary side for
right connection.
 Switch on the main switch.
 Connect the fuses of the current transformer and power supply unit.
 Now check the voltage on the primary and secondary side of the voltage transformer and power
supply unit.
 Switch on the control fuses and switches.

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6.1.2 Putting into DO operation

The module must be completely piped. All mounted pipes are clean.
The module must be started with DO first. Therefore all components have to be put in the right position for
DO operation. The following steps must be taken:

 All drain valves on the module must be closed.
 Take care of the compressed air supply of the module.
 Open all pressure gauge valves.
 Open the valve EGD51 AA953 on DO inlet to the module.
 Set the change over valve END56 AA010 to DO operation.
 The drain valve END56 AA904 must be closed.
 Close the inlet and outlet valves END56 AA907 / AA908 for flowmeter END56 CF900 and open the
valves END56 AA905 / AA906 in bypass line. (In case of commissioning install of Promass 83F is
possible.)
 The drain valve END56 AA902 from mixing tank must be closed.
 Set the change over valve END56 AA020 on return to mixing tank operation.
 Open the inlet valves END56 AA929 / AA931 for the booster pumps END56 AP011/012.
 Open the outlet valves END56 AA930 / AA932 for the booster pumps.
 Open the inlet and outlet valves END56 AA935 / AA936 for the heater END56 AC010. Close the
bypass valve END56 AA937 for the heater.
 The drain valve LCA86 AA902 for the heater must be closed.
 Open the bypass valve END56 AA941 for viscosity sensor END56 CV010 and close the inlet and
outlet valves END56 AA939 / AA940.
 The drain valve END56 AA938 must be closed.
 The drain valves END56 AA952 /AA949 of the duplex filter END56 AT040 must be closed.
 Check that the filter switch‐over mechanism moves easily by switching it several times.
 Put both filter chambers into operation by placing the reversing lever in middle position.
 Open the pressure compensation valve.
 Open the shut‐off valves in the control line to the differential pressure monitoring system of duplex
the filter.
 The valve END56 AA946 must be closed.
 Open the valve END56 AA942 on the module outlet to the engine.
 Open the inlet valve END56 AA947 on return stroke fuel oil from the engine.
 Open the inlet and outlet valves MJG32 AA905 / AA911 for cooling water to the DO cooler
EGD53 AC020. The drain valve MJG32 AA909 must be closed.
 Fill up the water side of the cooler with water. Open the vent valve MJG32 AA908 until water is
coming, then close the vent valve.
 Check the DO cooler of any leakage.
 Open the inlet and outlet valves EGD53 AA911 / AA916 on oil side of the DO cooler. The drain valve
EGD53 AA913 must be closed.
 Set the change over valve END56 AA030 to DO cooler operation.
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Operation Manual
Now the module can be started and filled up with DO:


Hot liquid may be expelled when opening the vent. The hot liquids can cause severe burns
 Proceed with extreme caution.
 Wear the appropriate safety equipment and clothing.
Leaks must be caught immediately. Make sure that expelled liquid is disposed of
properly and in an environmentally friendly manner.

 Fill up the mixing tank with DO. The drain valve END56 AA902 must be closed.
 Open the valve END56 AA916 on the fuel oil outlet to the service tank.
 Open the valve END56 AA917 for manual degassing mixing tank until High Level alarm is coming,
then close this valve.
 Open the valve SCB73 AA905 for compressed air supply to degassing valve END56 AA913. Open the
inlet and outlet valves END56 AA911 / AA912 for degassing valve. The degassing valve is controlled
by Level Switch Low END56 CL098. It is possible to adjust the air flow with the needle valve END56
AA914.
 Open the valve SCB73 AA904 for compressed air supply to the filling valve CSB73 AA900. Open the
inlet and outlet valves CSB73 AA901 / AA902 for the filling valve. The filling valve is controlled by
Level Switch High END56 CL090. It is possible to adjust the air flow with the valve SCB73 AA902.

The description of Mixing Tank Level Automatic see bellow in chapter 6.1.3.

 Fill up the heater END56 AC010 with DO. Open the vent valve LCA86 AA901 for the heater until fuel
oil is coming and then close the vent valve.
 Open slowly the outlet valve END56 AA940 and then the inlet valve END56 AA939 for viscosity
sensor END56 CV010. Check the fuel oil pressure. When the fuel oil pressure is stable, close the
bypass valve END56 AA941 for viscosity sensor.
 Open the vents on the housing cover safety devices of the duplex filter END56 AT040.
 Slowly fill up the filter with DO.
 Close the vents as soon as medium is expelled from the vents without any bubbles.
 Put one of the two filter chambers into operation by shifting the reversing lever. The pressure
compensation valve remains open during operation.

WARNING! DANGER OF MATERIAL DAMAGE

Dry running can damage pump equipment
 Ensure that the pump is filled properly before starting the pump.

 Start the booster pumps END56 AP011/012 in short intervals, switch the pumps on and off and
check the direction of rotation of the motors.
 Vent the pumps.
 Start the booster pump END56 AP011. Control the pressure on the pressure gauge.
 When the pressure is rising, only one booster pump should be in service while other booster pump
remains in standby.
 Slowly open the valve SCB73 AA906 for manual filling of the mixing tank so that an air buffer is
formed in the mixing tank and the fuel level is just above the low level. Then close this valve.
 If the engine runs open slowly the inlet and outlet valves for flowmeter END56 CF900. Check the
pressure on the mixing tank. The bypass valves for flowmeter should be open.
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Operation Manual

Cavitation leads to measuring errors during operation and can destroy the measuring
systems! Pressure shocks must be avoided absolutely to not damage the counters!


Danger of counter damage due to blocked measuring element.
A lack of counter signal (two LEDs in the device plug) may indicate a blockage mechanism.
The resulting increase in pressure before the device can lead to further damage of the
device and / or the system.
 The system must be switched off immediately if the counter signal fails unexpectedly.
 Remove the cause of the disorder.

 Fill up the oil side of the cooler EGD53 AC020 with DO. Open the vent valve EGD53 AA915 on the oil
side of the cooler until fuel oil is coming, then close the vent valve.
 Take care that complete circuit, module and engine must be filled and vented, check for any
leakage.

6.1.3. Mixing Tank Level Automatic

The mixing tank is equipped with 3 level switches for Ex Zone 1. Venting line and compressed air supply line
are equipped with electric pneumatic valves. Both valves are equipped with two end position switches. All
signals are wired to the control cabinet and automatically controlled by the plc. Following automatic
function is provided:

 Venting the mixing tank if fuel level is to low
 Filling up with pressurized air if fuel level is to high
 Prevent the attached pump from dry running
 Alarming each critical or abnormal situation

6.1.3.1 Layout

AA913 Degassing Valve

AA900 Filling Valve

CL090 LS+
Level Switch High
@ 185 Liter

CL098 LS‐
Level Switch Low
@ 125 Liter

CL900 LS‐ ‐
Level Switch LowLow
@ 69 Liter

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Operation Manual
6.1.3.2 Automatic Air Refilling

All 24 h (6 min…99.9 h adjustable) open of compressed air valve AA900 for 30 sec (6 sec…99.9 min
adjustable). This automatic refilling of air should be adjusted very well during the commissioning. Optimal
the level has to reach the LS‐ position on every refilling period. If LS‐ will be activated (dry) the air refilling
will be stopped and the degassing valve will be opened as long as the LS‐ is activated (dry). By this the fuel
level should be always short above LS‐ Level and lost air will be refilled fully automatically.

6.1.3.3 LS+ Function

If level switch becomes active (wet):

 if LS+ is active for 6 sec (6 sec...99.9 min adjustable) generate alarm:
CL090 MIX.T.LEVEL HIGH

6.1.3.4 LS‐ Function

If level switch becomes active (dry):

 close filling valve
 open venting valve (done after filling valve is closed)
 if LS‐ is inactive (wet) close venting valve
 if LS‐ keeps active (dry) for 42 sec (6 sec…99.9 min adjustable) then:
 the booster bump will be stopped
 the degassing valve AA913 valve will be closed
 and following alarms are generated:

MIX.T.DRY RUN PROTECTION
CL098 MIX.T.LEVEL LOW

Reset to be done with local reset button!

6.1.3.5 LS‐ ‐ Function

If level switch becomes active (dry):

 Stop booster pumps hardwired

This function is hard wired and therefore without delay, alarm and reset.

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Operation Manual
6.1.3.6 Venting valve function

With module control in automatic also the venting valve is controlled fully automatically. In this mode the
valve must be in either OPEN or CLOSE position within a maximum travel time of 5 sec. (0...60 sec
adjustable), otherwise an alarm will be generated:

AA900 AIR FILLING VALVE POS.FAIL

The condition of both end positions will be indicated on the touch panel.

6.1.3.7 Refilling valve function

With module control in automatic also the venting valve is controlled fully automatically. In this mode the
valve must be in either OPEN or CLOSE position within a maximum travel time of 5 sec. (0...60 sec
adjustable), otherwise an alarm will be generated:

AA913 DEGASSING VALVE POS.FAIL

The condition of both end positions will be indicated on the touch panel.

6.1.4 Change over to HFO operation

After successful running on DO, the system can change over to HFO operation. Therefore some
components have to be changed:

 Open the valve END56 AA900 on HFO inlet to the module.
 Set the change over valve END56 AA010 to HFO operation.
 Set the change over valve END56 AA030 to bypass cooler operation.
 For putting the heater END56 AC010 in operation, open all valves in the steam and condensate line.

RECOMMENDATION

mas GmbH recommend that the first half year always one and the same pump run in
operation. During this first half year the standby pump must checked of function in short
intervals (fortnightly). After this half year change the pumps every month.


HFO will be viscous without heating and it can cause damages of the components
 When changing from HFO to DO operation, the components which are in bypass
position should also be filled with DO.

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Operation Manual
6.2 Putting the module out of service

For a short shut down of the engine without working on the fuel oil system, the module can keep running
on HFO. If a longer shutdown of the engine or working on the fuel oil systems of the engine is required, you
have to change over to DO and flush the complete module and pipe system; then the module can be
stopped.

Now follow the procedure for putting the module out of service:

 Flush the whole system with DO.
 Flush it again for a while.
 Shut off the booster pump.

6.3 Measures in case of frost danger

The fuel oil will be gumming at low temperatures and it can come to damages at the components.

Before starting to drain the module, the entire module must be rendered voltage‐free and protected
All pipes leading to and from the module must be shut off. All module pipes and components must be
cooled down and depressurized.




 Cool down the system before draining the module.


 Disconnect air supply and depressurize all air lines before draining the module.

Pumps:
 Drain the pumps completely.
 Clean the spindles of the pumps with cleaning petrol.

Flowmeter:
 Drain the flowmeter completely.
 Clean the flowmeter.
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Operation Manual
Mixing tank:
 Drain the mixing tank completely.
 All valves must be open.

Heater with piping and fitting:
 Drain the heater completely.
 Drain steam and condensate lines.
 Drain valve must be open.

Filter:
 Drain the filter completely.
 Clean the filter elements.

Cooler:
 Drain all fuel oil. Drain valve must be open.
 Drain cooling water and keep the outlet cooling water valve open.

Pressure gauges and piping:
 Drain all pipes of the pressure gauges and the valves must be open.

Drain the module completely. Preserve the module with the corrosion prevention means.


Hot liquids escaping from the system through undetected leakages can cause severe burns
 Before you start the module again, close all drain valves and control the complete
system for leakages on piping and fittings.
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Operation Manual
7. Servicing
7.1 Maintenance, inspection and repair work
7.1.1 Information on maintenance and inspection

We have provided you with information on maintenance and inspection below to ensure trouble‐free work
of the module. This should definitely be taken into account.

 The maintenance and inspection intervals stipulated by the manufacturers of the components
are to be observed.
 Non observance of these intervals can result in serious damage to the components, for which we
cannot assume any responsibility.




 During maintenance and inspection work the components to be tested must be switched
off and protected against being unintentionally switched on.

 Only specialist staffs that are familiar with the module should be assigned to carry out
maintenance and inspection work.
 Take your time for this work. Otherwise, you might make mistakes that could have fatal
consequences.


 All drain valves must be closed before maintenance and inspection work.
 When maintenance and servicing, make sure that the components are unpressurized.


 Disconnect air supply and depressurize all air lines on the module before servicing, or
conversion.
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Operation Manual
7.1.2 Inspection intervals

The module must be regular checked for leaks. We recommend a permanent visual check of all
components on the module.
For specified maintenance information of the components see please in operating manuals for these
components. All manufacturer documentations of the components which are installed on the module are
delivered with Appendix B. The specified maintenance intervals are recommendations which are only for
normal conditions.


Valves with seals made of EPDM are installed in cooling water circuit on the module.
Seals made of EPDM will be damaged if exposed to oil or grease.
 Do not use oil additives for corrosion protection in cooling water circuit!

AFTER ONE MONTH OR 1000 OPERATING HOURS
Components Activity Appendix B

Pumps At regular intervals check the pumps and motors both IMO
by looking at it and by listening to it.
Flowmeter The device is basically maintenance‐free. KRACHT
At regular intervals check the flowmeter both by looking
at it and by listening to it.

Heater At regular intervals visual inspection for leaks. Alfa Laval Aalborg

Viscosity system At regular intervals visual inspection to check for leaks VAF

and physical damage.

Duplex filter Regularly check for leaks, for corrosion and other damage, Boll+Kirch

for condition of the filter elements and of all screw
connections.
If the differential pressure reaches the preset maximum
value the filter will have to be cleaned.

Pulsation damper The device is basically maintenance‐free. HYDAC

At regular intervals check the pulsation damper both by
looking at it and by listening to it.

Cooler At regular intervals visual inspection for leaks. SONDEX

y‐strainer At regular intervals remove and clean inside screen. ARI, DRW

Ball valves At regular intervals visual check for leaks. Valtec

Globe valves At regular intervals visual inspection to check for leaks. ARI

Keep the stem well greased.
Electric terminals All screw type terminals have to be retighten.

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Operation Manual
AFTER 1/2 YEAR OR 4000 OPERATING HOURS

Pumps At regular intervals check the pumps and motors both by IMO

Heater At regular intervals visual inspection for leaks. Alfa Laval Aalborg

The heater should be cleaned regularly every six months
by removing the tube insert. Cleaning of the tube system
from the outside using a sharp liquid jet (citric acid or
water). Cleaning of the tube system from the inside is
carried out after removing the cover by flushing the tubes
with e.g. citric acid.


connections.





Ball valves At regular intervals visual check for leaks, replace Valtec

the gasket if necessary.



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Operation Manual
AFTER 1 YEAR OR 8000 OPERATING HOURS




Heater The heater should be cleaned regularly every six months Alfa Laval Aalborg

Once a year the safety valve must be checked for correct
set points.
connections.
Replace all seals when overhauling the filter.




Once a year as a minimum: Check general condition, look
for any signs of leakage. Wipe clean all painted parts and
check surfaces for signs of damage. Check bolts and bars
for rust and clean if necessary. Lightly coat threaded
parts with molybdenum grease or a corrosion inhibitor.


Ball valves At regular intervals visual check for leaks, replace the Valtec

gasket if necessary.


Safety valves At regular intervals visual check for leaks. ARI

Steam trap At regular intervals visual check for leaks. Spirax Sarco

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Operation Manual
AFTER 2 YEARS OR 16000 OPERATING HOURS

Use the 16000 h kit if contained in the scope of supply

Heater The heater should be cleaned regularly every six months Alfa Laval Aalborg

Once a year the safety valve must be checked for correct
set points.


connections. If the differential pressure reaches the
preset maximum value the filter will have to be cleaned.
Replace all seals at least every 2 years and when
overhauling.

Cooler Once a year as a minimum: Check general condition, look SONDEX

for any signs of leakage. Wipe clean all painted parts and
check surfaces for signs of damage. Check bolts and bars
for rust and clean if necessary. Lightly coat threaded parts
with molybdenum grease or a corrosion inhibitor.

y‐strainer At regular intervals remove and clean inside screen. ARI, Krombach

Ball valves At regular intervals visual check for leaks, replace the Valtec

gasket if necessary.


Safety valves At regular intervals visual check for leaks. ARI

Steam trap At regular intervals visual check for leaks. Spirax Sarco

These recommendations apply to a foresighted safe operation and to increase the life preservation of the
components, a permanent visual check of all components is not replaced by it.
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Operation Manual
7.1.3 Repair work

Repair work should generally only be carried out by persons that are familiar with this documentation or by
trained specialist staff.
Before starting the repair work you should check that a set of spares, recommended from manufacturer of
components, and the required wrenches are available.

WARNING!

Only use original replacement parts. Otherwise, any claim for compensation under
guarantee is rendered invalid!

7.2 Replacement parts and customer service address
7.2.1 Replacement parts

To ensure a safe and fast delivery of spare parts, the following details are needed:

Order No. of module (see name plate) : e. g. 131M083‐01
Type of module (see name plate) : e. g. Fuel Oil Booster Module
Name of replacement part : e. g. Safety valve
Pos‐No. (see component list) : e. g. EGD53 AA914
Part‐No. (see component list) : e. g. 679610015G1
Serial‐No. (see name plate of part) : e. g. 300405170

7.2.2 Customer service address

If you have any questions or want to order some replacement parts, please contact one of the following
addresses:

Zum Dock 3/4
23966 Wismar
Germany
Phone +49 3841 7125‐0
Fax +49 3841 7125‐23

Replacement parts department:
Phone +49 40 3070 8668‐3
Fax +49 40 3070 8668‐9
spareparts@mas‐wismar.com

Service department:
24‐h‐Service‐Hotline: +49 3841 7125‐21
Fax: +49 3841 7125‐23
service@mas‐wismar.com
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Operation Manual
8. Troubleshooting

Malfunction can have different causes. For a short number of possible malfunctions we have listed causes
and measures for elimination.

Problem Cause and remedy

No pressure at module inlet Check the valves on module inlet
 open the valves
Check whether there are metal plates/caps left in the supply line
 remove the metal plates/caps
Pressure to low at module Check the valves
outlet  open the valves in the line, if necessary
Check for possible leakages
 pay attention to leakages at valves and connection points. If
necessary, replace parts
Overflow valve of the pump opens during normal operation
 check opening pressure at the overflow valve
Overflow valve leaking
 clean overflow valve and re‐seat, or if defect, replace it
Pressure to high at module Check the valves
outlet  open the valves in the line, if necessary
Viscosity to low/ Check the viscosity system
Temperature to high  clean the viscosity system
 check the set‐point of viscosity system
Steam heating system

 check whether the control valve opens and closes correctly
Viscosity to high/ Check the viscosity system
Temperature to low  check the set‐point of viscosity system
Steam heating system
 check whether the control valve opens and closes correctly
 check whether the heating medium are valves open
 check the steam trap
 check whether the temperature of heating medium is correct
Unexpected start of stand‐by Check the pressure
pump  check whether the pressure is to low
 check pumps for leaks
Both LEDs on flowmeter do not Power failure
light up during operation  check supply cable and fuses
Since it is improbable that both sensors fail at the same time, it must
be assumed that the measuring unit has stopped
 Put the device out of operation immediately!

The device can be dismantled and cleaned.

In case of trouble with components of the module please refer at first to the individual leaflets of the
components. All manufacturer documentations of the components which are installed on the module are
delivered with Appendix B.
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Documentation
Appendix A
A.1 General drawing 1 page
A.2 Flow diagram 1 page
A.3 Electrical drawings and list of electrical material 32 pages
A.4 Automation instruction Siemens S7‐1200 / KTP600 26 pages

59/658
Documentation

60/658
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PROTECTION NOTE ACCORDING TO DIN 34 CONSIDER!
maritime assembly systems GmbH PHONE: +49 (0) 3841 - 7125 - 0

mas maritime assembly systems GmbH Zum Dock 3-4 FAX: +49 (0) 3841 - 7125 - 23
23966 Wismar info@mas-wismar.com
Germany www.mas-wismar.com
CABLE DUCTS: PVC 1309 PPO ...

CLIENT: MAN DIESEL & TURBO SE
5301770 CABINET DOOR HINGED: RIGHT LEFT ...
DOOR FIXING DEVICE: YES NO ...

PROJECT: Kodda, Bangladesh
INTERNAL WIRES TYPE: H07-VK H07-ZK ...
INTERNAL WIRES NUMBERS: SLIDE ON WITHOUT ...

PLANT: FUEL OIL BOOSTER MODULE
END56AP013 POWER MIN.CROSS SECTION: 2,5mm² 1,5mm² ...
CONTROL MIN.CROSS SECTION: 0,75mm² 0,5mm² ...

MAIN DIMENSION (HxWxD): 600x1000x250 CABINET CABLE GLANDS: POLYAMIDE BRASS/Ni ...
COLOR: RAL 7035
OUTSIDE LABEL TYPE: GLUED RIVETED ...
DEGREE OF PROTECTION: IP44
OUTSIDE LABEL LANGUAGE: ENGLISH GERMAN ...
CLASS: CE
VOLTAGE: 415V 50Hz
EXTERNAL POWER CABLE: LKM-HF LKSM-HF ...
NOMINAL POWER: 16kW
EXTERNAL CONTROL CABLE: RFE-HF ...
ORDER No.: 131M083-01_09
FIELD CABLE GLANDS: POLYAMIDE BRASS/Ni ...
CABINET: =E1 CONTROL CABINET CABLE NUMBERS: WITHOUT PLASTIC ...
REVISION: EXTERNAL WIRE NUMBERS: SLIP ON WITHOUT ...
F MOTOR GROUNDING: CABLE LOCAL ...
E
D MIN.AMBIENT TEMPERATURE: 5°C
C MAX.AMBIENT TEMPERATURE: 55°C
B WORKSHOP REVISION 06/14 KK RATED SHORT-TIME WITHSTAND CURRENT I CW: 20kA
A CABLE INFORMATIONS ADDED 03/14 RH MAX.ALTITUDE: 1000m
INDEX MODIFICATION DATE NAME
CLASS APPROVAL REMARK: CUSTOMER APPROVAL REMARK:
CHECK / DATE APPROVAL / STATUS CHECK / DATE APPROVAL / STATUS
print 11.06.2014 Date 25.02.2013 System: =E1

mas MAN DIESEL & TURBO SE
5301770
FUEL OIL BOOSTER MODULE COVER SHEET
Class CE Prep. RH maritime assembly systems GmbH Location: +
END56AP013
Norm DIN40719 Drawn RH Drawing No. Sheet: 1
Kodda, Bangladesh
based on 131M018-11 Check BT Zum Dock 3-4, 23966 Wismar, Germany, +49(0) 3841 7125 -0 63/658
CONTROL CABINET E-1-131M083-01 of: 1
DO NOT SCALE FROM THIS DRAWING! ARRANGEMENT DRAWING

IS ONLY FOR EXAMPLE AND MAY BE CHANGED WITHOUT PRIOR
NOTICE. EXACT DRAWINGS TO BE SPECIALLY REQUESTED!
55 600 250
-U1
MODULE MAX.
-A1-U4-U6
-F1-F2 -U3-U5 -K3 -K20
-T1
-A2 -A3 -A4 -A5

-K40
-P1
-H3
-S0
CENTER HMI
-Q1 -Q2 -Q0 -K1 -K2
-H0 -H1 -S6 -H2 -S7 -S8

1000
-S1 -S2-S3 -S4-S5 -S9-S10
-Q0 -U1-U2
-X5 -X6
-X2
1950
1600
-X3
-X1
-X4
SYMBOLIC GLAND VIEW
FOR DETAILS SEE BOTTOM VIEW
FRONT VIEW LEFT SIDE MOUNTING PLATE
FLOOR LEVEL

5301770
FUEL OIL BOOSTER MODULE FRONT VIEW
END56AP013
Kodda, Bangladesh
CABLE CONNECTED BY YARD
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
415VAC 230VAC L
/2.1
NSGAFöu
11 21
3x1x25mm²
-S0
red 12 22
NSGAFöu
PHASE BUS 1x2x2,5mm²
63A
1 3 5 33 43 1 3 5 33 43
1 3
-Q1 I >I >I >
34 44 -Q2 I >I >I >
34 44 -F1
S202-K1 2 4
/4.2
/2.2
/4.4
/2.4
10-16A 2 4 6 10-16A 2 4 6
H07VK H07VK H07VK

3x1x16mm² 3x1x4mm² 3x1x4mm²
-C1 L1 N PE 1 2 3 4 5
1 2 3 4 5 6 7 8 230V S1 Kx
1 3 5 1 3 5 1 3 5 50/60Hz
-T1
-Q0 -K1 AF16 -K2 AF16 230-600V 31 32 33 34
COOLING UNIT
40A 2x115V
2 4 6 /2.2 2 4 6 /2.4 2 4 6 250VA RITTAL SK 3201.200
1
H07VK H07VK H07VK

-F2 X1
S201-C2 2
3x1x16mm² 3x1x4mm² 3x1x4mm² -H0
white X2
N
/2.1
POWER SUPPLY
PE
/2.1
-X1
35mm² 1 2 3 PE 6mm² 4 5 6 PE 6mm² 7 8 9 PE 2,5mm² 10 11 PE
REMOVE JUMPER
PE WHEN CONNECTED
-W001 -W002
4G2,5mm² BK BN GY GNYE 4G2,5mm² BK BN GY GNYE
M40 M20 M20 M20

BRASS BRASS BRASS BRASS
=E1 U V W PE =E1 U V W PE
+EXT -X? L1 L2 L3 +END56 +END56 +EXT
POWER SUPPLY M M -S0
415V 50Hz 3 3
NOMINAL 27A
-AP011-M01 -AP012-M01
FIELD PROVIDED FUSE: BOOSTER PUMP 1 BOOSTER PUMP 2 EMERGENCY STOP
CLASS G 35A 6,5kW 11,6A 6,5kW 11,6A
* NOT mas SUPPLY *NOT mas SUPPLY

5301770
FUEL OIL BOOSTER MODULE CIRCUIT DIAGRAM
Class CE Prep. RH maritime assembly systems GmbH Location: +INT
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
L 230VAC L
/1.9 /13.1
43 43
-Q1 OVERLOAD TRIP -Q2 OVERLOAD TRIP
/1.3 44 /1.4 44
11 21
-K0 DRY RUNNING PROTECTION -K0 DRY RUNNING PROTECTION
/12.9 12 14 /12.9 22 24
51 51
-K2 PARALLEL RUNNING PROT. -K1 PARALLEL RUNNING PROT.
/2.4 52 /2.2 52
-A1
L L+ 24VDC L+
-S1
ONWS4PB
2 6 10 14
-S1
14
PE
~ /3.1
1 3 5 7 9 11 13 15 /2.2 13 15
1
N
= L- L-
/4.5
/4.5
/2.6
/2.6
/3.1
1-LOCAL MANUAL
2-LOCAL AUTOMATIC L.MAN 230VAC/24VDC
/6.2
OUT: 2,5A
L.AUT
/6.2
21 X2 11 21 X2 11
-S2 -K3 -S4 -K5
red 22 X1 /4.2 12 14 red 22 X1 /4.4 12 14
STOP STOP
/5.2
/5.4
13 X2 13 13 X2 13
-S3 -K1 -S5 -K2
green 14 X1 /2.2 14 green 14 X1 /2.4 14
START START
/5.3
/5.5
A1 A1
-K1 -K2
AF16 A2 AF16 A2
N N
/1.9 /6.2
P1 P2
PE PE
/1.9 /3.1
1 2 1 2
/1.3 3 4 /1.4 3 4
/1.3 /1.4
5 6 5 6
/1.3 /1.4
13 14 13 14
/2.2 /2.4
23 24 23 24
/5.3 /5.5
33 34 33 34
/4.3 /4.5
41 42 41 42
/5.2 /5.4
51 52 51 52
/2.4 /2.2

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
L+ 24VDC L+
/2.9 /4.1
L- L-
/2.9 /4.1
PE PE
/2.9 /4.1
-A2 -A3 -A4 -A5 -P1

L+ M PE L+ M 1M 2M 3L+ 3M L+ M PE 1M 2M L+ M PE L+ M PE L+ M PE
SIEMENS S7-1200 SIEMENS S7-1200 SIEMENS S7-1200 SIEMENS S7-1200 SIEMENS S7-1200
CPU 1214C 24VDC SM 1223 DI 16x14VDC, DO 16x24VDC SM 1222 DO 8x24VDC SM 1234 AI 4x13bit, AQ 2x14bit KTP600
DI0.0 /14.3 FLOW1 PULSES DI0.0 /8.6 COV2 MIXING DQ0.0 /17.3 PUMP 2 RUNNING 0+ AI0.0 /13.3 DYN.VISCOSITY
DI0.1 /14.4 FLOW1 PULSES DI0.1 /8.7 COV2 FLUSHING DQ0.1 /17.4 PUMP 1 FAILURE 0- AI0.0 DYN.VISCOSITY
DI0.2 /4.2 P1 FAILURE DI0.2 /9.6 COV3 BYPASS DQ0.2 /17.5 PUMP 2 FAILURE 1+ AI0.1 /13.5 TEMP.AT VISCO 5,7" LCD-TFT
DI0.3 /4.3 P1 RUNNING DI0.3 /9.6 COV3 COOLER DQ0.3 /17.6 FO VALVE IN MDO 1- AI0.1 TEMP.AT VISCO 320 x 240 PIXEL
DI0.4 /4.4 P2 FAILURE DI0.4 /10.6 COV4 CLOSED DQ0.4 /17.6 FO VALVE IN HFO 2+ AI0.2 /13.7 SPARE AI 256 COLORS
DI0.5 /4.5 P2 RUNNING DI0.5 /10.6 COV4 OPEN DQ0.5 /17.7 HEAT VALVE OPEN 2- AI0.2 SPARE AI TOUCHSCREEN + 6 FUNCTION KEYS
DI0.6 /4.6 AUTOMATIC ON DI0.6 /11.6 COV5 CLOSED DQ0.6 /17.8 HEAT VALVE CLOSED 3+ AI0.3 /6.8 CV1 POSITION
DI0.7 /4.6 PUMP 2 MASTER DI0.7 /11.6 COV5 OPEN DQ0.7 /18.2 COV2 MIXING POS. 3- AI0.3 CV1 POSITION
DI1.0 /4.7 MODULE RESET DI1.0 /12.3 MIXING TANK LSA+ DQ1.0 /18.3 COV2 FLUSHING POS. 0M AQ0.0 /19.6 KIN.VISCOSITY
DI1.1 /5.1 LAMP TEST DI1.1 /12.5 MIXING TANK LSA- DQ1.1 /18.4 COV3 COOLER POS. 0 AQ0.0 KIN.VISCOSITY
DI1.2 /6.6 CV1 CLOSED DI1.2 /12.6 Ex i SPARE DQ1.2 /18.5 COV3 BYPASS POS. 1M AQ0.1 /19.8 TEMPERATURE
DI1.3 /6.6 CV1 OPEN DI1.3 /14.6 FILTER DPAH DQ1.3 /18.6 FILTER DPAH 1 AQ0.1 TEMPERATURE
DI1.4 /7.6 COV1 MDO POSITION DI1.4 /14.7 FILTER DPAHH DQ1.4 /18.6 FILTER DPAHH
DI1.5 /7.6 COV1 HFO POSITION DI1.5 /14.9 PUMP PRESSURE DQ1.5 /18.7 LOCAL AUTO MODE
DI1.6 /15.2 REMOTE START ORDER DQ1.6 /18.8 LOCAL MANUAL MODE ETH1
DI1.7 /15.4 REMOTE HFO ORDER DQ1.7 /19.2 FO COUTER
DQ0.0 /4.2 P1 START/STOP DQ0.0 /8.1 COV2 MIXING

DQ0.1 /4.4 P2 START/STOP DQ0.1 /8.2 COV2 FLUSHING
DQ0.2 /5.7 P1 FAILURE DQ0.2 /9.1 COV3 BYPASS
DQ0.3 /5.8 P2 FAILURE DQ0.3 /9.2 COV3 COOLER
DQ0.4 /6.1 CV1 DECREASE DQ0.4 /10.1 COV4 CLOSE ORDER
DQ0.5 /6.2 CV1 INCREASE DQ0.5 /10.2 COV4 OPEN ORDER
DQ0.6 /7.1 COV1 MDO ORDER DQ0.6 /11.1 COV5 CLOSE ORDER
DQ0.7 /7.2 COV1 HFO ORDER DQ0.7 /11.2 COV5 OPEN ORDER
DQ1.0 /5.6 COMMON ALARM LED DQ1.0 /16.3 STBY START ALARM
DQ1.1 /16.2 COMMON ALARM RLY DQ1.1 /16.4 TEMP.HIGH ALARM
AI0 DQ1.2 /16.5 VISCO HIGH ALARM
AI1 DQ1.3 /16.6 TEMP.LOW ALARM
DQ1.4 /16.6 VISCO LOW ALARM
DQ1.5 /16.7 MIX.TANK LAL
DQ1.6 /16.8 PRESS.LOW
ETH1 DQ1.7 /17.2 PUMP 1 RUNNING

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
L+ 24VDC L+
/3.9 /5.1
0
1
33 33 33 33 10 13 23 13
-Q1 -K1 -Q2 -K2 -S1 -S6 -S7
/1.3 34 /2.2 34 /1.4 34 /2.4 34 /2.2 9 11 C2SS2-10B-20 14 24 black 14
0-PUMP 1 MASTER MODULE RESET
1-PUMP 2 MASTER
-A2 -A2 -A2 -A2 -A2 -A2 -A2

/3.1 /3.1 /3.1 /3.1 /3.1 /3.1 /3.1
DI0.2 DI0.3 DI0.4 DI0.5 DI0.6 DI0.7 DI1.0

P1 FAILURE P1 RUNNING P2 FAILURE P2 RUNNING AUTOMATIC ON PUMP 2 MASTER MODULE RESET
P1 START/STOP P2 START/STOP
DQ0.0 DQ0.1
-A2 -A2
/3.1 /3.1
A1 A1
-K3 -K5
A2 A2
L- L-
/3.9 /5.1
PE PE
/3.9 /5.1
/2.3 14 /2.5 14
12 11 12 11
/2.3 /2.5

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
L+ 24VDC L+
/4.9 /6.1
13 X2
-S8
blue 14 X1
COMMON ALARM LED P1 FAILURE P2 FAILURE
/5.9
DQ1.0 DQ0.2 DQ0.3
41 23 41 23
-K1 -K1 -K2 -K2 -A2 -A2 -A2
/3.1 /3.1 /3.1
/2.2 42 /2.2 24 /2.4 42 /2.4 24
-A2
/3.1
DI1.1 -V1
1 2 3 4 5 6 7 8 9 10 11 12 13 14
LAMP TEST
X1 X1 X1 X1 X1 X1 X1 X1
-S2 red -S3 green -S4 red -S5 green -H1 -H2 -H3 -S8 blue
/2.2 X2 /2.2 X2 /2.4 X2 /2.4 X2 red X2 yellow X2 yellow X2 /5.1 X2
L- L-
/4.9 /6.1
PUMP 1 OFF PUMP 1 ON PUMP 2 OFF PUMP 2 ON COMMON ALARM PUMP 1 FAILURE PUMP 2 FAILURE LAMP TEST
PE PE
/4.9 /6.1

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
L+ 24VDC L+
/5.9 /7.1
L.MAN 230VAC L.MAN

/2.6 /7.2
L.AUT L.AUT
/2.6 /7.2
N N
/2.9 /7.2
-U2.+
/19.4
C3SS2-10B-20
24/14
-S9
23 13 -A2 -A5
1
0
2
/3.1 /3.6
1-OPEN
0-OFF DI1.2 AI0.3 3+ 3-
2-CLOSE DIGITAL INPUT ANALOG INPUT
11
CV1 CLOSED CV1 POSITION
-K7
CV1 DECREASE CV1 INCREASE /6.1 14 12
DIGITAL OUTPUT DIGITAL OUTPUT -A2
DQ0.4 DQ0.5 11 /3.1
-A2 -A2 -K8 DI1.3

/6.2 14 12 DIGITAL INPUT
/3.1 /3.1
CV1 OPEN
A1 A1
-K7 -K8
A2 A2
L- L-
/5.9 /7.1
PE PE
/5.9 /7.1
/6.4 14 /6.4 14
/6.4
12 11
/6.4
12 11 -X2
2,5mm² 1 2 3 PE 4 5 6 7 PE 8 9 PE
-W003 -W004 -W005

2x2x0,75mm² 1 2 3 1 2 3 4 2x2x0,75mm² 1x2x0,75mm² WH BU
WH BU WH WH BU WH BU
M20 M20 M20
BRASS BRASS BRASS
N C O + - - +
=E1 1 2 3 4 5 11 12 13 14 15 16 1 2 3 4
2..10V 24VDC
+LBA81 4..20mA 4..20mA
STEAM ARI RI32

CONTROLL
VALVE
M
CLOSED OPEN
-AA010-M01 -CG920 -CG940 -CG900
-CV1

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
L+ 24VDC L+
/6.9 /8.1
L.MAN 230VAC L.MAN

/6.4 /8.2
L.AUT L.AUT
/6.4 /8.2
N N
/6.4 /8.2
-A2
/3.1
DI1.4
DIGITAL INPUT
11
COV1 MDO POSITION
-K9
COV1 MDO ORDER COV1 HFO ORDER /7.1 14 12
DQ0.6 DQ0.7 11 /3.1
-A2 -A2 -K10 DI1.5

/3.1 /3.1
COV1 HFO POSITION
A1 A1
-K9 -K10
A2 A2
L- L-
/6.9 /8.1
PE PE
/6.9 /8.1
/7.4 14 /7.4 14
/7.4
12 11
/7.4
12 11 -X2
2,5mm² 11 12 13 PE 14 15 16 17 PE
-W006 -W007
2x2x0,75mm² 1 2 3 1 2 3 4 2x2x0,75mm²
M20 M20
BRASS BRASS
N C O
=E1 1 2 3 4 5 11 12 13 14 15 16
+END56
MDO-HFO
CHANGE OVER
VALVE
M
MDO HFO
-AA010-M01 -CG920 -CG940
-COV1

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
L+ 24VDC L+
/7.9 /9.1
L.MAN 230VAC L.MAN

/7.4 /9.2
L.AUT L.AUT
/7.4 /9.2
N N
/7.4 /9.2
-A3
/3.2
DI0.0
DIGITAL INPUT
11
COV2 MIXING
-K11
COV2 MIXING COV2 FLUSHING /8.1 14 12
DQ0.0 DQ0.1 11 /3.2
-A3 -A3 -K12 DI0.1

/3.2 /3.2
COV2 FLUSHING
A1 A1
-K11 -K12
A2 A2
L- L-
/7.9 /9.1
PE PE
/7.9 /9.1
/8.4 14 /8.4 14
/8.4
12 11
/8.4
12 11 -X2
2,5mm² 21 22 23 PE 24 25 PE 26 27 PE
-W009
1 2 3 4 2x2x0,75mm²
WH BU WH BU
M20 M20 M20
BRASS BRASS BRASS
=E1 3 1 2 4 5 6
+END56
-CG960 -CG980
MIXING FLUSHING
POSITION FEEDBACK POSITION FEEDBACK
-COV2

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
L+ 24VDC L+
/8.9 /10.1
L.MAN 230VAC L.MAN

/8.4 /10.2
L.AUT L.AUT
/8.4 /10.2
N N
/8.4 /10.2
C3SS2-10B-20
24/14
-S10
23 13 -A3
1
0
2
/3.2
1-OPEN
0-OFF DI0.2
2-CLOSE DIGITAL INPUT
11
COV3 BYPASS
-K13
COV3 BYPASS COV3 COOLER /9.114 12
DQ0.2 DQ0.3 11 /3.2
-A3 -A3 -K14 DI0.3

/3.2 /3.2
COV3 COOLER
A1 A1
-K13 -K14
A2 A2
L- L-
/8.9 /10.1
PE PE
/8.9 /10.1
/9.4 14 /9.4 14
/9.4
12 11
/9.4
12 11 -X2
2,5mm² 31 32 33 PE 34 35 36 37 PE
-W010 -W011
2x2x0,75mm² 1 2 3 1 2 3 4 2x2x0,75mm²
M20 M20
BRASS BRASS
N C O
=E1 1 2 3 4 5 11 12 13 14 15 16
+END56
COOLER-BYPASS
CHANGE OVER
VALVE
M
BYPASS COOLER
-AA030-M01 -CG820 -CG840
-COV3

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
L+ 24VDC L+
/9.9 /11.1
L.MAN 230VAC L.MAN

/9.4 /11.2
L.AUT L.AUT
/9.4 /11.2
N N
/9.4 /11.2
-A3
/3.2
DI0.4
DIGITAL INPUT
11
COV4 CLOSED
-K15
COV4 CLOSE ORDER COV4 OPEN ORDER /10.1 14 12
DQ0.4 DQ0.5 11 /3.2
-A3 -A3 -K16 DI0.5

/3.2 /3.2
COV4 OPEN
A1 A1
-K15 -K16
A2 A2
L- L-
/9.9 /11.1
PE PE
/9.9 /11.1
/10.4 14 /10.4 14
/10.4
12 11
/10.4
12 11 -X2
2,5mm² 41 42 43 PE 44 45 46 47 PE
-W012 -W013
1x2x0,75mm² 1 2 1 2 3 4 2x2x0,75mm²
WH BU WH BU WH BU
M20 M20
BRASS BRASS
=E1 A1 4 5 6 1 2 3
+SCB73
MIX.TANK ENERGIZED
PRESSURERIZING A2 OPEN
VALVE
CLOSED OPEN
-AA900-Y01 -CG900 -CG920
-COV4

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
L+ 24VDC L+
/10.9 /12.1
L.MAN 230VAC
/10.4
L.AUT
/10.4
N N
/10.4 /13.1
-A3
/3.2
DI0.6
DIGITAL INPUT
11
COV5 CLOSED
-K17
COV5 CLOSE ORDER COV5 OPEN ORDER /11.1 14 12
DQ0.6 DQ0.7 11 /3.2
-A3 -A3 -K18 DI0.7

/3.2 /3.2
COV5 OPEN
A1 A1
-K17 -K18
A2 A2
L- L-
/10.9 /12.1
PE PE
/10.9 /12.1
/11.4 14 /11.4 14
/11.4
12 11
/11.4
12 11 -X2
2,5mm² 48 49 50 PE 51 52 53 54 PE
-W014 -W015
1x2x0,75mm² 1 2 1 2 3 4 2x2x0,75mm²
WH BU WH BU WH BU
M20 M20
BRASS BRASS
=E1 A1 4 5 6 1 2 3
+SCB73
MIX.TANK ENERGIZED
VENTING A2 OPEN
VALVE
CLOSED OPEN
-AA913-Y01 -CG910 -CG930
-COV5

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
L+ 24VDC L+
/11.9 /13.1
-A3 -A3 -A3

/3.2 /3.2 /3.2
DI1.0 DI1.1 DI1.2
DIGITAL INPUT DIGITAL INPUT DIGITAL INPUT
MIXING TANK LSA+ MIXING TANK LSA- Ex i SPARE

OPEN AIR INLET VALVE OPEN VENTING VALVE
CLOSE VENTING VALVE CLOSE PRESS.AIR INLET
DRY RUNNING PROTECTION
-U1 7 8 9 10 11 12 -U2 7 8 9 10 11 12
14 14
15 15
PEPPERL+FUCHS PEPPERL+FUCHS
KFD2-SR2-EX2.W 1+ 3- 4+ 6- KFD2-SR2-EX2.W 1+ 3- 4+ 6-
Ex i
Ex i
A1
-K0
24VDC A2
L- L-
/11.9 /13.1
DRY RUNNING PROTECTION
PE PE
/11.9 /13.1
-X3 /2.2 14
2,5mm² 1 12 11
2 PE 3 4 PE 5 6 PE 7 8 PE /2.2
blue 24
/2.4
22 21
/2.4
-W016 -W017 -W019
1x2x0,75mm² WH BU 1x2x0,75mm² WH BU 1x2x0,75mm² WH BU
blue blue blue
M20 M20 M20 M20
BRASS BRASS BRASS BRASS
=E1 21 13 13
VEGASWING 61
VEGASWING 61
VEGASWING 61
+END56
-CL090 -CL098 -CL900
22 14 14
LSA+ LSA- LSA--
MIXING TANK MIXING TANK MIXING TANK
LEVEL SWITCH LEVEL SWITCH LEVEL SWITCH
Ex i
Ex i
-T1

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
L 230VAC
/2.9
N
/11.4
-A5 -A5 -A5

/3.6 /3.6 /3.6
AI0.0 0+ 0- AI0.1 1+ 1- AI0.2 2+ 2-
ANALOG INPUT ANALOG INPUT ANALOG INPUT
DYN.VISCOSITY TEMP.AT VISCO SPARE AI
L+ 24VDC L+
/12.9 /14.1
L- L-
/12.9 /14.1
PE PE
/12.9 /14.1
-X4
2,5mm² 1 PE 2 3 4 PE 5 6 PE 7 8 PE
-W020
3G1,5mm² BK GNYEBN
-W021 -W022
1x2x0,75mm² 1 2 1x2x0,75mm² 1 2
wh bl wh bl
M16 M20 M20
BRASS BRASS BRASS
=E1 =E1
+END56 1 2 3 1 2 3 4 5 6 +END56 + -
J2 J1 4-20mA
-CV900 L PE N + - + - -CT900
POWER 4-20mA 4-20mA 0-200°C
115-230VAC 0-50cP 0-200°C
TEMPERATURE SENSOR
VAF VISCOSENSE II
AT VISCO SENSOR
-VA1

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
-A2 -A2 -A3 -A3 -A3

/3.1 /3.1 /3.2 /3.2 /3.2
DI0.0 DI0.1 DI1.3 DI1.4 DI1.5
DIGITAL INPUT DIGITAL INPUT DIGITAL INPUT DIGITAL INPUT DIGITAL INPUT
FLOW1 PULSES FLOW1 PULSES FILTER DPAH FILTER DPAHH PUMP PRESSURE
L+ 24VDC L+
/13.9 /15.1
L- L-
/13.9 /15.1
PE PE
/13.9 /15.1
-X4
2,5mm² 9 10 11 12 PE 13 14 15 16 PE 17 18 PE
-W024 -W025 -W026

2x2x0,75mm² 1 2 3 4 2x2x0,75mm² 1 2 3 4 1x2x0,75mm² WH BU
WH BU WH BU WH BU WH BU
M20 M20 M20
BRASS BRASS BRASS
=E1 =E1 =E1

+END56 + K1 K2 - +END56 2 1 3a 3 1a +END56
-CF920 SCV -CP920 P P -CP095 P

KRACHT
FUEL COUNTER 75% 100%
DIFFERENTIAL PRESSURE SWITCH PRESSURE SWITCH
AT DUPLEX FILTER PUMP OUTLET
-FLOW1

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
-A3 -A3
/3.2 /3.2
DI1.6 DI1.7
DIGITAL INPUT DIGITAL INPUT
REMOTE START ORDER REMOTE HFO ORDER
L+ 24VDC L+
/14.9 /16.1
L- L-
/14.9 /16.1
PE PE
/14.9 /16.1
-X5
2,5mm² 1 2 PE 3 4 PE
M20
BRASS
+EXT
OPEN CONTACT = STOP OPEN CONTACT = MDO

CLOSED CONTACT = START CLOSED CONTACT = HFO
REMOTE ORDERS
*NOT mas SUPPLY

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
L+ 24VDC L+
/15.9 /17.1
COMMON ALARM RLY STBY START ALARM TEMP.HIGH ALARM VISCO HIGH ALARM TEMP.LOW ALARM VISCO LOW ALARM MIX.TANK LAL PRESS.LOW
DIGITAL OUTPUT DIGITAL OUTPUT DIGITAL OUTPUT DIGITAL OUTPUT DIGITAL OUTPUT DIGITAL OUTPUT DIGITAL OUTPUT DIGITAL OUTPUT
DQ1.1 DQ1.0 DQ1.1 DQ1.2 DQ1.3 DQ1.4 DQ1.5 DQ1.6
-A2 -A3 -A3 -A3 -A3 -A3 -A3 -A3
/3.1 /3.2 /3.2 /3.2 /3.2 /3.2 /3.2 /3.2
A1 A1 A1 A1 A1 A1 A1 A1
-K19 -K20 -K21 -K22 -K23 -K24 -K25 -K26
A2 A2 A2 A2 A2 A2 A2 A2
L- L-
/15.9 /17.1
/16.2 14 /16.3 14 /16.4 14 /16.4 14 /16.5 14 /16.6 14 /16.7 14 /16.8 14

12 11 12 11 12 11 12 11 12 11 12 11 12 11 12 11
/16.2 /16.3 /16.4 /16.4 /16.5 /16.6 /16.7 /16.8
-K19 11 -K20 11 -K21 11 -K22 11 -K23 11 -K24 11 -K25 11 -K26 11

/16.2 /16.3 /16.4 /16.5 /16.6 /16.6 /16.7 /16.8
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14
PE PE
/15.9 /17.1
-X6
2,5mm² 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
M32
BRASS
+EXT
ALARMS
POTENTIAL FREE (DRY) CONTACTS
NORMALY CLOSED
*NOT mas SUPPLY

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
L+ 24VDC L+
/16.9 /18.1
PUMP 1 RUNNING PUMP 2 RUNNING PUMP 1 FAILURE PUMP 2 FAILURE FO VALVE IN MDO FO VALVE IN HFO HEAT VALVE OPEN HEAT VALVE CLOSED
-A3 -A4 -A4 -A4 -A4 -A4 -A4 -A4
/3.2 /3.5 /3.5 /3.5 /3.5 /3.5 /3.5 /3.5
A1 A1 A1 A1 A1 A1 A1 A1
-K27 -K28 -K29 -K30 -K31 -K32 -K33 -K34
A2 A2 A2 A2 A2 A2 A2 A2
L- L-
/16.9 /18.1
/17.2 14 /17.3 14 /17.4 14 /17.4 14 /17.5 14 /17.6 14 /17.7 14 /17.8 14

12 11 12 11 12 11 12 11 12 11 12 11 12 11 12 11
/17.2 /17.3 /17.4 /17.4 /17.5 /17.6 /17.7 /17.8
-K27 11 -K28 11 -K29 11 -K30 11 -K31 11 -K32 11 -K33 11 -K34 11

/17.2 /17.3 /17.4 /17.5 /17.6 /17.6 /17.7 /17.8
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14
PE PE
/16.9 /18.1
-X6
2,5mm² 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
M32
BRASS
+EXT
REMOTE INDICATIONS
NORMALY OPEN
*NOT mas SUPPLY

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
L+ 24VDC L+
/17.9 /19.1
COV2 MIXING POS. COV2 FLUSHING POS. COV3 COOLER POS. COV3 BYPASS POS. FILTER DPAH FILTER DPAHH LOCAL AUTO MODE LOCAL MANUAL MODE
-A4 -A4 -A4 -A4 -A4 -A4 -A4 -A4
/3.5 /3.5 /3.5 /3.5 /3.5 /3.5 /3.5 /3.5
A1 A1 A1 A1 A1 A1 A1 A1
-K35 -K36 -K37 -K38 -K39 -K40 -K41 -K42
A2 A2 A2 A2 A2 A2 A2 A2
L- L-
/17.9 /19.1
/18.2 14 /18.3 14 /18.4 14 /18.4 14 /18.5 14 /18.6 14 /18.7 14 /18.8 14

12 11 12 11 12 11 12 11 12 11 12 11 12 11 12 11
/18.2 /18.3 /18.4 /18.4 /18.5 /18.6 /18.7 /18.8
-K35 11 -K36 11 -K37 11 -K38 11 -K39 11 -K40 11 -K41 11 -K42 11

/18.2 /18.3 /18.4 /18.5 /18.6 /18.6 /18.7 /18.8
12 14 12 14 12 14 12 14 12 14 12 14 12 14 12 14
PE PE
/17.9 /19.1
-X6
2,5mm² 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48
M32
BRASS
+EXT
REMOTE INDICATIONS
NORMALY OPEN
*NOT mas SUPPLY

5301770
END56AP013
Kodda, Bangladesh
* SUPPLYED BY YARD
1 2 3 4 5 6 7 8 9
FO COUTER KIN.VISCOSITY TEMPERATURE

DIGITAL OUTPUT ANALOG OUTPUT ANALOG OUTPUT
DQ1.7 AQ0.0 0M 0 AQ0.1 1M 1
-A4 -U2.+
-A5 -A5
/3.5 /6.9 /3.6 /3.6
-U3 A2 A1 -U4 C+ D- -U5 C+ D- -U6 C+ D-

0-20mA 0-20mA 0-20mA
IN IN IN
OUT OUT OUT
0-20mA 0-20mA 0-20mA
14 13 F+ E- F+ E- F+ E-
L+ 24VDC
/18.9
L-
/18.9
PE
/18.9
-X6
2,5mm² 49 50 PE 51 52 PE 53 54 PE 55 56 PE
REMOVE JUMPER
WHEN CONNECTED
M20 M20 M20 M20 M32

BRASS BRASS BRASS BRASS BRASS
+EXT - +
FUEL OIL COUNTER TEMP.CONTROL VALVE FUEL OIL VISCOSITY FUEL OIL TEMPERATURE
1PULSE 0..100% 0..50cSt 0..200°C
1LITER 4..20mA 4..20mA 4..20mA
58VDC/100mA
REMOTE INDICATIONS
*NOT mas SUPPLY

5301770
END56AP013
Kodda, Bangladesh
/1.1
/1.1
/1.1
/1.2
/1.3
/1.3
/1.3
/1.3
/1.4
/1.4
/1.4
/1.4
/1.7
/1.7
/1.7
PAGE
SHEET / PATH
2
4
6
2
4
6
2
4
6
2
31
31
31
12
31
INTERNAL
CONNECTION
=E1+INT-X1
-Q0
-Q0
-Q0
-T1
-K1
-K1
-K1
-T1
-K2
-K2
-K2
-T1
-F2
-S0
-T1
INTERNAL
NAME
LINK
1
2
3
4
5
6
7
8
9
PE
GNYE =E1+END56-AP01 PE PE
=E1+END56-AP01 PE PE
10
11
PE
NUMBER
U
V
W
U
V
W
L1
L2
L3
EXTERNAL =E1+END56-AP01
=E1+END56-AP01
=E1+END56-AP01
=E1+END56-AP01
=E1+END56-AP01
=E1+END56-AP01
CONNECTION
STRIP:
=E1+EXT-X?
=E1+EXT-X?
=E1+EXT-X?
=E1+EXT-S0
=E1+EXT-S0
EXTRNAL
NAME
BK
BN
GY
-W001 4G2,5mm²
GNYE
BK
BN
GY
-W002 4G2,5mm²
EXTERNAL CABLE

5301770
FUEL OIL BOOSTER MODULE TERMINAL DIAGRAM
END56AP013
Kodda, Bangladesh
based on 131M018-11 Check BT
Zum Dock 3-4, 23966 Wismar, Germany, +49(0) 3841 7125 -0
84/658
Norm
PAGE
Class
print
EXTERNAL CABLE STRIP: =E1+INT-X2
based on
2
CE
NAME
DIN40719
NAME
LINK
131M018-11
11.06.2014
NUMBER
EXTRNAL
EXTERNAL
INTERNAL
INTERNAL
CONNECTION
CONNECTION
Date
Check
Drawn
Prep.
-W014 1x2x0,75mm²
-W013 2x2x0,75mm²
-W012 1x2x0,75mm²
-W011 2x2x0,75mm²
-W010 2x2x0,75mm²
-W009 2x2x0,75mm²
-W007 2x2x0,75mm²
-W006 2x2x0,75mm²
-W005 1x2x0,75mm²
-W004 2x2x0,75mm²
-W003 2x2x0,75mm²
BT
RH
RH
SHEET / PATH
25.02.2013
1 WH =E1+LBA81-AA01 1 1 -X1 PE /6.4
2 BU =E1+LBA81-AA01 2 2 -S9 13 /6.4
3 WH =E1+LBA81-AA01 3 3 -S9 23 /6.4
-W003 Sh PE -X1 PE /6.4
mas
1 WH =E1+LBA81-CG92 11 4 -A1 L+ /6.5
2 BU =E1+LBA81-CG92 13 5 -A2 DI1.2 /6.5
3 WH =E1+LBA81-CG92 14 6 -A1 L+ /6.5
4 BU =E1+LBA81-CG92 16 7 -A2 DI1.3 /6.6
-W004 Sh PE -X1 PE /6.6
WH =E1+LBA81-CG90 4 8 -A1 L+ /6.7
BU =E1+LBA81-CG90 3 9 -A5 3+ /6.8
-W005 Sh PE -X1 PE /6.8
=E1+END56-AA01 1 11 -X1 PE
maritime assembly systems GmbH

1 WH /7.4

2 BU =E1+END56-AA01 2 12 -K9 14 /7.4
3 WH =E1+END56-AA01 3 13 -K10 14 /7.4
-W006 Sh PE -X1 PE /7.4
1 WH =E1+END56-CG92 11 14 -A1 L+ /7.5
5301770
2 BU =E1+END56-CG92 13 15 -A2 DI1.4 /7.5
3 WH =E1+END56-CG92 14 16 -A1 L+ /7.5
4 BU =E1+END56-CG92 16 17 -A2 DI1.5 /7.6
-W007 Sh PE -X1 PE
Kodda, Bangladesh
/7.6
21 -X1 PE /8.4
MAN DIESEL & TURBO SE
85/658
22 -K11 14 /8.4
23 -K12 14 /8.4
PE -X1 PE /8.4
1 WH =E1+END56-CG96 1 24 -A1 L+ /8.5
2 BU =E1+END56-CG96 2 25 -A3 DI0.0 /8.5
PE -X1 PE /8.5
3 WH =E1+END56-CG98 5 26 -A1 L+ /8.6
4 BU =E1+END56-CG98 6 27 -A3 DI0.1 /8.6
-W009 Sh PE -X1 PE /8.6

1 WH =E1+END56-AA03 1 31 -X1 PE /9.4
2 BU =E1+END56-AA03 2 32 -S10 13 /9.4
END56AP013 3 WH =E1+END56-AA03 3 33 -S10 23 /9.4

-W010 Sh PE -X1 PE /9.4
1 WH =E1+END56-CG82 11 34 -A1 L+ /9.5
CONTROL CABINET
2 BU =E1+END56-CG82 13 35 -A3 DI0.2 /9.5
3 WH =E1+END56-CG82 14 36 -A1 L+ /9.5
4 BU =E1+END56-CG82 16 37 -A3 DI0.3 /9.6
-W011 Sh PE -X1 PE /9.6
FUEL OIL BOOSTER MODULE
1 WH =E1+SCB73-AA90 A2 41 -X1 PE /10.4

42 -K15 14 /10.4
2 BU =E1+SCB73-AA90 A1 43 -K16 14 /10.4
-W012 Sh PE -X1 PE /10.4
1 WH =E1+SCB73-CG90 11 44 -A1 L+ /10.5
2 BU =E1+SCB73-CG90 13 45 -A3 DI0.4 /10.5
3 WH =E1+SCB73-CG90 14 46 -A1 L+ /10.5
4 BU =E1+SCB73-CG90 16 47 -A3 DI0.5 /10.6
Drawing No.
-W013 Sh PE -X1 PE /10.6

=E1+SCB73-AAxx A2 41 -X1 PE
E-1-131M083-01
1 WH /11.4
TERMINAL DIAGRAM
42 -K17 14 /11.4
2 BU =E1+SCB73-AAxx A1 43 -K18 14 /11.4
of:
-W014 Sh PE -X1 PE /11.4

Sheet:
System:
Location: +
8
2
=E1
/11.5
/11.5
/11.5
/11.6
/11.6
PAGE
SHEET / PATH
L+
L+
PE
DI0.6
DI0.7
INTERNAL
CONNECTION
=E1+INT-X2
-A1
-A3
-A1
-A3
-X1
INTERNAL
NAME
LINK
1 WH =E1+SCB73-CGxx 11 44
2 BU =E1+SCB73-CGxx 13 45
3 WH =E1+SCB73-CGxx 14 46
4 BU =E1+SCB73-CGxx 16 47
Sh PE
NUMBER
EXTERNAL
CONNECTION
STRIP:
EXTRNAL
-W015
NAME
-W015 2x2x0,75mm²
EXTERNAL CABLE

5301770
END56AP013
Kodda, Bangladesh
86/658
/12.2
/12.2
/12.3
/12.4
/12.4
/12.4
/12.6
/12.6
/12.6
/12.7
/12.8
/12.8
PAGE
SHEET / PATH
1+
3-
PE
4+
6-
PE
1+
3-
PE
4+
6-
PE
INTERNAL
CONNECTION
=E1+INT-X3
-U1
-U1
-X1
-U1
-U1
-X1
-U2
-U2
-X1
-U2
-U2
-X1
INTERNAL
NAME
LINK
1
2
3
4
5
6
7
8
Sh PE
Sh PE
PE
Sh PE
NUMBER
=E1+END56-CL09 21
=E1+END56-CL09 22
=E1+END56-CL09 13
=E1+END56-CL09 14
=E1+END56-CL90 13
=E1+END56-CL90 14
EXTERNAL
CONNECTION
STRIP:
EXTRNAL
-W016
-W017
-W019
NAME
WH
BU
-W016 1x2x0,75mm² blue

WH
BU

WH
BU

EXTERNAL CABLE

5301770
END56AP013
Kodda, Bangladesh
87/658
Norm
PAGE
Class
print
based on
5
CE
NAME
DIN40719
NAME
LINK
131M018-11
11.06.2014
NUMBER
EXTRNAL
EXTERNAL
INTERNAL
INTERNAL
CONNECTION
CONNECTION
-W020 3G1,5mm²
Date
Check
Drawn
Prep.
-W026 1x2x0,75mm²
-W025 2x2x0,75mm²
-W024 2x2x0,75mm²
-W022 1x2x0,75mm²
-W021 1x2x0,75mm²
BT
RH
RH
SHEET / PATH
25.02.2013
BK =E1+END56-CV90 1 1 -S0 11 /13.1
GNYE =E1+END56-CV90 2 PE -X1 PE /13.1
BN =E1+END56-CV90 3 2 -X1 PE /13.2
1 wh =E1+END56-CV90 1 3 -A5 0+ /13.2
mas
2 bl =E1+END56-CV90 2 4 -A1 L- /13.2
-W021 Sh PE -X1 PE /13.2
1 wh =E1+END56-CT90 + 5 -A1 L+ /13.4
2 bl =E1+END56-CT90 - 6 -A5 1+ /13.4
-W022 Sh PE -X1 PE /13.5
7 -A1 L+ /13.6
8 -A5 2+ /13.6
PE -X1 PE /13.6
=E1+END56-CF92 + 9 -A1 L+

1 WH /14.2

2 BU =E1+END56-CF92 K1 10 -A2 DI0.0 /14.2
3 WH =E1+END56-CF92 K2 11 -A2 DI0.1 /14.2
4 BU =E1+END56-CF92 - 12 -A1 L- /14.2
-W024 Sh PE -X1 PE /14.2
5301770
1 WH =E1+END56-CP92 2 13 -A1 L+ /14.4
2 BU =E1+END56-CP92 1 14 -A3 DI1.4 /14.5
3 WH =E1+END56-CP92 3a 15 -A1 L+ /14.5
=E1+END56-CP92 1a 16 -A3 DI1.3
Kodda, Bangladesh
4 BU /14.5
-W025 Sh PE -X1 PE /14.5
88/658
WH =E1+END56-CP09 Ws 17 -A1 L+ /14.8
BU =E1+END56-CP09 Wc 18 -A3 DI1.5 /14.8
-W026 Sh PE -X1 PE /14.8
END56AP013
CONTROL CABINET
Drawing No.
E-1-131M083-01
TERMINAL DIAGRAM
of:
Sheet:
System:
Location: +
8
5
=E1
/15.2
/15.2
/15.2
/15.3
/15.3
/15.3
PAGE
SHEET / PATH
L+
PE
L+
PE
DI1.6
DI1.7
INTERNAL
CONNECTION
=E1+INT-X5
-A1
-A3
-X1
-A1
-A3
-X1
INTERNAL
NAME
LINK
1
2
3
4
PE
PE
NUMBER
EXTERNAL
CONNECTION
STRIP:
EXTRNAL
NAME
EXTERNAL CABLE

5301770
END56AP013
Kodda, Bangladesh
89/658
Norm
PAGE
Class
print
based on
7
CE
NAME
DIN40719
NAME
LINK
131M018-11
11.06.2014
NUMBER
EXTRNAL
EXTERNAL
INTERNAL
INTERNAL
CONNECTION
CONNECTION
Date
Check
Drawn
Prep.
BT
RH
RH
SHEET / PATH
25.02.2013
1 -K19 14 /16.2
2 -K19 11 /16.2
3 -K20 14 /16.3
4 -K20 11 /16.3
mas
5 -K21 14 /16.4
6 -K21 11 /16.4
7 -K22 14 /16.4
8 -K22 11 /16.5
9 -K23 14 /16.5
10 -K23 11 /16.6
11 -K24 14 /16.6
12 -K24 11 /16.7
13 -K25 14

/16.7

14 -K25 11 /16.8
15 -K26 14 /16.8
16 -K26 11 /16.9
17 -K27 14 /17.2
5301770
18 -K27 11 /17.2
19 -K28 14 /17.3
20 -K28 11 /17.3
21 -K29 14
Kodda, Bangladesh
/17.4
22 -K29 11 /17.4
90/658
23 -K30 14 /17.4
24 -K30 11 /17.5
25 -K31 14 /17.5
26 -K31 11 /17.6
27 -K32 14 /17.6
28 -K32 11 /17.7
29 -K33 14 /17.7
30 -K33 11 /17.8
31 -K34 14 /17.8
32 -K34 11 /17.9
33 -K35 14 /18.2
END56AP013 34 -K35 11 /18.2

35 -K36 14 /18.3
36 -K36 11 /18.3
CONTROL CABINET
37 -K37 14 /18.4
38 -K37 11 /18.4
39 -K38 14 /18.4
40 -K38 11 /18.5
41 -K39 14 /18.5
42 -K39 11 /18.6
43 -K40 14 /18.6
44 -K40 11 /18.7
45 -K41 14 /18.7
46 -K41 11 /18.8
47 -K42 14 /18.8
48 -K42 11 /18.9
Drawing No.
49 -U3 14 /19.2
50 -U3 13
E-1-131M083-01
/19.2
TERMINAL DIAGRAM
PE -X1 PE /19.2
51 -U4 F+ /19.4
of:
52 -U4 E- /19.4
Sheet:
PE -X1 PE /19.4
System:
53 -U5 F+ /19.6
Location: +
8
7
54 -U5 E- /19.6
=E1
PE -X1 PE /19.6
55 -U6 F+ /19.8
/19.8
/19.8
PAGE
SHEET / PATH
E-
PE
INTERNAL
CONNECTION
=E1+INT-X6
-U6
-X1
INTERNAL
NAME
LINK
56
PE
NUMBER
EXTERNAL
CONNECTION
STRIP:
EXTRNAL
NAME
EXTERNAL CABLE

5301770
END56AP013
Kodda, Bangladesh
91/658
No. Qty. Part No. Description Manufacturer Name Page
Norm
Class
print
1 1 6EP1332-2BA20 POWER SUPPLY SITOP PSU100 24VDC 2,5A SIEMENS -A1
based on
2 1 6ES7214-1AE30-0XB0 S7-1200 CPU 1214C 24VDC 14DI/10DO/2AI SIEMENS -A2
CE
3 1 6ES7223-1BL30-0XB0 S7-1200 SM 1223 24VDC 16DI/16DO SIEMENS -A3
4 1 6ES7222-1BH30-0XB0 S7-1200 SM 1222 16DO 24VDC SIEMENS -A4
DIN40719
5 1 6ES7234-4HE30-0XB0 S7-1200 SM 1234 24VDC 4AI/2AO SIEMENS -A5
131M018-11
11.06.2014
6 1 SK 3201.200 COOLING UNIT 100W 230VAC RITTAL -C1
7 1 2CDS252001R0217 MINIATURE CB S202-K1A ABB -F1
Date
8 1 2CDS251001R0024 MINIATURE CB S201-C2A ABB -F2
Check
Drawn
Prep.
9 1 1SFA619402R5235 INDICATOR LAMP LED white 230V ABB -H0
BT
RH
RH
10 1 1SFA619402R5021 INDICATOR LAMP LED red 24V ABB -H1
11 2 1SFA619402R5023 INDICATOR LAMP LED yellow 24V ABB -H2
12 1 788-312 RELAY 24VDC 2W WAGO -K0
25.02.2013
13 2 1SBL177001R1310 CONTACTOR AF16-30-10-13 100-250V50/60Hz/DC ABB -K1
14 4 1SBN010110R1010 AUX.CONTACT CA4-10 1S F.AF9-AF38, N, BC ABB
15 4 1SBN010110R1001 AUX.CONTACT CA4-01 1OE F.AF9-AF38, N,BC ABB
16 38 1SNA645565R0400 RELAY 24VDC 1W ABB -K16
17 1 6AV6647-0AD11-3AX0 S7-1200 KTP600 color SIEMENS -P1
mas
18 1 1SCA104902R1001 DISCONNECTOR OT 40F3 ABB -Q0
19 1 1SCA105296R1001 DISCONNECTOR HANDLE OHYS2AJ OT16-125 Y/R ABB
20 1 1SCA105317R1001 DISCONNECTOR TERMINAL SHROUD OTS40T3 OT16-4 ABB
21 1 1SCA101661R1001 DISCONNECTOR SHAFT OXS6X330 OT16-125 ABB
22 2 1SAM201902R1002 AUX.CONTACT HK1-20 ABB -Q1
23 1 1SFA619550R1051 PUSH BUTTON 2Ö CE4T-10R-02 EMRG.STOP ABB -S0
24 1 1SCA022532R9520 SELECTOR SWITCH 4p 1-2 ONWS4PB ABB -S1
25 2 1SFA619100R1141 PUSH BUTTON 1Ö CP1-11R-01 red iluminated 24 ABB -S2

26 2 1SFA619100R1112 PUSH BUTTON 1S CP1-11G-10 green iluminated ABB -S3

27 1 1SFA619201R1026 SELECTOR SWITCH 2p 0-1 C2SS2-10B-20 ABB -S6
28 1 1SFA619100R1016 PUSH BUTTON 1S CP1-10B-10 black ABB -S7
29 1 1SFA611100R1104 PUSH BUTTON 1S MP1-11G blue iluminated 24VD ABB -S8
30 1 1SFA611605R1100 SELECTOR SWITCH HOLDER FOR 3 ELEMENTS ABB
5301770
31 1 1SFA611610R1001 SELECTOR SWITCH CONTACT BLOCK 1NO ABB
32 1 1SFA611621R1014 SELECTOR SWITCH LED ELEMENT BLUE 24V ABB
33 2 1SFA619211R1026 SELECTOR SWITCH 1p 1-0-2 C3SS2-10B-20 ABB -S9
Kodda, Bangladesh
34 1 SK 3361.100 DOOR POSITION SWITCH RITTAL -S11
35 1 4AM4042-8ED40-0FA0 TRANSFORMER 230-600/2x115V 250 VA SIEMENS -T1
92/658
36 2 KFD2-SR2-Ex2.W ISOLATING AMPLIFIER Ex 24VDC, 1channel PEPPERL+FUCHS -U2
37 1 1SNA645521R2000 OPTICAL CONVERTER OBRIC 0100-24VDC ABB -U3
38 3 1SVR010200R1600 SIGNAL CONVERTER CC-E I/I-1 0-20mA/0-20mA ABB -U5
39 14 280-763/281-410 TERMINAL CAGE CLAMP 3pin gray 2,5 DIODE WAGO -V1
40 1 6220640 CABLE GLAND M40 BRASS 15-27mm SCHLEMMER -W001

43 1 1SAM201906R1012 PHASE BUS PS1-2-1 ABB -X
44 3 1SNA115124R0700 TERMINAL SCREW gray 35/16 ABB -X1
45 2 2006-1207 TERMINAL CAGE CLAMP 2pin gn/ye 6 WAGO -X1
46 18 870-687 TERMINAL CAGE CLAMP 3pin gn/ye 2,5 WAGO -X1
END56AP013 47 24 870-681 TERMINAL CAGE CLAMP 3pin gray 2,5 WAGO -X1
48 6 2006-1201 TERMINAL CAGE CLAMP 2pin gray 6 WAGO -X1
49 1 1SNA165111R1400 TERMINAL SCREW gn/ye 35/16 ABB -X1
CONTROL CABINET
50 20 870-551 TERMINAL CAGE CLAMP 3x2pin gray 2,5 WAGO -X2
51 8 870-684 TERMINAL CAGE CLAMP 3pin blue 2,5 WAGO -X3
52 28 870-501 TERMINAL CAGE CLAMP 2x2pin gray 2,5 WAGO -X6
53 1 22010010 LABEL 20x80x1,5mm, 3color mas-LOGO FLEXIGRAPH -L1
54 1 AE 1090.500 CABINET 1000 x 600 x 250 RAL7035 RITTAL -U1

Drawing No.
APPARATUS
E-1-131M083-01
of:
Sheet:
System:
Location: +
1
1
= =E1
USED INTERNAL EXTERNAL

CABLE TYPE LENGHT CORE'S DESTINATION DESTINATION PAGE /PATH
-W001 LKM-HF 4G2,5 11,0mm 4 =E1+INT-X1 =E1+END56-AP011-M01 BOOSTER PUMP 1 =E1 /1.3
-W002 LKM-HF 4G2,5 11,0mm 4 =E1+INT-X1 =E1+END56-AP012-M01 BOOSTER PUMP 2 =E1 /1.4
-W003 RFE-HF 2x2x0,75 Qu 9,0mm 3 =E1+INT-X2 =E1+LBA81-AA010-M01 STEAM CONTROLL VALVE =E1 /6.4
-W004 RFE-HF 2x2x0,75 Qu 9,0mm 4 =E1+INT-X2 =E1+LBA81-CG920 =E1 /6.5
-W005 RFE-HF 1x2x0,75 7,5mm 2 =E1+INT-X2 =E1+LBA81-CG900 =E1 /6.7
-W006 RFE-HF 2x2x0,75 Qu 9,0mm 3 =E1+INT-X2 =E1+END56-AA010-M01 MDO-HFO CHANGE OVER VALVE =E1 /7.4
-W007 RFE-HF 2x2x0,75 Qu 9,0mm 4 =E1+INT-X2 =E1+END56-CG920 =E1 /7.5
-W009 RFE-HF 2x2x0,75 Qu 9,0mm 4 =E1+INT-X2 =E1+END56-CG980 FLUSHING POSITION FEEDBACK =E1 /8.6
-W010 RFE-HF 2x2x0,75 Qu 9,0mm 3 =E1+INT-X2 =E1+END56-AA030-M01 COOLER-BYPASS CHANGE OVER VALVE =E1 /9.4
-W011 RFE-HF 2x2x0,75 Qu 9,0mm 4 =E1+INT-X2 =E1+END56-CG820 =E1 /9.5
-W012 RFE-HF 1x2x0,75 7,5mm 2 =E1+INT-X2 =E1+SCB73-AA900-Y01 MIX.TANK PRESSURERIZING VALVE =E1 /10.4
-W013 RFE-HF 2x2x0,75 Qu 9,0mm 4 =E1+INT-X2 =E1+SCB73-CG900 =E1 /10.5
-W014 RFE-HF 1x2x0,75 7,5mm 2 =E1+INT-X2 =E1+SCB73-AAxxx-Y01 MIX.TANK VENTING VALVE =E1 /11.4
-W015 RFE-HF 2x2x0,75 Qu 9,0mm 4 =E1+INT-X2 =E1+SCB73-CGxxx =E1 /11.5
-W016 RFE-HF 1x2x0,75 bl 7,5mm 2 =E1+INT-X3 =E1+END56-CL090 MIXING TANK LEVEL SWITCH =E1 /12.2
-W020 LKM-HF 3G1,5 9,0mm 3 =E1+INT-X4 =E1+END56-CV900 VISCOSITY SENSOR =E1 /13.1
-W021 RFE-HF 1x2x0,75 7,5mm 2 =E1+INT-X4 =E1+END56-CV900 VISCOSITY SENSOR =E1 /13.1
-W022 RFE-HF 1x2x0,75 7,5mm 2 =E1+INT-X4 =E1+END56-CT900 TEMPERATURE SENSOR AT VISCO SENSOR =E1 /13.4
-W024 RFE-HF 2x2x0,75 Qu 9,0mm 4 =E1+INT-X4 =E1+END56-CF920 =E1 /14.2
-W025 RFE-HF 2x2x0,75 Qu 9,0mm 4 =E1+INT-X4 =E1+END56-CP920 DIFFERENTIAL PRESSURE SWITCH AT DUPLEX FILTER =E1 /14.4
-W026 RFE-HF 1x2x0,75 7,5mm 2 =E1+INT-X4 =E1+END56-CP095 PRESSURE SWITCH PUMP OUTLET =E1 /14.8

5301770
FUEL OIL BOOSTER MODULE CABLE LISTING
END56AP013
Kodda, Bangladesh
93/658
EG-Konformitätserklärung
EC-Declaration of Conformity
CE-Déclaration de conformité
Erklärung Nr.:
Declaration No.:
Déclaration N°.:
CE-1-131M083-01_23
Wir
We
Nous mas maritime assembly systems GmbH
Name des Anbieters | supplier's name | nom du fournisseur
Diese Konformitätserklärung
entspricht der Europäischen Zum Dock 3
Norm EN 45014
"Allgemeine Kriterien für die
D-23966 Wismar
Konformitätserklärungen von
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Die Grundlage der Kriterien
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ISO/IEC Leitfaden
declare under our sole responsibility that the product(s)
17050-1:2010, déclarons sous notre seule responsabilité, que le(s) produit(s)
"Information on
manufacturer's declaration of
conformity with standards or
other technical specifications"
This Declaration of Conformity CONTROL CABINET E-1-131M083-01_09

is suitable to the European TERMINAL BOX E-1-131M083-21_23
Standard EN 45014
"General criteria for supplier's Bezeichnung, Typ oder Modell, Los-, Chargen- oder Serien-Nr., möglichst Herkunft und Stückzahl
declaration of conformity". name, type or model, batch or serial number, possibly sources and number of items
nom, type ou modèle, N° de lot ou de série, si possible l’origine et guantité
The basis for the criteria has
been found in international
documentation, particularity mit folgenden Europäischen Richtlinien übereinstimmt (übereinstimmen):
in: ISO/IEC Guide
17050-1:2010, is (are) in conformity with the following directives:
"Information on répond (ent) aux directives suivantes:
other technical specifications". Niederspannungsrichtlinie Nr.: 2006/95/EG
Low Voltage Directive No.: 2006/95/EC
Cette Déclaration de Directive Basse Tension N°: 2006/95/CE
conformité correspond à la
norme européenne EN 45014
"Critères généraux pour les EMV Richtlinie Nr.: 2004/108/EG
déclarations de conformité des EMC Directive No.: 2004/108/EC
fournisseurs". Directive CEM N°: 2004/108/CE
La base des critères sont des
documents internationaux, en
particulier le guide Dies wird nachgewiesen durch die Einhaltung folgender Norm(en):
17050-1:2010 ISO/IEC, This is documented by the accordance with the following standard(s):
"Information on Justifié par le respect de la (des) norme(s) suivante(s):
other technical specifications".
DIN EN 60204-1: 2011
DIN EN 61439-1: 2011
Titel und/oder Nummer sowie Ausgabedatum der Norm(en) oder der normativen Dokumente
Title and/or number and date of issue of the standard(s) or other normative document(s)
Titre et/ou numéro et date d’édition de la (des) norme(s) ou autre(s) document(s) nominative(s)
i.A. Andreas Kleedehn i.V. Gerold Vetter

Wismar, 12. Mrz. 2014 Controlling / QM Technischer Leiter | Technical Director
Ort und Datum der Ausstellung Name und Unterschrift oder gleichwertige Kennzeichen des Befugten
Place and date of issue Name and signature or equivalent marking of authorized person
Lieu et date d’édition Nom et signature ou signe équivalent de la personne autorisée
94/658
AUTOMATION INSTRUCTION
Part: module automation

PLC‐type: Siemens S7‐1200

HMI‐type: Siemens KTP400
KTP600

Point of Control: local and/or remote
95/658

This manual is giving general information’s about operating the electrical equipment. The details
are for examples only. The exact design and layout of schemes, pictures and menus depends on
the size of the module and on the number and type of the module main components.
Due to product development this manual as well as the equipment described herein may changed
without further notice.
MANUAL EOM KTP400.doc 2 / 26
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Contents
Cabinet Hardware 4

Manual Operation 6
MAIN SWITCH 6
POWER SUPPLY INDICATION 6
ALARM INDICATION 6
SELCTOR SWITCHES 7
INDICATION LED 7

Automation Hardware 8
TOUCH PANEL 8
CPU 9
SIGNAL MODULES 9
COMMUNICATION MODULES 11

Automation Operation 12
FUNCTION BUTTONS 14
NAVIGATION KEYS 14
STATUS LINE 14

Pictures 15
ALARM LIST 15
MENU 16
OVERVIEW 16
READING 17
PUMP CONTROL 17
PUMP SETTINGS 18
PID CONTROLLER 18
CONTROLLER SETTINGS 19
CONTROLLER LIMITS 19
VALVE CONTROL 20
OTHER SETTINGS 20
CONSUMPTION 20
CONSUMPTION SETTINGS 21
AUTOFILTER 21
AUTOFILTER SETTINGS 22
HISTORY 22
TREND 23
SYSTEM SETTINGS 23
MODBUS SETTINGS 24
I/O SETTINGS, OPTIONS 24
CHANGING OF VALUES 25
97/658
Cabinet Hardware
All electrical components are assembled in standard industrial cabinets. Redundant parts are divided in
different cabinets or in different sections of one cabinet.

Front View Mounting Plate
Every cabinet is labeled with information’s about the cabinet name, the nominal voltage and frequency of
the main power supply and the system number.

98/658

All electrical units are tagged with an identifier according to DIN 40719. This will allow to indentify every
component and to refer to the correct object in the electrical drawing.
99/658
Manual Operation
The basic operation of the modules is made by the control elements on the cabinet doors. These elements
are labeled with clear text and easy to understand.
MAIN SWITCH
The main switch is designed as a main disconnector. All main power supplies for the cabinet are equipped
with such a switch. Normally the cabinet door cannot be opened if the main switch is in position on.

Auxiliary supplies for trace heating or remote control may not be switched off by the main switch.
POWER SUPPLY INDICATION
The POWER SUPPLY LED indicates that the power feeder is alive, the main switch is switched on, the fuses
are ok and the emergency stop is not active.

Dangerous voltage may be present also if POWER SUPPLY LED is off.

ALARM INDICATION
Abnormal conditions, warnings and alarms are signalized by a red LED. This will give a fast indication about
the module status:
 no alarm: LED off
 not acknowledged alarms: LED flashes
 acknowledged alarms, pending: LED steady

100/658
SELCTOR SWITCHES
For main and important functions a manual control is realized by use of selector switches. These switches
are normally in operation also if the automation systems failed.

INDICATION LED
Main and important functions are indicated individual from the automation system.

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Automation Hardware
The module automation is made by a programmable logic controller (plc). The plc components S7‐1200 are
combined according to the module requirements. Please refer to the electrical drawings for details about
your system setup.

Example for an assembled unit
TOUCH PANEL
All automatic functions are realized with a PLC which can be controlled by touching the Panel directly and
by using the 4 (КТР400) or 6 (КТР600) separate push buttons.

KTP400 KTP600
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CPU
The main component and part of every system is the CPU. It contains the processor, the memory, the
program and as well some inputs and outputs. The CPU is also equipped with an RJ45 Ethernet port for
programming and communicating with other systems.

CPU 1214C CPU 1214C
SIGNAL MODULES
If more inputs and outputs are needed the system can be extended by different signal modules. These
modules are available for digital and analog signals.

Signal Module 1221 8DC Signal Module 1221 8DC

Signal Module 1222 8 RLY Signal Module 1222 8 RLY
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Signal Module 1222 16 RLY Signal Module 1222 16 RLY

Signal Module 1223 16DC16DC Signal Module 1223 16DC16DC

Signal Module 1223 16DC16RLY Signal Module 1223 16DC16RLY
104/658

Signal Module 1234 4AI2AO Signal Module 1234 4AI2AO
COMMUNICATION MODULES
For intercommunication with other systems different communication modules are available.

Communication Module 1241 RS232 Communication Module 1241 R485

Compact Switch 1277
105/658
Automation Operation
All process data, values, parameters and conditions are shown on a number of different pictures and pages.
Most of these pages can be called directly from the main menu which is always available by pressing the
[MENU] button. Number and Contents of pictures depends on module and project type.

KTP400
106/658

KTP600
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FUNCTION BUTTONS
The function buttons below the touch screen are always available for the same function.
F1 F2 F3 F4
MENU HISTO ALARM ACK
KTP400

F1 F2 F3 F4 F5 F6
MENU STATUS TREND HISTORY ALARMS ACK
KTP600
 MENU: change to the MENU picture
 STATUS: change to the system P&ID picture
 TREND: change to the TREND picture
 HISTORY: change to HISTORY picture
 ALARMS: change to ALARM LIST picture
 ACK : acknowledgement of the last alarm
NAVIGATION KEYS
The upper right corner in all pictures is used to offer a different set of soft key for navigation.
The “compass” key will call then MENU picture.
The “arrow” key will call to the last viewed picture.
Individual keys for calling different setting pages are available in relation to the
actual picture.
STATUS LINE
The lowest line of the touch screen is used to indicate the most important readings at any time. The line
above will display the latest alarm (if any). By this the main module condition can be checked without
changing to other pictures
KTP400

KTP600
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Pictures
Number and contents of pictures depends on module and project type. This may be changed without
further notice.
ALARM LIST
Additional to the red LED the alarms are given in clear text messages. These messages are visible in the
status line of every page or in the ALARM LIST. The ALARM LIST picture is always available by pressing
button F3 / F5 [ALARMS].

KTP400 KTP600
The alarm‐list is sorted twice:
 1st according to the status: Not acknowledged before acknowledged messages.
nd
 2 according to the time stamp: Newest on top.

The first alarm in the list is marked with a "Q" and can be acknowledged with the touch key [Quit] or with
the push button [ACK]. With the arrow keys the alarm‐list can be scrolled. The headline gives following
additional information:
 "LIVE" Newest alarm is visible.
 "SCROLLED" List is scrolled down and newest alarm is not visible.
 "UQ" Number of unacknowledged alarms.
 “Q" Number of acknowledged but active alarms.

Every single alarm must be acknowledged with the push button F4 / F6 [ACK] or with the touch
key [QUIT] at the “ALARM LIST” picture
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MENU

KTP400 KTP600
The MENU picture gives an overview about the available main pictures and allows calling these pictures
directly.
OVERVIEW

KTP400 KTP600
This picture is based on the system P&ID and gives an overview about position and status of the main
components. Two pictures are used for larger systems. The dynamic elements are colored according to
their condition. By touching the symbols the corresponding detail picture will be called.
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READING

KTP400 KTP600
The most important readings are displayed in bar graphs with a color according to the condition. Dotted
line represents the actual alarm limits. Touching the bar graph will call the corresponding control picture.
Also the statuses of the important pumps are indicated. Touching a pump will call the PUMP CONTROL
picture.

This picture will be automatically activated after 4 minutes of panel inactivity.
PUMP CONTROL

KTP400 KTP600

This picture is used to control the pumps. A pump can be selected for running by touching the
corresponding touch key [P1: START P2: STANDBY] or [P2: START P1: STAND BY]. The other pump will set to
“Standby” automatically. A pump changeover will be performed with changeover time. A “Stand‐By‐Start”
must be reset by pressing the touch key [RESET STBY] which is available after a standby start.
For each pair of pumps an individual picture is available.

Both selector switches on the manual pump control must be switched to “Automatic“ position.
Otherwise the control from the touch panel and the automatic functions are disabled.
Acknowledging of the “stand by start” alarm will not reset the standby function.
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PUMP SETTINGS

KTP400 KTP600

This picture allows adjusting the pump automatic function by setting the parameter:
 PRESSURE LOW LIMIT (bar): low pressure limit to start the standby pump
 PRESSURE BUILD UP TIME (sec): delay time for the pressure monitoring after pump start
 STAND BY START DELAY TIME (sec): delay time for standby start after pressure drops below
start limit
 CHANGE OVER TIME (sec): delay time for stopping the faulty pump

For each pair of pumps an individual picture is available.
PID CONTROLLER

KTP400 KTP600

For different values PID controller are implemented. This can be temperature, viscosity or pressure. For
each controller a set of pictures is available. The CONTROLLER picture is for the main operation and
indications like:
 switching from manual to automatic,
 changing the controller modes,
 controlling the actuator manually,
 changing the set point and
 checking the status
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CONTROLLER SETTINGS

KTP400 KTP600
The CONTROLLER SETTING picture contains the basic settings for the controller performance
 P, I, D performance adjustment
 INV output characteristics direct or inverted
 T ON (ON TIME) is the maximum length of an output signal
 T OFF (OFF TIME) is the minimum break time between two output signals
 DEAD BAND range, around the set point, where the output signals are suppressed
CONTROLLER LIMITS

KTP400 KTP600
The CONTROLLER LIMIT picture contains settings which are related to the controller functions. These are

limits for the alarms and additional values. Especially for the combined Viscosity‐Temperature Controller
more complex parameters are needed.
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VALVE CONTROL

KTP400 KTP600
All information and touch keys for change over valves are combined on VALVE CONTROL pictures. For each
controlled or indicated valve an individual picture is available.
OTHER SETTINGS

KTP400 KTP600
In this picture contains times, limits and values, which cannot be assigned to other objects.
CONSUMPTION

KTP400 KTP600
Also for flow counters or for a set of flow counters an individual picture is available.
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CONSUMPTION SETTINGS

KTP400 KTP600
 K‐Factor: manufacturer value (depends on the counter type)
 Filter‐Factor: for damping the input signal
 CYCLES: number of pulses for calculating the actual consumption
(higher value gives higher accuracy but longer refresh times)
 TIME OUT: maximum time between 2 pulses, otherwise the actual consumption is set to zero
AUTOFILTER

KTP400 KTP600
This picture contains operating and indication objects for the automatic filter.
The “FLUSH” button is only available if the delay time between two flushes is running.
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AUTOFILTER SETTINGS

KTP400 KTP600
This picture is used to adjust the automatic filter function:
 INTERVAL TIME: time between two flashes
 VENTING TIME: venting before flushing
 FLUSHING TIME flushing
 RECOVERY TIME time after flushing for refilling the flushed chamber
HISTORY

KTP400 KTP600
The HISTORY stores the last 255 alarms and messages. The oldest entries will be replaced by newer alarms
or messages (First In ‐ First Out)
 LIVE: last entry is visible
 SCROLLED: list is scrolled down.
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TREND

KTP400 KTP600
The trend stores and represents some process values of the last 2.5 hours with a sample rate of 10 seconds.
The touch keys are for adjusting of the display.
SYSTEM SETTINGS

KTP400 KTP600
 CLEAN PICTURE: disable touch functions for 30 seconds
 RUN, STOP: changing system time is possible when time is stopped
 TOUCH CALIB: for adjusting of the touch area, if the touch screen is not responding
properly (password protected)
 SYSTEM: permits access to the configuration settings and MODBUS setting
picture (password protected)
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MODBUS SETTINGS

KTP400 KTP600
The serial interface is made with 8 data bits and 1 stop bit. This is not adjustable. All other parameter can
be changed according to master requirements.
To activate changed values, the PLC must be started again (switch off and on the power).

For the MODBUS register addresses see document “PLC‐SIGNAL‐LIST” of the actual project.
I/O SETTINGS, OPTIONS

KTP400 KTP600
These settings are password protected too, and normally correct adjusted on the test bed. Please contact
the mas GmbH service for further assistance.
118/658
CHANGING OF VALUES

To edit the different values a KEY PAD, a NUM PAD or a DROPDOWN LIST will be displayed.
KEY PAD NUM PAD DROPDOWN LIST

Changed parameters are automatically stored in the PLC EEPROM (fail safe)!

Changed parameter becomes effective immediately. Be sure, that no persons or devices are
endangered.
119/658
Zum Dock 3/4
23966 Wismar
Germany

Phone +49 3841 7125‐0
Fax +49 3841 7125‐23



120/658
Documentation
Appendix B
B.1 Manufacturers documentation of main components

 Change over valve, electrically operated END56 AA010 / AA030 register 1
 Flowmeter END56 CF900 register 2
 Mixing tank END56 BB010 register 3
 Booster pumps END56 AP011 / AP012 register 4
 Heater END56 AC010 register 5
 Heating medium control valve LBA81 AA010 register 6
 Viscosity sensor END56 CV010 register 7
 Indication filter END56 AT040 register 8
 Pulsation damper END56 BB021 / BB022 register 9
 DO cooler EGD53 AC020 register 10
 Change over valve, manually operated END56 AA020 register 11
 Strainer END56 AT900 / AT910 / AT920 register 12
B.2 Manufacturers documentation of other components

 Vibration limit switch VEGASWINGS 61 register 13
 Temperature transmitter PT1000 type MBT 3560 register 14
 Pressure switch type 900 register 15
 Steam trap type FT14 register 16
 Strainer type 23.050 register 17
 Ball valves register 18
‐ Automatic ball valve with pneumatic actuator type AKP 87E
‐ Ball valve type V3NBC, V1
‐ Ball valve type 79
‐ Ball valve type 020002040002
 Non‐return valves register 19
‐ Non‐return valve type SR 20.40‐St
‐ Non‐return valve type RK76
‐ Non‐return valve type RHDI
 Safety valve type SAFE TCP register 20
 Globe valve type STOBU register 21
 Butterfly valve type GESA register 22
 Needle valve type 2221 register 23
1/2
121/658
Documentation
 Sight glass type 880 register 24

 Thermometer register 25
 Pressure gauge register 26
 Pressure gauge shock absorber register 27
 Pressure gauge and test valve register 28
 Pressure gauge valve register 29
 Pressure measuring connection register 30
 Check valve register 31

2/2
122/658
Motor control valve in three way form 461 4/5.. E
with bellow sealing Page 1 of 2
EN-GJS-400-18-LT (GGG-40.3), PN 16/25
Body: EN-GJS-400-18-LT (GGG-40.3), three way form

for heat transfer oil, as mixing valve
(diverted purpose restricted, see page 038 990)
Pressure range: PN 16, PN 25
Immersion length acc. to DIN EN 558, basic series 1
Flanges acc. to DIN EN 1092-2 type 21
Spindle sealing: double wall bellow
and safety stuffing box
Internal parts: stainless steel, replaceable seat rings
Flow characteristic: linear
Positioning ratio: 50:1
Leakage: < 0,01% Kvs
Actuator: with manual emergency operation

and load dependent limit switches
Thrust: 2000 N
Power input: 12 VA
Alternatively: 4000 N / 28 VA (appendix ...c)
5500 N / 28 VA (appendix ...d)
Power supply: 230V/50...60Hz
Optionally: 115V/50...60Hz, 24V/50...60Hz, 24VDC
Motor rating standard acc. to DIN EN 60034-1: S1 – 100%
Protection class acc. to DIN EN 60529: IP65
Accessories, special types:

Add. limit switches load dependent (see page 49e)
Add. signal switches travel dependent (see page 49w)
Feedback potentiometer (see page 49f)
Integrated positioner (see page 49sr)
Integrated process controller (see page 49r)
Feedback signal 4-20mA / 0-10V
Actuator heater (on request)
Other positioning speed (on request)
Other Kvs- values (on request)
Weld-on ends (on request)
Flange drillings acc. to ANSI / JIS (on request)
Order text:
Motor control valve in three way form, with mixing plug
EN-GJS-400-18-LT (GGG-40.3), PN . ., DN . ., Kvs . . .
Spindle sealing with bellow
Power supply . . ., closing pressure . . . bar
List-No. 461 . . . , accessories . . .
Pressure-temperature ratings acc. to DIN EN 1092-2:

by: -10…120 150 200 250 300 350 °C
PN 16 16 15,5 14,7 13,9 12,8 11,2 bar
PN 25 25 24,3 23 21,8 20 17,5 bar
DN List-No. Kvs Stroke Pos. time Closing pressure* (bar)

PN 16 PN 25 m³/h mm sec 2000N 4000N 5500N
15 461 400. 461 500. 4 20 66 25,0
20 461 401. 461 501. 6,3 20 66 25,0
25 461 402. 461 502. 10 20 66 25,0
32 461 403. 461 503. 16 20 66 17,3 25,0
40 461 404. 461 504. 25 20 66 10,8 25,0
50 461 405. 461 505. 40 20 66 6,6 16,0 23,0
65 461 406. 461 506. 63 30 100 3,4 9,1 13,3
80 461 408. 461 508. 100 30 100 2,0 5,8 8,6
100 461 410. 461 510. 160 30 100 1,1 3,5 5,4
125 461 412. 461 512. 230 35 116 2,1 3,3
150 461 415. 330 38 126 1,3 2,1
* higher closing pressure and bigger DN on request
data subject to alteration 4615_e.doc 1009522

123/658
Motor control valve in three way form 461 4/5.. E
with bellow sealing Page 2 of 2
EN-GJS-400-18-LT (GGG-40.3), PN 16/25
ø153
Place required
Actuator type: 145 to replace
2,0 kN: 4e1235 (with 49sr5 or 49r: 190) the bonnet
4,0 kN: 4e1435
5,5 kN: 4e1635
Bonnet
Motor
Limit switch
Gear
Spring plate unit H*
Spindle (actuator)
Hand wheel
Mounting rod
Stuffing box
staggered
drawn
Spindle with bellow
Mixing plug
AB
A
H1
B
Valve body type: 6a61...
L
DN 15 20 25 32 40 50 65 80 100 125 150

Height H* 661 675 669 676 681 683 813 814 821 924 940
Stud length H1 65 70 75 80 90 100 120 130 150 200 210
Length L 130 150 160 180 200 230 290 310 350 400 480
Weight kg 16 17 18 21 22 25 44 48 62 116 137
* = add. 45mm for actuators with positioner 49sr5 or controller 49r
Electrical wiring:
Basic version: Accessories** (optionally):

230/115/24 V 50...60 Hz 24 V DC
M Limit switch Potentiometer Signal switch Heater

M U load dependent travel dependent
for position: A-AB
OPEN CLOSE
1 2 3 4 5 1 2 3 4 5 6 11 12 13 14 15 16 21 22 23 24 25 26 31 32 33 34 35 36 40 41
N L L L+ L- L+ L-
L on 2 = A-AB opens 24V on 1/2 = A-AB closes ** = for actuators with positioner 49sr5 or controller 49r
L on 3 = A-AB closes 24V on 3/4 = A-AB opens see electrical wiring on page 49sr5 or 49r

124/658
Parts list vg61-t E
Control valve in three way form, type 61, GGG-40.3, PN16/25 Page 1 of 2
01
02
03
04
05
06
07
08
09
10
A AB
11
12
No.• Designation• Part-No.•

01• Screw joint 6a61sv
02 Safety stuffing box 6a61st
03 Pin 6a61vss
04 Mounting bonnet 6a61vd..
05 Spindle with bellow 6a61sf..
06 Studs with hexagon nuts 6a61ss..
07 Gasket 6a61dd..
08 Lock washer 6a61ssc
09 Upper seat ring 6a61so..
10 Lower spindle with plug 6a61ks
11 Lower seat ring 6a61su..
12 Valve body 6a61vg..
data subject to alteration VG61-TE.DOC / 0105508

125/658
Motor control valve for diverting function 462 4/5.. E
three way form with bellow sealing
EN-GJS-400-18-LT (GGG-40.3), PN 16/25
Body: EN-GJS-400-18-LT (GGG-40.3), three way form

Version with diverting plug, for heat transfer oil
Spindle sealing: double wall bellow
and safety stuffing box
Flow characteristic: linear

Thrust: 2000 N
Power input: 12 VA

Other kvs- values (on request)
Order text:
Motor control valve in three way form, with diverting plug
EN-GJS-400-18-LT (GGG-40.3), PN . ., DN . ., kvs . . .
Spindle sealing with bellow

by: -10…120 150 200 250 300 350 °C
PN 16 16 15,5 14,7 13,9 12,8 11,2 bar
PN 25 25 24,3 23 21,8 20 17,5 bar

PN 16 PN 25 m³/h mm sec 2000N 4000N 5500N
32 462 403. 462 503. 12 20 66 17,3 25,0
40 462 404. 462 504. 20 20 66 10,8 25,0
50 462 405. 462 505. 27 20 66 6,6 16,0 23,0
65 462 406. 462 506. 50 30 100 3,4 9,1 13,3
80 462 408. 462 508. 83 30 100 2,0 5,8 8,6
100 462 410. 462 510. 123 30 100 1,1 3,5 5,4
125 462 412. 462 512. 190 35 116 3,5 5,4
150 462 415. 250 35 116 2,3 3,6
* see page 462He/f/h for higher closing pressure

126/658
Motor control valve for diverting function 462 4/5.. E
three way form with bellow sealing
EN-GJS-400-18-LT (GGG-40.3), PN 16/25
ø153
Place required
Actuator type: 145 to replace
2,0 kN: 4e1235 (with 49sr5 or 49r: 190) the bonnet
4,0 kN: 4e1435
5,5 kN: 4e1635
Bonnet
Motor
Limit switch
Gear
Spring plate unit H*
Spindle (actuator)
Hand wheel
Mounting rod
Stuffing box staggered

drawn
Spindle with bellow
Diverting plug two-parts A

AB
H1
Valve body type: 6a62... B
L
DN 32 40 50 65 80 100 125 150

Height H* 676 681 683 813 814 821 924 940
Stud length H1 80 90 100 120 130 150 200 210
Length L 180 200 230 290 310 350 400 480
Weight kg 22 23 26 43 47 59 115 135
* = add. 45mm for actuators with positioner 49sr5 or controller 49r
Electrical wiring:
Basic version: Accessories** (optionally):
230/115/24 V 50...60 Hz 24 V DC

for position: AB-A
CLOSE OPEN
1 2 3 4 5 1 2 3 4 5 6 11 12 13 14 15 16 21 22 23 24 25 26 31 32 33 34 35 36 40 41
N L L L+ L- L+ L-
L on 2 = AB-A closes 24V on 1/2 = AB-A opens ** = for actuators with positioner 49sr5 or controller 49r
L on 3 = AB-A opens 24V on 3/4 = AB-A closes see electrical wiring on page 49sr5 or 49r

127/658
Parts list: Control valve in three way form vg62-t E
for diverting function, type BR62, GGG-40.3, PN16/25
01
02
03
04
05
06
07
08
09
10
11
AB A
12
13
14
No. Designation Part-No.

01 Screw joint 6a61sv
02 Safety stuffing box 6a61st
03 Pin 6a61vss
05 Spindle with bellow 6a61sf..
07 Gasket 6a61dd..
08 Lock washer 6a61ss
09 Spindle middle part 6a62sz..
10 Upper plug 6a62ko..
11 Upper seat ring 6a62so..
12 Lower seat ring 6a62su...
13 Lower plug with spindle 6a62ksu...
14 Valve body complete 6a62...
data subject to alteration VG62-TE.DOC / 0510517
128/658
Installation and operating manual B4E
for motor control valves Page 1 of 1
Installation:
Attention: - Installation, operation and maintenance should be done only by qualified personnel.
- Disconnect supply voltage before working on the valve and make sure, that it is impossible to switch
the power on unintentionally (death and injury hazards)
- It is not permitted to work on the valve body and to exchange the actuator as long as
the valve is subjected to pressure and temperature.
- Crushing and injury hazard because of rotating and moving parts
The mounting site should be easily accessible and have sufficient clearance for maintenance and for removing
the actuator. Ensure that the pipe line axes are flush and connection flanges are parallel. Provide suitable
measures to absorb possible tensile and pressure forces. The valve must not serve as a fixed point.
It must be carried by the piping.
Clean pipelines thoroughly prior to installing the control valves in order to avoid damage through residual
installation material, welding beads or forging scale. If possible, provide a dirt trap in front of each control valve.
Installation position should be vertical to horizontal. Ensure that the installation direction is correct (directional
arrows of the flow on the valve housing). Observe a 10 x DN spacing to flanges, elbows, etc., to avoid an
impaired valve function.
Remove flange covers before the installation. Use suitable handling and lifting equipment for installing the valve
(see corresponding data sheet for the weights).
Regard the permitted max. operating pressure and temperature as described in the corresponding valve data sheet.
Observe the ambient temperature limits (-20...+60°C), if necessary, provide a drive heater at lower temperatures
and for higher temperatures insulate the pipeline, provide conductive plates or cooling possibilities.
An additional protecting cover for the actuator is necessary, if the valve is installed outdoors.
Retighten the screws of all flange connections (also cover and connection piece flanges) prior to
commissioning/start-up and following initial heat-up.
Electrical connection:
Check supply voltage according to the rating plate, loosen screws on the motor hood and remove hood.
Route signal and control lines separately from high-voltage lines, if necessary, run in screened cables.
Insert cables (1.5 mm²) through a twisting sleeve or cable gland.
Perform electrical connection with the supply voltage switched off according to the connection diagram
(observe VDE, EVU and regional electrical regulations).
In the event of deviations, the connecting diagram in the motor hood has precedense.
Maintance:
Following the initial temperature and pressure load, retighten the screws of all flange connections (also cover
and connection piece flanges), the valve cone should be located in the centre.
Attention: - Never loosen the lid and flange screws as long as the fittings are subjected
to pressure and temperature.
Protect valve spindle against soiling, if necessary, clean it in order to protect stuffing boxes and PTFE-V-rings
against increased wear.
Retighten stuffing box seals slightly in the event of leaks.
No further maintenance work is required for fittings with PTFE-V-rings or bellows.
Undertake maintenance on the actuator in accordance with the corresponding information in the separate
operating instructions.
data subject to alteration 4_b_e.DOC 1011526

129/658
n
c
e
s
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E
w
A
iar:lc
ie
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r
Electric actuator 4e1 4e1... E

Page 1 of 2
Electric actuator for valves

with integrated manual emergency
Controlling device: 3-point step controller r
Power supply: 230V / 50...60Hz
alternatively: 115V / 50...60Hz (option 49u1)
24V / 50...60Hz (option 49u2)
24V DC (option 49u8)
Thrust: 2000 N
Power input: 10 VA
alternatively: 4000/5500 N / 20 VA
Positioning time: 3,3 s/mm
alternatively: 2,2 s/mm (option 49t12)
Stroke: 41 mm
alternatively: 60 mm (on request)
Protection class: IP 65
Limit switches: 1 changeover switch for each limit position,
load dependent, ratings: 250V / 2A
Mounting position: any, avoid hanging position
(damaging by effluent media possible)
Max. ambient temperature: -15...60° C
Accessories, special designs:

Add. load dependent signal switches (see page 49e)
Add. travel dependent signal switches (see page 49w)
Order text:
Electric actuator, thrust . . ., power supply . . .,
pos. time . . ., mounting rod lenght . . .,
List-No. 4e1 . . .
List-No. Thrust Mounting rod* Pos.time Weight

N mm s/mm kg
4e1134 1500 195 3,3 6
4e1230 2000 200 3,3 6
4e1231 2000 218 3,3 6
4e1232 2000 231 3,3 6
4e1235 2000 250 3,3 6
4e1430 4000 200 3,3 7
4e1431 4000 218 3,3 7
4e1432 4000 231 3,3 7
4e1435 4000 250 3,3 7
4e1630 5500 200 3,3 7
4e1631 5500 218 3,3 7
4e1632 5500 231 3,3 7
4e1635 5500 250 3,3 7
* = other rod lenghts on request
Electrical wiring: Accessories (optionaly):
Limit switches Potentiometer Signal switches

M load dependent travel dependent
for valve position
DOWN UP
1 2 3 4 5 11 12 13 14 15 16 21 22 23 24 25 26 31 32 33 34 35 36
N L on 2 = stroke downwards
L on 3 = stroke upwards
data subject to alteration 130/658 4e1-1-E.DOC / 0411504
Page 2 of 2
153 Space required to

Bonnet remove the bonnet h
Motor
Gear
Limit switch for

valve end position
“down”
H
Terminal bar
Mounting plate with

wiring diagram
Limit switch for

valve end position
“up”
Base plate
Cable bushing
Spring housing
Disc spring unit

A
Spindle
Mounting rod
Stroke
Hand wheel with
blocking lever Cmax
Coupling nut Cmin

100
Screw collar ring
Type Thrust A Cmin Cmax H h G g

N mm mm mm mm mm mm mm
4e1134 1500 195 40 81 146 145 M12 24
4e1230 2000 200 45 86 146 145 M16 32
4e1231 2000 218 63 104 146 145 M16 32
4e1232 2000 231 76 117 146 145 M16 32
4e1235 2000 250 95 136 146 145 M16 32
4e1430 4000 200 45 86 191 190 M16 32
4e1431 4000 218 63 104 191 190 M16 32
4e1432 4000 231 76 117 191 190 M16 32
4e1435 4000 250 95 136 191 190 M16 32
4e1630 5500 200 45 86 191 190 M16 32
4e1631 5500 218 63 104 191 190 M16 32
4e1632 5500 231 76 117 191 190 M16 32
4e1635 5500 250 95 136 191 190 M16 32
Electric actuator 4e1 B 4e1... E
Operating instructions Page 1 of 2
Attention:
- Adjustment of and work on the actuator may only be done by skilled labour
- Disconnect power supply before removing the cover
- Observe local instructions and terminal diagram
Actuator disassembly: Actuator assembly:

- disconnect supply - lift actuator onto valve connection and secure nuts (18)
- loosen fixing screw (21) (see Fig.1)
(see Fig.1) - tighten (19) coupling nut and fixing screw (21)
- unscrew coupling nut (19) - connect lines acc.to wiring diagram
- unscrew nuts (18) - if necessary, move actuator in both limit positions and
- take off actuator from valve connection adjust stroke indikators (17) on mounting rod
Maintenance: the spindle has to be kept cleen and lubricated, if necessary, lubricate the spindle with
molykote including grease
Limit switches:
Attention! The limit switches work load dependent and turn off automatically when the valve drives in
end position, so that a readjustment, as for travel dependent limit switches, is not necessary
and not allowed. Change of the factory adjustment endangers correct operation, no warranty
will be given and no liability will be accepted in case of damage of the varnish sealing.
If for extraordinary reasons, for instance by previous damages, a readjustment is exceptionally
necessary, the actuator should preferably be sent in for new factory adjustment. Only if this is
exceptionally not possible, a new coarse adjustment can be directly done, with our agreement
and acc. to the following operating instruction.
Special information for actuators with integrated positioner:

No reaction of limit switch can occur when the positioner turns off the actuator to early,
before the valve is in the end position. Don’t readjust limit switch in this case, control
at first adjustment of positioner and correct it if necessary.
Upper limit switch
Add. upper switch

Add. lower switch
Lower limit switch

Lower limit switch
Fig.1
data subject to alteration 4E1_1BE.DOC / 0310522

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01
02
03
04
05
06
07
08
09
10
11
12
13
detail X
14
15
16
17
19
20
X
18
Fig.2

01 Bonnet: 2kN / 4kN e3h136 / e3h180
02 Motor 230V / 50/60Hz: 2kN / 4kN*** e2m220 / e2m220.4
02a Capacitor: 2kN / 4kN e2k033 / e2k068
03 Gear: pos. speed 3,3s/mm / pos. speed 2,2s/mm e2g1875 / e2g1250
04 Limit switch for spindle position "down" eheo
05 Mounting plate for motor e3zp
06 Terminal bar e6k12
07 Gear wheel e3zr75
08 Mounting plate with wiring diagram e3hb
09 Limit switch for spindle position "up" eheu
10 Base plate e3gp
11 Screw-type cable bushing PG11 e1kv11
12 Spring housing e3fg
13 Set of disc springs e5ft355+e5fs335
14 Spindle e3s
15 Mounting rods e3s... / e3s...n
16 Hand wheel with blocking lever ehhr
17 Stroke indicator e5ak
18 Hexagonal nut M16 e8mv16
19 Coupling nut e5vk
20 Screw collar ring e3sr...
*** = only for standard actuator: voltage 230V / 50/60Hz

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Accessories for electric actuators 49e.E
Additional load dependent signal switch Page 1 of 2
Electric actuators type 4e... can be equipped with an additional load dependent limit switch for
valve positon "up" and/or "down". The zero-potential change over switches have a contact rating
of 250V / 2A (ohmic load).
Adjustment screw
Mounting plate
Additional upper limit switch
for valve position "down"
Additional lower limit switch

for valve position "up"
Lateral view Mounting plate
upper limit switch Adjustment screw
Additional terminals:
11 12 13 14 15 16
Upper switch for valve position "down" Lower switch for valve position "up"
Summary of types: List-No.
1 add. upper limit switch for valve position "down" 49eo

1 add. lower limit switch for valve position "up" 49eu
1 upper and 1 lower additional limit switch 49ev
data subject to alteration 49E-E.DOC / 0103506

134/658
Operating instructions
BSVC0094EN
Screw-type flow meter SVC
BSVC0094EN_D0026400002-01
Englisch
2011-01-14
135/658
Table of Content
1 General points 4
1.1 About the documentation 4

1.2 Intended use 4
2 Safety 6
2.1 Safety instructions and symbols 6

2.2 Staff qualification and training 6
2.4 Hazard statements 7
3 Device description 10
3.1 Structure and function 10

3.2 Type key 11
4 Technical data 12
4.1 General characteristics 12

4.2 Overview of nominal size 12
4.3 Permissible operating fluid temperature 13
4.4 Overview materials 13
4.5 Dimensions and weights 14
4.5.1 Series A; Attachment G1, F1; Electronics S, H; Nom- 14
inal size 10
4.5.2 Series A; Attachment D; Electronics S, H; Nominal 15
size 10
inal size 40
size 40
inal size 100
size 100
5 Transport and storage 21
5.1 Transport damage 21

5.2 Transport 21
5.3 Corrosion protection 22
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6 Installation 23
6.1 General points 23

6.2 Mechanical installation 23
6.3 Pipe connections 25
6.4 Installation position 25
6.5 Assembly with further components and devices 26
6.6 Electrical connection 27
6.6.1 Standard plug version 28
7 Operation start-up 29
7.1 Preparation 29
7.2 Further operation start-up 31
7.3 Permissible limits for operation 31
8 Removal 32

8.2 Removing the device 32
9 Maintenance 34

9.2 Unusual noises 36
9.3 Static seals 36
9.4 Screw joints 36
9.5 Surface temperature 36
9.6 Cleaning 37
10 Repairs 38

10.2 Troubleshooting 38
10.3 Elimination of damage 38
10.4 Return 39
10.5 Disposal 39
10.6 Detecting and eliminating problems 40
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1 General points
1.1 About the documentation
These operating instructions describe the installation, operation and mainte-

nance of the screw-type flow meter SVC, also referred to below as the device.
The device is manufactured in different versions. Information about the ver-
sion concerned in the individual case can be found on the device's type plate.
The structure of the type designation and a more detailed description of the
individual series and nominal sizes can be found in the chapter 3 “Device
description” and in the chapter 4 “Technical data”.
If you have any questions about this operating manual, please contact the
manufacturer.
1.2 Intended use
The screw-type flow meter is a measuring device for the continual flow meas-
urement of combustible and non-combustible fluids. The different seal mate-
rials allow the use of media of different viscosity and lubricating ability.
The device has been designed for operation with fluids. Dry operation is not
permitted. The medium must guarantee a minimum lubrication.
Operation is only permitted within the specified enviromental and ambient
conditions.
Use in explosive areas is not permissible.
It must be guaranteed that the medium is compatible with the materials used
in the device (see section 4.4 “Overview materials”). The chemical compe-
tence is necessary for this. Be careful with ethylene oxide and/or other
catalytic and/or exothermic and/or self-decomposing materials! Please con-
sult the manufacturer in cases of doubt.
The device may only be used when its materials are resistant to mechanical
and/or chemical influences or corrosion under the respective operating con-
ditions.
A filter must be installed if required to avoid the device blocking on account
of contaminants.
The device may only be operated when closed and must not be exposed to
any impermissible vibrations.
The maximum permissible operating data listed in the chapter 4 “Technical
data” must always be observed.
Deviations from the above-mentioned data and operating conditions require
express approval by the manufacturer and/or are specified on the type plate.
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Type plates or other references on the device must not be removed nor made
illegible or irrecognisable.
In cases of noncompliance, all warranty claims and manufacturer responsi-
bility shall be void.
BSVC0094EN_D0026400002-01 2011-01-14 5
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2 Safety
2.1 Safety instructions and symbols
The safety notices in these operating instructions are marked with caution
symbols.
Non-compliance can lead to hazards for people and the device.
In addition, the safety instructions are marked with signal words. They have
the meanings as explained below:
Caution: Identification of a low risk hazard, which could lead to minor or
medium bodily injury if not avoided.
Warning: Identification of a potential medium risk hazard, which would lead
to death or severe bodily injury if not avoided.
Danger: Identification of an immediate hazard, which would result in death
or severe bodily injury if not avoided.
Notice: Flagging of notices to prevent property damage.
Flagging of special user tips and other especially useful or important infor-
mation.
2.2 Staff qualification and training
The staff designated to install, operate and maintenance the device must be
properly qualified. This can be through training or specific instruction. Staff
must be familiar with the contents of this operating manual.
The operational safety of the device delivered is only guaranteed when it is

used for the intended purpose (see chapter 1 “General points”).
The limit values given must never be exceeded (see chapter 4 “Technical
data”).
National regulations concerning accident prevention and health and safety
at work must be observed, as well as internal regulations laid down by the
operator, even if these are not specifically mentioned in this manual.
The operator must ensure that this operating manual is accessible to the
staff responsible at all times.
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2.4 Hazard statements
DANGER
Danger due to breakage or squirting fluids!
If the device is blocked it acts like a closed gate. The pressure level that
occure in this case can result in damage to the device and to the up or
downstream plant elements. Breakage can lead to parts flying around un-
controlled or to fluids squirting out which can lead to accidents and severe
injuries or even result in death.
● A pressure relief valve or other kind of over-pressure safeguard must
be installed before the device. The pressure relief device must be di-
mensioned so that the volume flow can be conducted through it with the
lowest possible pressure or must be depressurized.
● Do not put the unit into operation without a pressure relief valve.
DANGER
Danger due to pressure loaded lines.
When working on pressure loaded lines, uncontrolled or squirting fluids can
lead to accidents and severe injuries or even result in death.
● Always depressurize all lines during all work on the unit and before dis-
assembly.
DANGER
Using unsuitable connections and lines can lead to breakage. Parts flying
around uncontrolled or squirting fluids can lead to accidents with severe
injuries or even lead to death.
● Use only connections and lines approved for the expected pressure
range.
● Comply with each manufacturer's regulations.
DANGER
Using damaged connections and lines can cause parts to fly around un-
controlled or fluids to squirt out, which can lead to accidents and severe
● Immediately replace damaged connections, pipes and hose lines.
BSVC0094EN_D0026400002-01 2011-01-14 7
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DANGER
Danger due to electric voltage!
Danger of death due to electric shock.
● Follow the special safety regulations during all work on electrical instal-
lations.
● Only allow electricians to work on electrical systems.
WARNING
Danger due to hazardous fluid!
Danger of death upon contact with hazardous fluids and when inhaling va-
pours from these liquids.
● Comply with the safety data sheets and regulations on handling the
hazardous liquids!
● Collect and dispose leaks of hazardous materials so that no hazards
arise for people or the environment.
● Comply with national and international rules at the place of installation.
● Wear suitable protective clothing.
WARNING
Danger due to falling loads and or loads falling over!
Due to the size and weight of the device, accidents can occur resulting in
severe injuries or death during transport and shipping.
● Compliance with applicable industrial safety requirements is mandatory.
● Use only suitable means of conveyance and lifting tackle with sufficient
load-bearing capacity.
● Attach the lifting tackle in such a manner that it cannot slip.
● Secure the device so that toppling over and falling down is impossible.
● Always avoid jerks, impacts and strong vibrations during transportation.
● Never walk under suspended loads, never work under suspended
loads.
● To prevent damage to the device, be extremely cautious when shipping
or transporting.
CAUTION
Danger due to hot surfaces!
When operating the device with hot media, there is a danger of being
burned and scalded when touching the hot surfaces.
● At medium temperatures above 60 °C, take measures against uninten-
ded contact.
● Wear safety gloves.
8 2011-01-14 BSVC0094EN_D0026400002-01
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CAUTION
● Let the device cool off first when the medium temperature is over 48 °
C.
BSVC0094EN_D0026400002-01 2011-01-14 9
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3 Device description
3.1 Structure and function
The basic structure of the individual design sizes is shown in the dia-
gram below using size 10 as an example.
The device is a displacement counter. Two measuring spindles (pos. 2) with
screw-shaped profile are engaged with one another. They are supported by
anti-friction bearings (pos. 3) and surrounded by a housing (pos. 1).
The liquid flow makes the spindles rotate and runs through the device in axial
direction. During this, closed part volumes are formed that are continually
filled and emptied. The measuring principle does not cause any pressure or
volume flow pulsation.
A transmitter wheel (pos. 4) fixed to the measuring spindle is scanned without
contact by two sensors and transformed into electrical signals. The use of two
sensors allows determination of the direction of flow and any direction of
cross-flow. Flow in and out takes place without hardly any deflection, which
means the device only loses comparatively little pressure.
This measuring principle means there is no need for steadying areas at the
inlet and outlet. All moving parts are lubricated by the measuring medium.
Tab. 3.1: Basic structure SVC
1. Housing
2. Screw spindles
(Measuring unit)
3. Roller bearing
(Bearing)
4. Transmitter wheel and sen-
sor
5. O-Ring
(Seal)
6. Device plug
10 2011-01-14 BSVC0094EN_D0026400002-01
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3.2 Type key
Tab. 3.2: Ordering example
SVC 10 A 1 G1 F 1 S 1 /...
1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Tab. 3.3: Explanation type key SVC
Explanation type key

1. Product name
2. Nominal size
10 Qnenn= 100 l/min (Qmax= 150 l/min)
3. Series
A Standard
4. Spindel bearing
1 Roller bearing unsealed 2 Roller bearing sealed *
5. Attachement
G1 Pipe thread F1 SAE-flange SAE J518 Code 61
D. DIN-flange DIN EN 1092
6. Seal material
F FKM E EPDM
N NBR P FEP
7. Specified internally
8. Electronics
S Standard H High temperature
V Without pre-amplifier
9. Steckervariante
1 Hirschmann plug
10. Special number for specific types
* only for nominal size 10
BSVC0094EN_D0026400002-01 2011-01-14 11
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4 Technical data
4.1 General characteristics
Tab. 4.1: General characteristics SVC
General characteristics
Materials See section 4.4 “Overview materials”
Pipe connection Pipe connection, SAE connection
Installation position / direction of flow Any
-15 ... 80 °C (seal material F)
Permissible ambient temperature ϑ
-30 ... 80 °C (seal materials N, E, P)
4.2 Overview of nominal size
Tab. 4.2: Nominal sizes SVC
Nominal size* 10 40 100

Qmax l/min 150 600 1500
Qnenn l/min 100 400 1000
Qmin l/min 1,0 4,0 10,0
Span - 1:150 1:150 1:150
Max. operating pressure bar 250 200 140
Pressure peak bar 300 240 170
Volume of measuring chamber 3 27,04 123,6 354,6
cm
Impulse volume cm3/Imp 1,423 5,15 9,85
Speed (Qnenn) 1/min 3698 3236 2820
Resolution (K-Faktor) Imp/l 702,7 194,2 101,5
Resolution (K-Faktor) 4-fach ** Imp/l 2811 776,7 405,1
Impulse frequency (Qnenn) Hz 1171 1295 1889
* See type key and type description on the device: SVC ...
**Resolution with 4-times evaluation of the two measuring channels
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4.3 Permissible operating fluid temperature
Tab. 4.3: Permissible temperature of operating media SVC
Seal variant * Version S Version H

(Standard) (High temperature)
[°C] [°C]
N = NBR -30...100 -
F = FKM -15...120 -15...150
E = EPDM -30...120 -
P = FEP -30...120 -30...150
Spindle bearing Version 2 [°C]: max. + 110
4.4 Overview materials
Tab. 4.4: Materials SVC
Nominal size 10 40 100

Housing / flange connections EN-GJS-400-15 (GGG 40)
Measuring unit Heat-treated steel
Materials
Bearing Heat-treated steel
Seals* NBR, FKM, EPDM, FEP
Type of bearing Anti-friction bearing
Viscosity of the operating fluid in mm2/s 1 ... 1.000.000
(depending on the flow)
Lubricating properties of the operating fluid good
Permissible size of foreign particles in operating fluid in µm 400
BSVC0094EN_D0026400002-01 2011-01-14 13
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4.5 Dimensions and weights
4.5.1 Series A; Attachment G1, F1; Electronics S, H; Nominal size 10
Tab. 4.5: Series A; Attachment G1, F1; Electronics S, H; Nominal size 10
Type code Weight Dimensions [mm]

[kg]
A B D G H L P T X
SVC 10 A. G1 .1 S1 9,6 - - 99 1" 101,5 196 - 19 33
SVC 10 A. F1 .1 S1 9,6 52,4 26,2 99 Ø25 101,5 197 M10 - 17 deep - 32
SVC 10 A. G1 .1 H1 9,6 - - 99 1" 104,5 196 - 19 33
SVC 10 A. F1 .1 H1 9,6 52,4 26,2 99 Ø25 104,5 197 M10 - 17 deep - 32
Tab. 4.6: SVC 10 A. G1 .1 .1
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Tab. 4.7: SVC 10 A. F1 .1 .1
4.5.2 Series A; Attachment D; Electronics S, H; Nominal size 10
Tab. 4.8: Series A; Attachment D; Electronics S, H; Nominal size 10
Type code Weigt [kg] Dimensions [mm]

D G H K L P X
SVC 10 A. D1 .1 S1 17,20 140 32 167 100 265 M16 - 25 deep 76
SVC 10 A. D2 .1 S1 17,30 140 25 167 100 265 M16 - 25 deep 76
SVC 10 A. D3 .1 S1 19,15 150 25 172 105 275 M20 - 30 deep 81
SVC 10 A. D1 .1 H1 17,20 140 32 170 100 265 M16 - 25 deep 76
SVC 10 A. D2 .1 H1 17,30 140 25 170 100 265 M16 - 25 deep 76
SVC 10 A. D3 .1 H1 19,15 150 25 175 105 275 M20 - 30 deep 81
BSVC0094EN_D0026400002-01 2011-01-14 15
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Tab. 4.9: SVC 10 A. D. .1 .1
Tab. 4.10: Available DIN-flange version SVC 10
Nominal width NW [mm] Compression PN [bar]

D1 32 40
D2 25 160
D3 25 250
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[kg]
A B D G H L P T X
SVC 40 A. G1 .1 S1 17,15 - - 121 1 1/2" 123,5 265 - 23 26
SVC 40 A. F1 .1 S1 17,90 69,9 35,7 121 Ø38 123,5 287 M12 - 27 - 38
deep
SVC 40 A. G1 .1 H1 17,15 - - 121 1 1/2" 134,5 265 - 23 26
SVC 40 A. F1 .1 H1 17,90 69,9 35,7 121 Ø38 134,5 287 M12 - 27 - 38
deep
Tab. 4.12: SVC 40 A. G1 .1 .1
Tab. 4.13: SVC 40 A. F1 .1 .1
BSVC0094EN_D0026400002-01 2011-01-14 17
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Type code Weight [kg] Dimensions [mm]

D G H K L P X
SVC 40 A. D1 .1 S1 24,65 150 40 183 110 285 M16 - 20 deep 37
SVC 40 A. D2 .1 S1 27,50 170 40 193 125 295 M20 - 25 deep 42
SVC 40 A. D1 .1 H1 24,65 150 40 183 110 285 M16 - 20 deep 37
SVC 40 A. D2 .1 H1 27,50 170 40 193 125 295 M20 - 25 deep 42
Tab. 4.15: SVC 40 A. D. .1 .1

D1 40 40
D2 40 160
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[kg]
A B D G H L P T X
SVC 100 A. G1 .1 S1 39,1 - - 158 3" 160 357 - 32 30
SVC 100 A. F1 .1 S1 38,7 106,4 61,9 158 Ø76 160 347 M16 - 32 deep - 32
SVC 100 A. G1 .1 H1 39,1 - - 158 3" 171 357 - 32 30
SVC 100 A. F1 .1 H1 38,7 106,4 61,9 158 Ø76 171 347 M16 - 32 deep - 32
Tab. 4.18: SVC 100 A. G1 .1 .1
Tab. 4.19: SVC 100 A. F1 .1 .1
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Type code Weight [kg] Dimensions [mm]

D G H K L P X
SVC 100 A. D1 .1 S1 46,20 200 80 226 160 365 M16 - 25 deep 45
SVC 100 A. D1 .1 H1 46,20 200 80 226 160 365 M16 - 25 deep 45
Tab. 4.21: SVC 100 A. D. .1 .1

D1 80 40
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5 Transport and storage
5.1 Transport damage
Inspect the device for shipping damage as soon as the delivery has been
received.
If shipping damage is discovered, inform the shipping company.
If proper operation of the device is impaired by the damage, the device must
be replaced or repaired. In that case, contact the manufacturer.
5.2 Transport
WARNING
Danger due to falling loads and or loads falling over!
Due to the size and weight of the device, accidents can occur resulting in
severe injuries or death during transport and shipping.
● Compliance with applicable industrial safety requirements is mandatory.
● Use only suitable means of conveyance and lifting tackle with sufficient
load-bearing capacity.
● Attach the lifting tackle in such a manner that it cannot slip.
● Secure the device so that toppling over and falling down is impossible.
● Always avoid jerks, impacts and strong vibrations during transportation.
● Never walk under suspended loads, never work under suspended
loads.
● To prevent damage to the device, be extremely cautious when shipping
or transporting.
Handling aid
● The transport of the SVC 100 can be made using the two supplied eye-
bolts.
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5.3 Corrosion protection
The device's function is tested in the plant with mineral hydraulic oil. Then all
connections are closed. The remaining residual oil protects the interior parts
for about 6 months.
Clean bare outer metal parts have also been protected by anti-corrosive oil
or protective metal paint for a period of 6 months against corrosion.
The device must not be exposed in the influence of the weather and major
fluctuations in temperature during transport and storage and must be stored
in a dry place.
If the device is stored over a longer period, it must be treated on the inside
and outside with a suitable corrosion protecting oil. In addition, it must be
protected from humidity by a humidity-absorbing agent.
If high air humidity or aggressive atmosphere is to be expected during trans-
port, suitable corrosion prevention measures must be carried out.
NOTICE
Corrosion damage on units with EPDM seals
The functionality of units with EPDM seals is not tested. There is no pres-
ervation of the interior parts. If the unit is not put into operation immediately,
corrosion damage can occur.
● Protect the unit by using suitable corrosion-preventing measures.
NOTICE
Chemical impact on the device and the sealing materials
Incompatibility between the preservation agents and the materials and
elastomers used in the device can lead to damage of the device and the
seals being used.
● Check to make sure the preservation agent is compatible with the ma-
terials and elastomers used in the device.
● Check to make sure the preservation agent is compatible with the media
to be pumped.
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6 Installation
6.1 General points
DANGER
assembly.
NOTICE
Danger of property damage due to insufficiently qualified personnel
Improper work can lead to damages and malfunctions in the device and in
the plant.
● Permit only expert and technically qualified personnel to work on the
device.
NOTICE
Danger of property damage due to a lack of cleanliness
During installation, foreign bodies can get into the interior of the device or
the plant due to a lack of cleanliness and cause malfunctions there.
● Pay attention to cleanliness during all work.
6.2 Mechanical installation
DANGER
If the device is blocked it acts like a closed gate. The pressure level that
occure in this case can result in damage to the device and to the up or
downstream plant elements. Breakage can lead to parts flying around un-
controlled or to fluids squirting out which can lead to accidents and severe
● A pressure relief valve or other kind of over-pressure safeguard must
be installed before the device. The pressure relief device must be di-
mensioned so that the volume flow can be conducted through it with the
lowest possible pressure or must be depressurized.
● Do not put the unit into operation without a pressure relief valve.
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DANGER
Using unsuitable connections and lines can lead to breakage. Parts flying
around uncontrolled or squirting fluids can lead to accidents with severe
injuries or even lead to death.
● Use only connections and lines approved for the expected pressure
range.
● Comply with each manufacturer's regulations.
CAUTION
ded contact.
NOTICE
Danger of property damage due to incorrect installation
Incorrect installation can cause malfunctions or damage the device and /
or the system.
● During transport and installation, the device must always be held by the
housing and never by the plug.
● The device must be installed in such a way that it is not exposed to any
impermissible vibrations.
● Hot parts must not be installated since any escaping fluid could ignite.
● It must be guaranteed that all lines and connections are tight and no
leakages can occur
● During operation start-up, the device must be checked for leaks under
operating conditions.
The device was tested in the factory before delivery and can be used imme-
diately following installation and connection of the electrical cables.
The space required for the device is specified in the chapter 4 “Technical
data”.
The built-in measuring device should also be safely accessible for visual in-
spection at any time during operation.
Depending on the type of connection the device is connected to the system
via a connection plate or connections within the housing.
● Before installation, the device must be checked for transport damage and
soiling.
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● Any preserving agents must be removed before installation using ben-

zine or solvent.
● Clean the pipework of dirt, scale, sand, swarf, etc. prior to installation.
Welded pipes in particularly must be pickled or flushed. Cotton waste
must not be used for cleaning.
6.3 Pipe connections
NOTICE
Danger of device damage due to collision
For devices with threaded connection, a too long thread of the connecting
cable can cause damage on the internal parts of the device.
● Make sure that the thread lenght of the cable is not greater than the
thread depth in the device port (see section 4.5 “Dimensions and
weights”).
NOTICE
Danger of property damage caused by foreign bodies in the device
During installation, when using unsuitable sealing materials foreign bodies
can get into the interior of the device or the plant due to a lack of cleanliness
and cause malfunctions there.
● During installation, do not use any hemp or filler as sealing material.
NOTICE
Danger of property damage due to distortion
The load on the device due to impermissible external loads can lead to
malfunctions or to breakage of the flange or housing.
● Pipelines must be fitted absolutely tension-free to the device connec-
tions.
● Pipelines must be designed in such a way that no tension e.g. caused
by changes in length due to fluctuations in temperature can be trans-
ferred to the device.
● Connect the connection pipelines to the inlet and outlet points on the
measuring devices. Always heed the respective manufacturer's instruc-
tions.
● After the system has been put into operation, check all connections for
air-tightness.
6.4 Installation position
Basically, the device can be installed and operated in any position at all.
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In the case of particle-charged media, heavy soiling or coarse filtering, a hor-

izontal installation position is recommended (see diagram below).
Tab. 6.1:
6.5 Assembly with further components and devices
NOTICE
Danger of property damage if installation is not correct
Incorrect assembly with components or devices from other manufacturers
can lead to breakdowns.
● Comply with each manufacturer's operating instructions when assem-
bling with additional components or devices.
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6.6 Electrical connection
DANGER
lations.
Tab. 6.2: Electrical data
Electrical data for standard configuration 24 V

Number of measuring channels 2
UB = 24 V DC ± 20%, protected
Operating voltage
against reverse polarity
Impulse amplitude UA ≥ 0,8 UB
Impulse shape with symmetrical out- Rectangular, pulse-duty factor/
put signal channel 1:1 ± 15%
Impulse offset between the two chan-
90° ± 30°
nels
Power requirement Pb max = 0,9 W
Power output / channel Pa max = 0,3 W, short-circuit resistant
Normal protective rating IP 65 (DIN 40050)
Signal output PNP
Pre-condition: A 24 V (DC) supply cable (± 20%) must be planned for power

supply to the pre-amplifier.
NOTICE
Damage by overvoltage
Devices that are designed for an operation voltage of 12 V DC (polarity
protected) shall not be operated at a voltage of 24 V DC. The excessively
high voltage can cause damage and malfunction of the device. This applies
to devices with the special numbers 74, 75, 90, 110, 137, 138, 151 and 167.
● Operate the equipment only with the correct voltage (12 V DC or 24 V
DC).
● If you are not sure which version is present, please consult the manu-
facturer.
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6.6.1 Standard plug version
● The electrical connections have to be carried out according to the as-

signment diagram shown below.
Comfortable work
● To make wake more convenient, the plug may be pulled off the housing
cover for cable connection.
The assignment of the terminals for channel 1 and channel 2 influences the
direction of rotation of the measuring unit indicated and thus the sign with
which the measured volume flow is indicated in the evaluation unit.
Tab. 6.3: Assignment standard plug
H1: Status display channel 1 1: 24 Volt (brown)

H2: Status display channal 2 2: Channel 1 (green)
* Cable screw connection 3: Channel 2 (yellow)
** Attachment screw cover 4: 0 Volt (white)
*** Strain relief
NOTICE
Danger of malfunction due to incorrect installation
Loose cable or connections may cause malfunction of the device..
● After installation, the fastening screws (slightly) an the cable screw con-
nection have to be tightened.
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7 Operation start-up
7.1 Preparation
NOTICE
Danger of proerty damage due to incorrect commisioning
Improper commissioning can lead to damages and malfunctions in the de-
vice and in the plant.
● All work on the device may only be carried out by trained and profes-
sionally qualified staff.
● Comply with the permissible operating data such as rotational speed,
pressure temperature, permissible media, etc. (see chapter 4 “Techni-
cal data”).
● The medium must guarantee a minimum lubrication.
● Before starting the system make sure that a sufficient quantity of the
service fluid is extant to avoid dry running.
● Before starting the plant, the device must be filled with operating fluid
to prevent damage during dry operation.
● It must be guaranteed that all lines and connections are tight and no
leakages can occur
WARNING
hazardous liquids!
CAUTION
ded contact.
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● Check the permissible operating data against the operating states to be

expected.
● Check all fastening screws on the device.
● Fill the device with operating fluid.
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7.2 Further operation start-up
The device was tested in the factory before delivery. It can be put into oper-
ation immediately, as soon as the mechanical and electrical connections have
been set up. During operation, the two LEDs in the device plug light up as
long as there is a continual flow of fluid through the measuring unit.
NOTICE
Danger of propery damage due to blocked measuring plant
A lack of counter signal may indicate a blockage mechanism. The resulting
increase in pressure before the device can lead to further damage of the
device and / or the system.
● The system must be switched off immediately if the counter signal fails
unexpectedly.
● Remove the cause of the disorder.
7.3 Permissible limits for operation
The device may only be operated within the given limit values (see section
1.2 “Intended use” and chapter 4 “Technical data”).
NOTICE
Danger of device damage due to overload
A too high flow resistance ∆p can cause mechanical damage on the device.
● The maximum pressure loss in the device must not exceed 25 bar.
● The permanent permissible pressure loss is max. 7 bar at max. 50 % of
nominal volume.
For the ambient conditions, the limit values giben in the chapter 4 “Technical
data” must be observed.
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8 Removal
8.1 General points
NOTICE
the plant.
device.
NOTICE
A lack of cleanliness can lead to damages and malfunctions in the device
and in the plant.
● Close all openings with protective caps to prevent dirt from penetrating
into the system.
8.2 Removing the device
DANGER
assembly.
DANGER
lations.
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WARNING
hazardous liquids!
CAUTION
C.
● If operating a high temperature, wait until the device has cooled to am-
bient temperature.
● Loosen the attachment screwon the plug.
● Pull the plug off the housing.
● Connection: Loosen the housing connections or take the housing off the
fixture.
NOTICE
Danger of malfunction due to curing liquids
Curing liquids can engage the device mechanically and make it unusable.
● Immediately clean the pump or store it in such a way that curing is def-
initely prevented in cases where the pump was operated with curing
liquids.
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9 Maintenance
9.1 General points
NOTICE
the plant.
device.
NOTICE
Danger of damages and malfunctions due to a lack of maintenance
If the device is not regularly maintained, damage that is not discovered or
not repaired can lead to malfunctions and to the failure of the device.
● Maintain the device regularly.
● Check the device initially right after commissioning.
● Adapt the scope and time between maintenance intervals to the de-
mands posed by the location.
● During visual inspections, look purposefully for possible damages.
● The device must not be used if visible damages are found.
● Document the type and extent of the maintenance work. That allows the
fastest possible detection of a change in operating performance.
When designed to the conditions of use and fitted correctly, the devices are
able to be used for long and problem-free operation. They only require a little
maintenance. This is absolutely essential for problem-free operation, howev-
er. Experience shows that a high percentage of the problems and damage
that occur can be traced back to dirt and lack of maintenance.
The device is basically maintenance-free. If, however, fluids are pumped that
can lead to deposits in the measuring device, the device may need cleaning.
Otherwise the device can be cleaned within the context of normal system
cleaning. A change in measuring accuracy can be an indication of wear. We
recommend checking this regularly.
The scope and time intervals for inspections and maintenance are generally
specified by the operator in a respective plan.
Barriers and instructions

● All removed barrieres and warning signs must be put back to their orig-
inal position on completing maintenance and/or repair.
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Checking the operating data

● Regular checking of all operating data such as pressure, temperature,
current consumption, degree of filter soiling etc. contributes to early
problem detection.
NOTICE
A lack of cleanliness can lead to damages and malfunctions in the device
and in the plant.
● Close all openings with protective caps to prevent dirt from penetrating
into the system.
DANGER
assembly.
DANGER
Using damaged connections and lines can cause parts to fly around un-
controlled or fluids to squirt out, which can lead to accidents and severe
● Immediately replace damaged connections, pipes and hose lines.
WARNING
hazardous liquids!
BSVC0094EN_D0026400002-01 2011-01-14 35
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DANGER
lations.
CAUTION
C.
9.2 Unusual noises
Some damage is indicated by unusual noises. If there is a change in the dec-

ive's operating noise, a thorough examination of the cause must always take
place.
9.3 Static seals
The static seals on the device's separation joints and the connection lines
must be periodically checked for leakproofness.
If there are any visible leaks, immediately stop plant operation.
If the leaks cannot be stopped by simply retightening the connection, replace
all affected seals.
9.4 Screw joints
All the screw joints must be checked at regular intervals to make sure they
are tight fit. Loose screw joints must be tightened and, if necessary, secured
against loosening by e.g. Loctite (medium stregth).
9.5 Surface temperature
The temperatures at the device surface can be checked to prevent premature

wear or detect device overload. This temperatures should never be much
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higher than the media temperature at the device inlet. If the temperature on
the device surface is much higher, this is an indication of a device malfunction.
In this case the device must be replaced immediately.
9.6 Cleaning
The device is basically maintenance-free. If, however, fluids are pumped that
can lead to deposits in the measuring device, the device may need cleaning.
Otherwise the device can be cleaned within the context of normal system
cleaning. A change in measuring accuracy can be an indication of wear. We
recommend checking this regularly.
NOTICE
Danger of malfunction due to curing liquids
Curing liquids can engage the device mechanically and make it unusable.
● Immediately clean the pump or store it in such a way that curing is def-
initely prevented in cases where the pump was operated with curing
liquids.
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10 Repairs
10.1 General points
The term repairs covers:

● Troubleshooting, in other words establishing damage, determining and
localising the reason for the damage.
● Elimination of the damage, in other words eliminating the primary cau-
ses and replacing or repairing faulty components.
10.2 Troubleshooting
Leaks are the most frequent problem. If these occure on the pipelines, they
can be eliminated by straightforward tightening of the screw joints.
If the device itself is leaking, the respective seals have to be replaced.
10.3 Elimination of damage
Repair damage onsite, predominantly by replacing the defective device. The

device itself is generally repaired by the manufacturer.
If correspinding expertise and sufficient equipment is available, the consumer
or OEM can also make the repairs. For support spare part lists and sectional
drawings are available. They can be requested from the manufacturer.
NOTICE
Danger of property damage due to incorrect work and use of non-
original spare parts
the plant. That also applies to the use of non-original spare parts.
device.
● Use only genuine original spare parts.
Warranty
The screws of the sensor fittings are marked with a seal point. If the seal
point is damaged the warranty will be void.
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10.4 Return
If the device has to be repaired or checked over the manufacturer's premises,

it must be packed suitably for transport. In addition, a safety data sheet for
the medium used must be enclosed with the device. In case of well-known
mineral oils, at least the exact type description is required.
If harding or agglutinative media are involved, the device must be cleaned
befor it is returned.
Cleaning is also necessary if the device has been operated with hazardous
fluids.
Any openings must be closed.
10.5 Disposal
Disposal of the packaging and used parts must be carried out according to
the regualtions valid in the country where the device is installed.
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10.6 Detecting and eliminating problems
If the device does not function properly, the electrical components should be
checked first. The measuring device must remain in operation for this.
DANGER
lations.
If there is no analytical evaluation software available, the following trouble-

shooting table is to be used for problem analysis.
Tab. 10.1:
Fault Potential causes Remedy

Both LEDs on the discon- The connection between de- Check the connection and replace the
nection amplifier are lit, vice and evaluation device is cables or plugs if necessary.
but incorrect values are faulty.
displayed.
One LED does not light The wiring between sensor Send the measuring device back to the
up during operation. and board or individual solder manufacturer for repair.
spots an the board is dam-
aged.
The respective sensor is faul-
ty.
Both LEDs do not light up Power failure Check supply cable and fuses.
during operation. Since it is improbable that Put the device out of operation im-
both sensors fail at the same mediately!
time, it must be assumed that The device can be dismantled and
the measuring unit has stop- cleaned (see chapter 9 “Maintenance”).
ped.
Leaks, media escaping O-ring in the housing not air- Check seal compatibility, consult the
tight. manufacturer if necessary and fit new
set of seals (purchase from the manu-
facturer)
O-ring between device and Check seal compatibility, install new O-
connection pipeline not air- rings.
tight.
Decrease in measuring Wear Check the measuring device or send it
accuracy back to the manufacturer for repair.
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Operation Manual

Mixing tank

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Operation Manual

Zum Dock 3/4
23966 Wismar
Germany

Phone +49 3841 7125‐0
Fax +49 3841 7125‐23



©maritime assembly systems GmbH Edition 01‐2012
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Operation Manual

Table of contents

1. GENERAL INFORMATION 4
1.1 Concerning this documentation 4
1.1.1 Copyright 4
1.2 Symbols used 4
1.4 Standards and guidelines 5

2. TECHNICAL DATA 6
2.1 Technical specification 6
2.2 General drawing 6
2.3 Functional description 6

3. TRANSPORT, STORAGE, DISPOSAL OF CONSERVATION MATERIALS 7
3.1 Transport 7
3.2 Storage 7
3.3 Disposal of conservation materials 7

4. INSTALLATION, CONNECTION, DISMANTLING AND REMOVAL 8
4.1 Installation and connection 8
4.2 Dismantling and removal 8

5. OPERATION 10
5.1 Start‐up 10
5.2 Putting out of service 10
5.3 Measures in case of frost danger 10

6. SERVICING 11
6.1 Maintenance, inspection and repair work 11
6.2 Customer service address 12

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Operation Manual
1. General information
1.1 Concerning this documentation

This documentation is to be read and understood by all persons who are responsible for using the mixing
tank of the mas GmbH and all its points must be observed.

You should carefully read this documentation before initially putting into service because we cannot be
held responsible for any breakdowns and damage of mixing tank to that result in the case of non
observance. Furthermore, we will not assume liability for any injuries resulting from non observance either.

Operating errors on the mixing tank can only be avoided by studying this documentation correctly. For
this reason, the documentation should always be accessible to persons responsible and kept near the
mixing tank.

In the case of any difficulties, please contact our customer service and replacement parts department or
one of our agencies.

1.1.1 Copyright

The copyright of this documentation remains in the property of mas GmbH.
The sole purpose of this documentation is to instruct and support the staff responsible for installation,
operation and monitoring.

It is prohibited to pass on, duplicate, utilize or to communicate the contents of this documentation unless it
has been expressly permitted. Any persons contravening this are obliged to pay compensation. All rights
reserved in the case of the patent design, registered utility model or registered design entry.

1.2 Symbols used

Symbol Meaning

Warning!

Warning! Danger of explosion

Danger! High voltage

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Operation Manual

The mixing tank has only been designed for the area of use specified under item 2.1 Technical specification.
Before you use the mixing tank for any other purpose than it was designed for, please seek advice from our
customer service (address and phone number under item 6.2), because otherwise the guarantee for the
mixing tank is rendered invalid!

Particular attention should be paid to the work safety information below:

 The mixing tank has been built according to the state‐of‐the‐art and is safe to operate.
However, there is still the possibility of danger occurring with the mixing tank if it is misused or
operated by untrained staff. Therefore, the operating staff should read through this documentation
very carefully.
 The operator is recommended to get written confirmation from his operating staff acknowledging
that they have carefully read and understood this documentation.
 The operating staff must ensure that no unauthorized persons work on the mixing tank or carry out
any other activity on it.
 Modifications that impair the safety of the mixing tank are not permitted. Any modifications carried
out on the mixing tank, which impair the safety, must be reported to the manufacturer
immediately.
 The operator and his operating staff are obliged to operate the mixing tank in perfect condition.
Cleanliness and neatness should always be ensured.
 The mixing tank must be used only in accordance with this requirement.
 Suitable work safety measures are to be met with all work on the mixing tank.
 Protective gear may only be removed when the mixing tank has stopped and must always be
reinstalled again before putting into service. Otherwise, the operating staff and/or mixing tank
could be put at risk.
 When working on electrical components such as level switch for control of actual capacity and
similar components, these must be switched to a voltage‐free state and protected against being
switched on again without authorization.
 After installing the electrical system or carrying out repair work, the protective measures must
always be checked.
 The local safety and accident prevention regulations apply when operating the mixing tank.

1.4 Standards and guidelines

This documentation corresponds to the following standards:

 DIN EN 62079 (Preparing of instructions)
 VDI 4500 Part 1 / 2 (Technical documentation: Definitions and legal basics / Organisation and
management)
 DIN‐Fachbericht 146 (Technical product documentation)
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Operation Manual
2. Technical data
2.1 Technical specification

capacity: 49 / 99 / 150 / 200 / 300 l
max. operating pressure: 1.0 MPa
test pressure: 1.5 MPa
max. operating temperature: 150 °C

The technical parameters for the mixing tank are project‐specific (see operation manual of the module).

2.2 General drawing

Fig. 1

2.3 Functional description

The mixing tank is a component of the fuel oil module and is provided for mixing up the unconsumed fuel
oil return from the engine with the fuel oil coming from the day tank.
As a result of engine manoeuvring the return flow may cause a sudden temperature variation. Therefore
the mixing tank is designed with a precise capacity to avoid unstable control system and viscosity
measurement.
According to customer requirements are arranged connections to equip the mixing tank with venting and
drain valves, with safety valve, as well as with manometer, thermometer and sensor for the level
supervision. The mixing tank can be insulated with Rockwool mats and covered with galvanised metal
sheets.
The technical parameters for the mixing tank are project‐specific (see operation manual of the module).

WARNING! BURNING DANGER

The tank is completely insulated. If the isolation is damaged or is removed, there is a
burning danger in case of touching.

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3. Transport, storage, disposal of conservation materials
3.1 Transport

The mixing tank can be delivered as a part installed in a fuel oil module or as loose item. Depending on
customer requirements, the packing of the mixing tank varies from unpacked up to seaworthy packing
including 12 month conservation.

DANGER! RISK OF ACCIDENT FROM FALLING LOADS

During transport of the mixing tank, accidents may occur due to sizes and weights
 Attach the separate lifting accessories properly to the mixing tank.
shoes).

3.2 Storage

In some cases it is inevitable that the mixing tank must be stored for a certain period of time. In this case
make sure that it is stored somewhere dry and clean. A high humidity, salty air etc. will noticeably reduce
the life time. We recommend not exceeding a storage time of 4 months.

WARNING! MATERIAL DAMAGE DUE TO IMPROPER STORAGE

Improper storage will cause damage to the mixing tank
 The transport case should not be stored outdoors.
 Protect the mixing tank from moisture and contamination during storage.
 Do not store the mixing tank below the frost line.

3.3 Disposal of conservation materials

The mixing tank is emptied after the test run and keeps back oil leftovers on the bottom of the tank. During
transport small quantities of oil also can accumulate at the cup plugs of the connecting pipes. Therefore it is
required to take corresponding precautions before the connecting pipes and the drain valve of the mixing
tank will be opened and to collect such remnants and to dispose them professionally.


account.
 Unscrew the counter‐flanges and remove the metal plates/caps which have sealed the
pipes up and dispose of them professionally.
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Operation Manual
4. Installation, connection, dismantling and removal
4.1 Installation and connection

 The mixing tank must be firmly connected to the base frame of the module or to the foundation on
mounting place.
 Pipes leading to and from the mixing tank must be installed strain‐free.
 Attention should be paid to the pipe diagrams so that pipes are not installed incorrectly.
 The mixing tank must be covered when welding next to it, on it or above it.
 Only clean pipes that have been cleaned on the inside can be connected to the mixing tank.

WARNING! MATERIAL DAMAGE DUE TO DIRT

Dirt can damage components and the engine
 Ensure that the pipe system has been cleaned carefully.
If dirt causes damages to the components, this is not a guarantee case!

Additional instructions for installation, assembly, operation and maintenance see operation manual of the
module.

4.2 Dismantling and removal

The mixing tank together with its floor stand is screwed to the base frame of the module or to the
foundation on mounting place and can also be dismantled. After this, it is no longer possible to operate the
module.

Before starting to dismantle, the entire module or the system must be rendered voltage‐free and protected
All pipes leading to and from the mixing tank must be shut off. The mixing tank must be cooled down and
drained.


 First disconnect the control cabinets from the mains and safeguard them against being
unintentionally switched on again.


 Cool down the system before draining.
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WARNING! DANGER OF EXPLOSION

Danger of explosion due to combustible residue and its vapours in the pipes and
components
 Do not use gas‐burning equipment or other parting‐off tools that have a thermal effect
during the dismantling.


When dismantling the mixing tank always be aware that it has a heavy deadweight
 Attach the separate lifting accessories properly to the mixing tank.
shoes).


account.
 When dismantling the mixing tank, pay particular attention that it is disposed of
professionally.

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Operation Manual
5. Operation
5.1 Start‐up

After connection of the pipes to the mixing tank it can be put into operation.
 Close the drain valve from mixing tank.
 Full up the mixing tank with fuel oil.
 Open the vent valve until fuel oil is coming, then close the vent valve.
 Check the mixing tank of any leakage.

Additional instructions for operation see operation manual of the module.

5.2 Putting out of service

For a short shut down of the engine without working on the fuel oil system, the mixing tank can keep
running on HFO. If a longer shutdown of the engine or working on the fuel oil systems of the engine is
required, you have to change over to MDO and then the mixing tank can be putting out of service.

5.3 Measures in case of frost danger

The fuel oil will be gumming at low temperatures and it can come to damages at the components.




 Cool down the system before draining.

Mixing tank:
 Drain the mixing tank completely.
 All valves must be open.

Pressure gauges and piping:
 Drain all pipes of the pressure gauges and the pressure gauge valves must be open.


Hot liquids escaping from the system through undetected leakages can cause severe burns
 Before you start the system again, close all drain valves and control the complete
system for leakages on piping and fittings.
10 / 12
184/658
Operation Manual
6. Servicing
6.1 Maintenance, inspection and repair work

WARNING!

Only use original replacement parts. Otherwise, any claim for compensation under
guarantee is rendered invalid!

 Only specialist staffs that are familiar with the system should be assigned to carry out maintenance
and inspection work.
 Take your time for this work. Otherwise, you might make mistakes that could have fatal
consequences.
 The view controls should be carried out at regular intervals to prevent leakage of the ball valves and
of the safety valve as well as after exterior damages of the mixing tank.


 During maintenance and inspection work the components to be tested must be switched
off and protected against being unintentionally switched on.


 All drain valves must be closed before maintenance and inspection work.
 Before servicing make sure that mixing tank is unpressurized.

WARNING! BURNING DANGER

The tank is completely insulated. If the isolation is damaged or is removed, there is a
burning danger in case of touching.

11 / 12
185/658
Operation Manual
6.2 Customer service address

If you have any questions or want to order some replacement parts, please contact one of the following
addresses:

Zum Dock 3/4
23966 Wismar
Germany
Phone +49 3841 7125‐0
Fax +49 3841 7125‐23

Replacement parts department:
Phone +49 40 3070 8668‐3
Fax +49 40 3070 8668‐9
spareparts@mas‐wismar.com

Service department:
24‐h‐Service‐Hotline: +49 3841 7125‐21
Fax: +49 3841 7125‐23
service@mas‐wismar.com
12 / 12
186/658
Opti Line
ACG8
Screw pump
Maintenance & Start up Instruction

ACG80601.01GB
187/658
Introduction
A screw pump from IMO is a quality product that is designed for a long problem free operation in tough environ-
ments. As all other mechanical products they do however requires a certain grade of maintenance and service in
order to guarantee a faultless and economic favourable operation.
A recommendation is to go through the pump each 5 year in order to replace wear details such as ball bearings and
certain gaskets and o-rings. A relatively small review of a screw pump from IMO means that the pump in most of
the cases will be in a condition “as new” and therefore give the operator another long and problem free operation.
Indentification of safety instructions

Non complience of safety instruc- Safety instructions where Safety instructions which shall be considered
;
tions identified by the following electrical safety is invol- for reasons of safe operation of the pump
m c
symbol could affect safety for ved are identified by: or pump unit and/or protection of the
persons pump or pump unit itself are marked
by the sign:
ACG80601.01GB
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Contents
Introduction 2
List of components................................................................................................................................................................ 4
Ordering Code....................................................................................................................................................................... 5
Recommended Spare Parts Kitsand tool kits................................................................................................................... 5
Service intervals.................................................................................................................................................................... 6
Inspection of rotors............................................................................................................................................................... 6
Inspection of the magnetic coupling................................................................................................................................. 6
Common aspects whit magnetic couplings...................................................................................................................... 6
DANGER................................................................................................................................................................................ 6
Precautions prior to starting maintenance on the pump............................................................................................... 6
List of tools necessary for dismantling and reassembly................................................................................................. 7
Sectional View....................................................................................................................................................................... 7
Dismantling 8
Reassembly 13
Installation 21
Transport and storage........................................................................................................................................................ 21
Lifting of pump................................................................................................................................................................... 21
Strainer................................................................................................................................................................................. 21
Pipe connections................................................................................................................................................................. 22
Suction line.......................................................................................................................................................................... 22
Discharge line...................................................................................................................................................................... 22
Deaeration............................................................................................................................................................................ 22
Liquid trap........................................................................................................................................................................... 22
Gauges.................................................................................................................................................................................. 23
Pressure relief valve........................................................................................................................................................... 23
Startup 24
Pressure testing and flushing........................................................................................................................................... 24
Before starting:.................................................................................................................................................................... 24
Direction of rotation........................................................................................................................................................... 24
Differential pressure........................................................................................................................................................... 24
Air in the pumped fluid..................................................................................................................................................... 24
Trouble shooting 26
ACG80601.01GB
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List of components
Valid for all ACG Optiline Generation 8 pumps with sizes 045, 052, 060 & 070 and leads K, N & D
With version codes NHBP, NJBP, NKBP, NLBP & NMBP.
Pos Included components in Spare part sets Explanations:

No Designation Qty G012 G054 G057 G070 G098 G012: Rotor set
002 Motor 1 G054: G012+G057 +
003 Connecting frame 1 pos. no 122
004 Angle bracket 1 G057: Joint kit
005 Magnetic coupling complete 1 x G070: Valve element
005A Retaining ring 1 x x x G098: Magnetic cou-
005B Sealing can 1 x pling
005C Inner magnetic rotor 1 x
005D Outer magnetic rotor 1 x
006A Screw 4
007A Screw 6/8
007B O-ring 1 x x x
1020 Power rotor 1 x x
113 Shaft key 1 x x
122 Ball bearing 1 x
124 Retaining ring 1 x x
124A Support ring 1 x x
202 Idler rotor 2 x x
401 Pump body 1
451 Screw 4/6
453 Screw 4
462 Plug 2
462A Sealing washer 2 x x
480 Valve housing 1
5010 Front cover 1
502 Plug 2
506 Gasket 1 x x
514 Retaining ring 1 x x
556 Gasket 1 x x
601 Valve cover 1 x
602 Sealing washer 1 x x x
605 O-ring 1 x x x
608 Valve spindle 1 x
608A Retaining ring 1 x
612 Regulating nut 1 x
614 Valve piston 1 x
615 Valve spring 1 x
701 Screw 4
701A Washer 4
702 Screw 4
702A Washer 4
703 Screw 3
703B Nut 3
998 Drive hub 1
ACG80601.01GB
998B Screw 1
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m
1 Before commencing any work, read this instrucion carefully! Failure to comply with these instrutions
may cause damage and personal injury!
For more information about the pumps identification code, technical data and performance we refer to the ACG
Product description.
Recommended Spare Parts Kits

and tool kits
Every shutdown for service of a plant is costly.
The time for repair should therefore be limited
to a minimum which can be accomplished by
Ordering Code keeping a spare pump. The changed pump
can later be repaired at a suitable place and
Part numbers for pump size can then be used as a spare pump. For mainte-
nance the following spare parts kits and tools
Item Spare Parts sets 045 052 060 070 are recommended:
G012 Rotor set D-lead 193023
Kit Contents To be used for
N-lead 193015 193017 193019 193021
G057 Gaskets, Dismantling of the
K-lead 193016 193018 193020 193022 o-rings etc. pump
G054 Major kit = - - - - G012 Rotorset Repair after major
G012+G057 + breakdown or great
pos.no.122 wear
G057 Joint kit 193031 193032 193033 193034 122 Ball bearing Repair after major
breakdown or great
G070 Valve element 190990 190990 190984 190984 wear
G098 Magnetic coupling H 193035 193035 - - 193128 Guide pins For dismantling and
J 193036 193036 - - pump size 045 assembly of the pump
K 193037 193037 193040 193043 193129 Guide pins For dismantling and
pump size 052 assembly of the pump
L 193038 193038 193041 193044
193130 Guide pins For dismantling and
M 193039 193039 193042 193045 pump size 060 assembly of the pump
122 Ball bearing 192855 192855 192827 192827 193131 Guide pins For dismantling and
ACG80601.01GB
480 Valve housing 191022 191025 191028 191031 pump size 070 assembly of the pump
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Service intervals
e
2 ATTENTION! In areas where permanent
The intervals for inspection and replacement of wear magnetic couplings are handled or stored
parts vary greatly with the properties of the pumped with open access, persons with heart
liquid and can only be determined by experience. All pacemakers should keep a distance
internal parts of the ACG Optiline pump are lubricated of 3 meters. For permanent magnetic
by the pumped liquid. Pumping liquid which contain couplings assembled within a pump a
abrasive materials, or liquid that is corrosive, will sig- safety distance of 3 meter is sufficient.
nificantly reduce service life and call for shorter service
intervals. Wear in the pump will normally show as:
• Vibration
• Noise
• Loss of capacity
• Reduction in flow/pressure
• Loss of the magnetic power
We recommend planned inspections and/or overhaul
at regular intervals, not exceeding 5 years. It is recom-
mended to always have the spares included in joint
spare part kit G057 together with the ball bearing 122
available for a planned inspection.
Inspection of rotors
To reach the idler rotors in a quicker way than de-
scribed in the dismantling section, loosen the rear cover
(480) with the valve. Screw out the idler rotors back-
wards. 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 follow-
ing max clearance values may apply: Between rotor and
bores: 0.2 mm, Between rotor flanks: 0.4 mm For light
duties (low pressure, medium viscosity) even bigger Precautions prior to starting maintenance on
clearances may be acceptable but for low viscosity/high
pressure duties the limit will be lower. Also watch if
the pump
there are major scratches on these parts.
m
Inspection of the magnetic coupling 3 If the pumps operating temperature
exceeds 60°C, let the pump cool off before
The magnetic coupling with all its components is con- any service, maintenance or dismantling
sidered to be maintenance free if operated and mount- work is commenced to avoid burn injury
ed according to our instructions.
The lifetime of the magnets is well within the lifetime
m
of the pump and exchange of the magnets is only neces- 4 All work carried out on the pump has to be
sary if a major breakdown has occurred as a result of performed in such a manner that risks for
for example excessive amounts of dirt or particles in the personal injury are observed!
pumped fluid.
m
5 When handling liquids that may harm skin,
Common aspects whit magnetic couplings use gloves and/or protecting clothing!
Permanent magnetic couplings generate a strong
magnetic field. The installation must be carried out
only by trained staff that has the understanding of how
m
6 When handling liquids which may involve
a magnetic coupling acts and all the safety precau- fire hazard appropriate precautions to
tions related to it. All installation instructions must be avoid danger are to be taken.
strictly followed. Modifications or changes to the mag-
netic coupling or its components are not to be allowed
m
under any circumstances. IMO does NOT take any 7 In case of failure for system with elevated
responsibilities for damages caused by improper use or pressure, fluid jets may cause injury and/
damages related to this. or damage.
m
Magnetic data carriers such as bank cards, floppy disks 8 Oil leakage may make the floor slippery
etc may become unreadable and should always be kept and cause personal injury.
separated from the magnetic field.
DANGER
m
9 Before any maintenance work, ensure that
Installations and maintenance must always take place the driver is deenergized and the pump
during complete shutdown in an un-pressurised condi- hydraulically isolated.
tion. The drive unit must be secured against inadvert-
ent switching on by means of blocking the electrical
c
supply to the electric motor in order to avoid serious 10 Connecting and disconnecting of electrical
injuries due to rotating parts. cables must be done only by personnel
ACG80601.01GB
authorized to do such work.
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Dismantling and reassembling the pump
List of tools necessary for dismantling and reassembly
Mounting sleeve
dimensions (mm)
ACG size d-min D L-min
045 - 052 21 32 ±3 110
060 - 070 36 50 ±3 145
A = Puller F = Screw driver

B = Spanner various sizes G = Circlip pliers
C = Plastic mallet H = Guide Pins (for ordering code, see table page 5)
D = Allen keys various sizes J = Oil can
E = Mounting Sleeve for ball bearing (sizes - see table)
Sectional View
ACG80601.01GB
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Dismantling
A. C.
• Mount the first half of the 4 guide pins which

• Turn the electricity OFF. comes in two parts through the pumps front
cover into the connecting frame.
• Close the valves.
• Attach the dismantling bolts and slowly start
• Disconnect the electric motor. to tight them until the pump is separated from
• For horizontal installation drain the pump by the electrical motor.
loosen screws 453 3-4 turns and loosen valve • Continue to tight the bolts while making sure
housing 480. that the pump and the electric motor with its
connecting frame is in a straight line with each
other.
B. D.
• Remove the 4 bolts 701 and the washers 701A • Mount the extension guide pins when it is pos-
sible and continue to separate the pump from
the electrical motor in an straight line in order
to avoid damages on the magnets.
• The use of a strap or similar devices on the
electrical motor in order to stabilize and secure
the package from the magnetic force is recom-
mended.
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E. G.
• Unscrew the bolts 007A • Remove the inner magnetic rotor with a suit-
• Pull out the sealing can 005B with its o-ring able three arm puller
007B
F. H.
• Remove the circlip 005A with a suitable plier. • Remove the key 113 from the pump shaft.
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I. K.
• Remove the circlip 514 from the front cove with • Remove the circlip 124 with a suitable plier
a suitable plier. from the power rotor 1020.
• Remove the support washer 124A.
J. L.
• Pull out the power rotor 1020 with its ball bear- • Unscrew the bolts 451 from the front cover 5010
ing 122 by hand force from the pump body. • Separate the front cover 5010 with its gasket 506
from the pump house 401.
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M. O.
• Pull out the idlers 202 from the pump body 401 • Unscrew the 4 bolts 453 with a suitable spanner
by hand force. and remove the rear cover 480 with its gasket
556 from the pump body 401
N. P.
• Unscrew the complete internal relief valve by • Unscrew the 4 bolts 702 with a suitable spanner
means of a suitable open spanner and pull it and separate the connecting frame 003 from
out from the rear cover 480 together with its the electrical motor 002
seal ring 602.
ACG80601.01GB
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Q. S.
• Unscrew the bolts 006A with a suitable allen • Unscrew the locking bolt 998B from the cou-
key and remove the outer magnet from the pling 998.
coupling 998
R. S.
• Measure the distance on the shaft coupling and • Use a three arm legged puller and remove the
note the value so that it can used during the coupling 998 from the electrical motor.
assembly later on.
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Reassembly
A. C.
• Mount the coupling half 998 onto the drive

shaft of the electrical motor by means of a big
washer and a threaded pin and a nut that is
tightened in order to press the coupling half
onto the shaft.
NOTE: Do not use a hammer as this can Dam-
age the shaft!
B. D.
• Measure the distance in order to get the same • Tight the looking bolt 998B with a suitable
as before the coupling was removed. hexagon key
ACG80601.01GB
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E. G.
• Attach the outer magnet rotor 005D to the • Mount the ball bearing 122 on the power rotor
coupling half 998 and tight the screws 006A ac- 1020 with the mounting tool described on page
cording to the tightening torque table on page 8, use a threaded pin together with a nut and a
17 in this manual. washer and press down the ball bearing on the
shaft carefully. Note: in order to make the ball
bearing to slide on easier it is recommended to
grease the shaft surface.
F. H.
• Attach the connecting frame 003 to the electri- • Mount the washer 124A and slide on the circlip
cal motor 002 by means of tightening the bolts 124 with a suitable plier on the power rotor
702 according to the tightening torque table on 1020.
page 17 in this manual. • Mount the key 113 on the power rotor 1020.
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I. K.
• Mount the front cover 5010 with its gasket 506 • Attach the Circlip 514 with a suitable plier into
onto the pump body 401 with the bolts 451 the front cover.
• The bolts 451 are to be tightened according to
the tightening torque table on page 17 in this
manual.
J. L.
• Carefully slide the power rotor 1020 with its ball • Press the inner magnetic rotor onto the rotor
bearing 122 into the pump body 401 with hand shaft by means of a threaded pin and a nut/
force. Note: do not forget to lubricate the rotor washer, push it into its final position by means of
prior to the mounting. a suitable socket.
NOTE: DO NOT USE A HAMMER AS THIS

CAN DAMAGE THE PARTS!
ACG80601.01GB
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M. O.
• Mount the circlip 005A with a suitable plier. • Mount the rear cover 480 with its gasket 556
onto the pump body and tight the bolts 453 ac-
cording to the tightening torque table on page
17 in this manual.
N. P.
• Carefully slide the lubricated idlers into the • Mount the sealing can 005B with its o-ring
pump body 007B onto the pump and tight the bolts 007A
• Make sure that the lubrication slots are point- according to the tightening torque table on
ing backwards page 17 in this manual.
ACG80601.01GB
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Q. R.
• Mount the guiding pins into the connecting

frame 003.
S.
• Mount the pumps internal relief valve into

the back cover by means of letting the inner
threaded ring be mounted first with a distance
to the outer one of 1-2 mm
• Do not forget to include the seal ring 602
• Tight the nut accordingly with a suitable span-
ner.
• Attach 4 bolts in the pumps front cover in order

to avoid a to rapid mounting due the magnetic
forces that will take place when the pump
package is joined.
ACG80601.01GB
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T. U.
• Slowly lower the electric motor with the con- • Unscrew the stopping bolts and allow the
necting frame towards the pump until the stop pump to completely join with the electrical mo-
bolts touches the frame. tor/connecting frame
• Avoid side forces that could damage the • Avoid side forces that could damage the
magnets as it is crucial that the package is con- magnets as it is crucial that the package is con-
nected in a straight line nected in a straight line
NOTE: The magnetic forces are very high at • Unscrew the last part of the guide pins.
this point and can easily cause severe inju- NOTE: The magnetic forces are very high at
ries DO NOT EVER PUT YOUR FINGERS this point and can easily cause severe injuries
OR HANDS BETWEEN THE CONNECTING DO NOT EVER PUT YOUR FINGERS OR
FRAME AND THE PUMP AS AN ACCI- HANDS BETWEEN THE CONNECTING
DENTAL SLIP DOWNWARDS EASILY CAN FRAME AND THE PUMP AS AN ACCI-
CRUSH A HAND OR EVEN CUT A FINGER. DENTAL SLIP DOWNWARDS EASILY CAN
CRUSH A HAND OR EVEN CUT A FINGER.
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Tightening torque (Nm)
V. Pos.No
Size 045 052 060 070
006A 10 10 10 10
007A 20 20 20 20
451 47 47 81 81
453 47 47 81 61
462 74 74 74 74
502 47 47 47 47
301 13 20 47 47
702/IEC 100-132 30 30 30 30
702/IEC 160-225 74 74 74 74
703B/IEC 100-132 81 81 81 81
703B/IEC 160-225 197 197 197 197
998B 15 15 15 15
• Tight the bolts 701 with its washers 701A with a

suitable spanner according to the torque tight-
ening table on this page.
ACG80601.01GB
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Installation and Start-up Instruction
Valid for ACG 045-070 Opti Line Generation 8
BEFORE COMMENCING ANY WORK,

READ THIS INSTRUCTION CAREFULLY!
Indentification of safety instructions

Non complience of safety instruc- Safety instructions where Safety instructions which shall be considered
;
tions identified by the following electrical safety is invol- for reasons of safe operation of the pump
m c
symbol could affect safety for ved are identified by: or pump unit and/or protection of the
persons pump or pump unit itself are marked
by the sign:
ACG80601.01GB
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Installation
Design limitations and technical data for each pump

are found in the Product description. Installation of
IMO AB low pressure pumps does not require special
skills. However, these instructions presume that the
work is carried out by experienced fitters!
m
11 Failure to comply with these instructions
may cause damage and personal injury
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 Fig 1. Keep dry and clean
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.
Lifting of pump max 90°

min 60°
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.
m
12 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.
Strainer Fig 2. Lifting the pump

The pump has to be protected from foreign matters
such as weld slag, pipe scale, etc., that could enter the
pump via the suction line. If the cleanliness of the sys-
tem cannot be guaranteed, a strainer must be installed
in the inlet pipe near the pump. For practical reasons
a suction strainer with 0.8-2.0 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 nor-
mal operating viscosity. A vacuum gauge between the
strainer and the pump inlet is recommended to indicate
when the strainer needs cleaning.
m
13 All work carried out on the pump has to be
performed in such a manner that risks for
personal injury are observed.
m
14 Lifting a complete pump unit, using Fig. 3 Strainer
slings or hooks attached to the pump or
connecting frame may be dangerous since
the centre of gravity of the pump unit may
be higher than the points of attachement.
ACG80601.01GB
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Pipe connections
The pipe work shall be installed and supported so that
no pipe stresses are transferred to the pump body.
The pipe forces and torque transferred to the pump
shall be in accordance with ISO 14847. 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.
Suction line
Fig. 4 Pipe connections
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 com-
ponents such as valves, strainer, pipe bends etc. Gener-
ally, the pressure drop in the suction line should be as
low as possible, which is achieved if the suction pipe is
short, straight and has a suitable diameter. The veloc-
ity 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.
Discharge line Fig. 5 Suction Line

The discharge line should be dimensioned to keep the
velocity in the range 1 - 3 m/s.
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 is recommend-
ed) 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 a stand-by
pump.
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.
Fig. 6 Deaeration
m
15 When handling liquids that may harm skin
use gloves and/or protective clothing
m
16 When handling liquids shich may involve
fire hazards appropriate precautions to
avoid danger are to be taken.
Fig. 7 Liquid trap

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Gauges
Gauges for monitoring the pump’s working conditions
are recommended. These gauges should be placed
readable as close to the pumps in- and outlet flanges as
possible. On the ACG Optiline standard pumps there
are gauge connections for both in- and outlet.
Pressure relief valve bar

All systems with screw pumps must be equipped with
a pressure relief valve installed immediately adjacent
to the pump. In the standard versions of IMO ACG
Optiline pumps, this pressure relief valve is an integral
part of the pump to protect the system against excess
pressure. When liquid is circulated through the valve it Fig. 8 Gauges
heats up in proportion to the set pressure level and the
percentage of by-passed liquid. 100% bypass can only
be tolerated for less than about 3 minutes, 50 %by-pass
generally for unlimited periods of time. If more than
50% recirculation is anticipated, a value specific to each
application should be determined by closely monitor-
ing the pump body temperature. If the pump is operat-
ing in line with a separate pressure control valve
(see fig. 9), the setting of the relief valve should be high
enough so as 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.
Also remember that a total bypass by the pumps inter-
nal relief valve will cut of the cooling flow to the pumps
magnetic coupling and cause an overheating with
destroyed magnets as a result quite fast.
m
17 Oil leakage may make the floor slippery
and couse personal injury. Fig. 9 Pressure Relief Valve
Fig. 10 External control with presssure relief valve

ACG80601.01GB
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Startup
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.
Before starting:
After installation and whenever it can be assumed that
the pump has been emptied, the pump must be thor- Fig. 11 Filling the pump
oughly filled with liquid. See fig 11.
m
18 Make sure the prime mover is locked out
and can not be started accidentally.
;
19 Don't mix up with arrow for inlet and
outlet!
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 ar-
row. The arrow is placed on the side of the front cover
5010 as well as on riveted steel plates on the connecting
frame 003.
Differential pressure
Differential pressures bellow 1 bar is strictly forbidden
as the magnetic coupling under these conditions may
loose its cooling flow and cause an overheating of the
magnetic coupling with a risk of a potential fire as a
result. We do strongly recommend magnetic coupled
pumps to be equipped with a differential pressure
monitoring device that stops the pump automatically if
the differential pressure for some reason should drop to
below 1 bar.
Fig. 12 Direction of rotation
Air in the pumped fluid
It is forbidden to use the ACG Optiline pump with flu-
ids that contains more than 0,2% of air due to the risk of
ignition during an eventual overheating of the pump.
Fig. 13 Differential Pressure

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Trouble shooting
Problem Cause What to do

Wrong direction of rotation - Electric cables to motor wrongly Reverse the terminal connection on
connected. electric motor.
c
20 Connecting and disconnec
ting 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 Check all components in suction line.
drop in the suction line is too high. The inlet condition should be checked
with a vacuum gauge at the pump inlet.
- Major air leakage into the suction Check the suction line.
line.
- The pump cannot evacuate the air See the chapter on Deaeration
through the discharge line due to (see page 22).
excessive counter pressure.
No flow - The pump is not primed. See above.
- The pressure relief valve is set be- Readjust the pressure relief valve to a
low the counter pressure. value above counter pressure.
Flow too low - The pressure relief valve is set too Readjust the pressure relief valve
low (Discharge pressure also low).
- Something is restricting the flow in Check all components in the suction
the suction line. (This would usually line (strainers, valves etc.).
cause noise).
- The pumped liquid contains a sig- See the chapter on Noise and Vibration.
nificant amount of compressible gas, ( Page 11).
such as free air. (This would usually
cause noise).
Pressure too low - The pressure relief valve is set too Readjust the pressure relief valve.
low.
- Counter pressure in the discharge Check the components in the discharge
line is too low due to a major leak- line inclusive the recipients.
age.
- The valve piston is stuck in open Check the valve. See Maintenance
position. and Service instruction for respective
pump.
- Something is restricting the flow in Check all components in the suction
the suction line. (This would usually line (strainers, valves etc.).
cause noise).
- The pumped liquid contains a sig- See the chapter on Noise and Vibration.
nificant amount of compressible gas, (Page 11).
such as free air. (This would usually
cause noise).
- A too small pump has been chosen. Contact your IMO AB representative.
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Problem Cause What to do
Pressure too high - The pressure relief valve is set too Readjust the pressure relief valve.
high.
- The oil is too cold (or has higher Reduce the pressure setting until opera-
viscosity than anticipated). tional temperature has been reached.
- Counter pressure in the discharge Check the discharge line.
line is too high.
Drive motor difficult to - Counter pressure too high. See above: Pressure too high.
start or tends to stop by - Liquid too cold. Readjust the pressure relief valve to a
tripping the motor overload lower value. Thus the power consump-
relay tion 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 prevail- Check the motor.
ing conditions.
- Electrical power supply faulty. Check the motor and motor connection.
- Motor overload relay set too low or Readjust or replace the relay.
is faulty.
- 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 vibration - The flow to the pump is insufficient. See chapter: The flow is too low.
- Insufficient support of pipe work. Check for pipe vibrations in the pump
connections. Check that the pipes are
m
21 Monitor the sufficiently clamped.
pump function
and shut down - Bad alignment Check alignment, see page 4.
if any sign of - Air leakage into the suction line. Check the suction line for air leakage.
malfunction is - Free air in the liquid or gas cavita- For pumps with Tuning:
noticed tion. Contact your IMO representative or
IMO service department.
- Faulty electrical supply. Check all three phases of the supply.
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www.imo.se
IMO AB: P.O. Box 42090, SE 126 14 Stockholm, Sweden

ACG80601.01GB
Telephone: +46 8 50 622 800, Telefax: +46 8 645 1509
214/658
ACG8
OptiLine
Product Description
Flow volume: 75 - 1180 l/min

Max differential pressure: 16 bar
Applications: Circulation and transfer
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1. Applications
1.1 Functionality
The ACG OptiLine pump is used for a number of different fluids:
Fuel oil, vegetable oil, hydraulic oil and other hydraulic fluids, polymers, emulsions and any
non-aggressive fluid with sufficient lubricating properties.
If requested, the ACE pump may be certified according to any of following classification societ-
ies: DNV, BV, LRS, ABS, RS, GL, RINA, KR, NK, RMR or CCS.
1.2 Applications
Typical applications are:
- Lubrication of diesel engines, gears, gas and steam turbines, hydro turbines and paper ma-
chines
- Circulation for cooling and filtration in large machineries, hydraulic systems and transformer
oil for insulation in transformers
- Transfer onboard ships, in oil factories, refineries, tank farms etc
- Fuel supply duties for diesel engines
1.3 Installation
The pump is designed to be flange-mounted to its electric motor via a connecting frame and a
magnetic coupling. By the angle bracket, the pump may be mounted horizontally or vertically.
As standard, the pump is supplied without counter flanges (DIN type) but they can be included
if requested.
As standard the pump is delivered with the discharge side to the right when seen from the
pump shaft side(see below).
For more information about installation, see Service, Maintenance and Installaton for ACG Op-
tiLine.
Mounting standard picture M93-0.
On request the pump can be delivered with opposite flow direction, M39-0.
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2. Pump model code
A C G 0 4 5 N 8 N K B P
Pump series
ACG
Size
Power rotor diameter [mm]
045, 052, 060, 070
Lead
K and N = Normal lead
D = High lead, sizes 070
Generation
Design generation 8
Material in pump body

N = Nodular cast iron
Shaft seal design

Magnetic shaft coupling
(Size of coupling selected)
H, J, K, L, M
Mounting
B = Flange mounting
Valve
P = Pressure relief valve included with spring for max. 16 bar
Special design
Code group omitted for standard design (A-number)
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3. Technical Data
3.1 Pressure Information
Pressure relief valve
The pump is equipped with an integral pressure relief valve with internal return, limiting
the differential pressure across the pump and protecting the pump. Should the discharge
line be blocked, the relief valve will open by the pressure.
The valve is adjustable for different opening pressures. The value of the pressure limit can
be set at the factory and should be adjusted at installation (see Service, Maintenance and
Installaton for ACG OptiLine).
The maximum pressure accumulation varies with pump size, speed and viscosity, but will
normally not exceed 4 bar.
The valve has a maximum set pressure of 16 bar.
Inlet pressure
Minimum inlet pressure (suction capability) is dependent on fluid viscosity and rotation
speed. It increases with decreasing viscosity and decreasing speed. Information about mini-
mum inlet pressure for each individual duty case can be obtained from IMO AB or pump
selection software WinPump.
Maximum inlet pressure is 15 bar.
Discharge pressure
Maximum discharge pressure is 16 bar.
Differential pressure
Maximum differential pressure is 16 bar but reduced at low viscosities according to table
below
Viscosity [cSt] 1,4 2 6 10 >12
Max. diff. pressure [bar] 6,9 8,0 12,4 15 16
Refer to your IMO representative or use the pump selection software WinPump to determine
the exact operating limits.
3.2 Driver information

Driver type
The power from motor to the OptiLine ACG pump is transmitted without mechanical con-
tact over a magnetic coupling. A coupling hub with a set of permanent magnets is mounted
on the pump shaft. This hub is totally enclosed by a stainless steel can. The motor hub with
another set of permanent magnets rotates on the outside of this can.
Thus the pumped liquid is totally confined within the pump without the use of a conven-
tional shaft seal.
Speed
The maximum speed is 3600 rpm. For higher speeds, contact IMO AB.
Rotation
The pump is designed to operate in one rotational direction only, as standard clockwise
when facing the shaft end. Pumps for CCW operation can be delivered on special request.
For shorter periods of time, a few minutes for emptying a discharge line, the pump may be
operated in reverse direction, provided the back pressure is limited to 3 bar.
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3. Technical Data
3.3 Sound level
Typical pump sound levels refer to free field conditions at a distance of 1 m from the pump.
Noise of driver excluded in the quoted figures. The sound levels are measured at a discharge
pressure of 5 bar, speed 2900 rpm and viscosity 37 cSt.
Size 045 052 060 070
Sound level dB [A] 59 63 66 68
3.4 Moment of Inertia

Moment of intertia [10-3 kgm2]
Size
Coupling sing 045 052 060 070
H 15 - - -
J 16 17 - -
K 17 17 28 67
L 17 17 28 72
M 19 19 34 78
3.5 Magnetic shaft coupling

< Torque values (greater than, at least) [Nm]
Size
Coupling 045 052 060 070
H 10 - - -
J 20 20 - -
K 30 30 25 85
L 40 40 50 140
M 60 40 80 180
3.6 Fluid viscosity

OptiLine:
1.4 – 1500 cSt
3.7 Fluid temperature

-20 – +180 °C
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4. Design
4.1 Ball bearing
No ball bearing for the pump is needed since the forces are handled by the ball bearing of the
motor.
4.2 Material & design
Model Material pump Material rotot Material idler Material seal Material elastomers
ACG OL Nodular cast Structural Cast iron, sur- Special rubber
iron steel, surface face treated
treated
4.3 Steam tracing

During cold start-up conditions, high viscosity could cause the rated torque for the coupling to
be exceeded.
The IMO OptiLine pump series have a way to warm up the pump by leading steam into small
channels at the front cover. This is recommended if cold upstart can be assumed.
See Pump Unit Dimensions for dimensions of the connections to the steam system.
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5. Performance Guide
Typical performance values at 5 bar
Flow calculated at 26 cSt, power at 260 cSt.
m3/h l/min
80 1400
70 1225
60 1050
50 875
40 700
30 525
20 350
10 175
0 0
045K 045N 052K 052N 060K 060N 070K 070N 070D
045K 045N 052K 052N

rpm l/min kW form l/min kW form l/min kW form l/min kW form
1470 77 1,5 NJBP 95 1,8 NJBP 125 2,2 NJBP 153 2,7 NKBP
1770 97 1,8 NJBP 119 2,2 NJBP 156 2,8 NJBP 191 3,4 NKBP
2950 174 3,5 NJBP 216 4,2 NJBP 277 5,3 NKBP 340 6,4 NKBP
3550 213 4,4 NKBP 265 5,4 NJBP 229 6,9 NLBP 415 8,0 NKBP
060K 060N 070K 070N
rpm l/min kW form l/min kW form l/min kW form l/min kW form
1470 197 3,7 NLBP 240 4,3 NLBP 314 6,8 NKBP 388 7,8 NKBP
1770 245 4,6 NLBP 298 5,5 NLBP 389 8,5 NKBP 480 9,9 NLBP
2950 432 8,9 NLBP 525 10,5 NLBP 686 16,8 NLBP 843 21,0 NLBP
3550 528 11,3 NLBP 641 13,3 NLBP 836 21,8 NLBP 1027 27,2 NLBP
070D
rpm l/min kW form
1470 440 9,7 NLBP
1770 548 12,4 NLBP
2950 971,3 24,7 NLBP
3550 1187,6 32,0 NLBP
OACG8 1102.01 GB
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6. Sectional view
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OACG8 1102.01 GB
Pos No Denomination Pos No Denomination Pos No Denomination
002 Motor 401 Pump body (608A) Retaining ring

003 Connecting frame 451 Screw (612) Regulating nut
004 Angle bracket 453 Screw (614) Valve piston
005 Magnetic coupling 462 Plug (615) Valve spring
005A Retaining ring 462A Sealing washer 602 Sealing washer
006A Screw 480 Valve housing 701 Screw
007A Screw 5010 Complete front cover 701A Washer
007B O-ring (502) Plug 702 Screw
1020 Complete power rotor 506 Gasket 702A Washer
(106) Balancing piston 514 Retaining ring 703 Screw
113 Key 556 Gasket 703A Washer
122 Ball bearing 6000 Complete valve element 703B Nut
124 Retaining ring (601) Valve top cover 998 Drive hub
124A Support ring (605) O-ring 998B Screw
202 Idler rotor (608) Valve spindle
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www.imo.se
Notes:
- Components with Pos No within parenthesis are parts of subassembly
9
8. Pump Dimensions
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OACG8 1102.01 GB
8. Pump Dimensions
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www.imo.se
Drawing remarks: Notes:
(1) Connection for heating. ISO G1/4 (5) Mounting distance to motor flange - Dimensions in mm - Counter flanges according to
(2) Control for relief valve - Weight is an approximate value DIN2633/ND16
(3) Inlet gauge. ISO G3/8 and valid for respective pump size 1) Tolerances ISO h7
(4) Outlet gauge. ISO G3/8 with it´s largest magnetic coupling
11
9. Pump Unit dimensions
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OACG8 1102.01 GB
9. Pump Unit dimensions
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Drawing remarks: Notes:
(1) Outlet gauge. ISO G3/8 (5) Space for dismantling - Dimensions in mm - Dimensions Z and Weight are valid
(2) Inlet gauge. ISO G3/8 - Dimensions A, A1, AC and Weight for respective pump size with it’s
(3) Control for relief valve are valid for Brook Crompton mo- largest magnetic coupling
(4) Connection for heating. ISO G1/4 tors - Weight is an approximate value
13
10. Accessories
A bare shaft pump (Fig. 1) can be ordered with the accessories in fig. 2-6.

Fig. 1 Bare shaft pump Fig. 2 Set of counter flanges Fig. 3 Connecting frame

Fig. 4 Electric motor Fig. 5 Angle bracket Fig 6. Gauge panel
11. Maintenance and Service

Spare parts for these pumps are easily available from stock. For detailed information and
know-how about service, see see Service, Maintenance and Installaton for ACG OptiLine or con-
tact IMO AB.
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For latest updates, check:
www.imo.se
OACG8 1102.01 GB
IMO AB: P.O. Box 42090, SE 126 14 Stockholm, Sweden. Telephone: +46 8 50 622 800
230/658
Pump calculation
Date of calculation Signature

2014-02-17 KE
Inquiry from MAN

Our ref. No 131M083-01
Cust. ref. No. 5301770
Item No Booster
Fluid type IF-380
Driver HMA2 132 S2-2 / 2900 rpm / 7.50 kW
Magnetic coupling Magnetic coupling 60 Nm/19 kW @ 2952 rpm
Selected pump ACG 045N8 NMBP
Duty case No. 1 2
Outlet press. bar 10.0 10.0

Inlet press. bar 4.0 4.0
Min. inlet pressure bar 1.0 0.64
Differential pressure bar 6.00 6.00
Speed rpm 2952 2923

Viscosity cSt 21.9 1000
Inlet temp °C 118 35.9
Calc'd flow m³/h 12.7 14.0

Required flow m³/h 12.8 12.8
Power kW 3.59 5.80
Efficiency tot 58.0 40.0
Calculations made by IMO pumpselection program WinPump 3.7.9 F2C7C950D2BDCF3B

Pump file V6.09, Oil file V1.9, Driver file V1,99
IMO AB TELEPHONE: E-MAIL: TELEFAX:

P.O. Box 42090 +46-(0)8-50622800 info@imo.se +46-(0)8-6451509
S-126 14 Stockholm
Visitors: Västberga allé 50
231/658
Driver specification

2014-02-17 KE
Inquiry from MAN

Item No Booster
Høyer HMA2 132 S2-2
Manufacturer Høyer
Model HMA2 132 S2-2
Frequency 50 Hz
Power 7.50 kW
Nominal speed 2900 rpm
Voltage 400 V
Y/D D
Current 13.5 A
Start current 113 A
IEC size 132
Weight 51.0 kg
Noise 72.0 dB(A)
Efficiency 88.1 %
cos(fi) 0.90
Isol/prot F/IP55
Classification Marine/Industrial
Mounting IM3001/B5
Cooling IC411
Cable 2xM25*1.5+M20*1.5
Material Aluminium
Inertia 0.0160 kgm²
Torque 87.5 Nm
Driver file V1,99 F2C7C950D2BDCF3B

P.O. Box 42090 +46-(0)8-50622800 info@imo.se +46-(0)8-6451509
S-126 14 Stockholm
232/658
Pump calculation

2014-02-17 KE
Inquiry from MAN

Item No Booster MGO
Fluid type Marine Diesel Oil
Driver HMA2 132 S2-2 / 2900 rpm / 7.50 kW
Magnetic coupling Magnetic coupling 60 Nm/19 kW @ 2954 rpm
Duty case No. 1 2
Outlet press. bar 10.0 10.0

Inlet press. bar 4.0 4.0
Min. inlet pressure bar -0.00 -0.63
Differential pressure bar 6.00 6.00
Speed rpm 2954 2950

Viscosity cSt 1.90 40.0
Inlet temp °C 96.1 -3.2
Calc'd flow m³/h 11.1 13.1

Required flow m³/h 10.0 10.0
Power kW 3.42 3.76
Efficiency tot 53.0 58.0
Calculations made by IMO pumpselection program WinPump 3.7.9 F2C7C950D2BDCF3B

Pump file V6.09, Oil file V1.9, Driver file V1,99

P.O. Box 42090 +46-(0)8-50622800 info@imo.se +46-(0)8-6451509
S-126 14 Stockholm
233/658
Driver specification

2014-02-17 KE
Inquiry from MAN

Item No Booster MGO
Høyer HMA2 132 S2-2
Manufacturer Høyer
Model HMA2 132 S2-2
Frequency 50 Hz
Power 7.50 kW
Nominal speed 2900 rpm
Voltage 400 V
Y/D D
Current 13.5 A
Start current 113 A
IEC size 132
Weight 51.0 kg
Noise 72.0 dB(A)
Efficiency 88.1 %
cos(fi) 0.90
Isol/prot F/IP55
Classification Marine/Industrial
Mounting IM3001/B5
Cooling IC411
Cable 2xM25*1.5+M20*1.5
Material Aluminium
Inertia 0.0160 kgm²
Torque 87.5 Nm
Driver file V1,99 F2C7C950D2BDCF3B

P.O. Box 42090 +46-(0)8-50622800 info@imo.se +46-(0)8-6451509
S-126 14 Stockholm
234/658
Electric Motors
Motor Manual
hoyermotors.com
Manual
235/658
Motor Manual
1. General Correct alignment is essential to avoid bearing, vibration

and shaft failure.
This manual concerns the following types of standard Use appropriate methods for alignment.
induction motors from Hoyer: Re-check the alignment after the final tightening of the
HMA2, HMC2, HMD, HMT, MS, Y2E1, Y2E2, YDT bolts or studs.
These motors are manufactured in accordance with IEC/EN Check that drain holes and plugs face downwards. We
60034-4 and IEC/EN 60072. recommend opening the drain hole for motors placed
Motors are rated for the ambient temperature range -20°C outdoors and not running 24 hours / day, so that the motor
to +40°C and site altitudes ≤1000 m above sea level. can breathe, thus ensuring a dry motor.
Low-voltage motors are components for installation in
machinery. They are CE marked according to the Low
Voltage Directive 2006/95/EC 4. Electrical connection
Work is only permitted to be carried out by qualified
2. Transport and storage specialists and must to be carried out in accordance with
Check the motor for external damage immediately upon local regulations.
receipt and, if found, inform the forwarding agent right Before work commences, ensure that all power is switched
away. Check all rating plate data, and compare it with the off and cannot be switched on again. This also applies to the
requirement of the motor. auxiliary power circuits, e.g. anti-condense heaters.
Turn the shaft by hand to check free rotation, remove Check that supply voltage and frequency are the same as
transport locking if used. rated data.
Transport locking must be used again for internal transport Motors can be used with a supply deviation of ± 5% voltage
also. It is also important that transport locking is used when and ± 2% frequency, according to IEC60034-1
motors are transported mounted on equipment.
All motors should be stored indoors, in dry, vibration- and Connection diagrams for main supply and accessory as PTC
dust-free conditions. or heater are located inside the terminal box.
Lifting eyebolts must be tightened before use. Damaged Connections must be made in such a way as to ensure that
eyebolts must not be used, check before use. Lifting eyes at a permanently safe electrical connection is maintained,
motor must not be used to lift the motor when it is attached both for the main supply and the earth connection.
to other equipment. We recommend that crimped connections are made in
accordance with IEC 60352-2.
Before commissioning, measure the insulation impedance.
If values are ≤ 10MΩ at 25°C, the winding must be oven dried. Tightening torques for terminal board screws:
The insulation resistance reference is halved for each 20°C Thread M5 M6 M8 M10 M12 M16 M20
rise in motor temperature.
T.(Nm) 2.5 3.5 7 12 18 35 55
It is recommended that shafts are rotated periodically by
hand to prevent grease migration.
Ensure that the terminal box is clean and dry.
Unused glands must be closed.
3. Installation Check the terminal box gasket before it is remounted.
The motor must be fixed on a stable, clear and flat founda-
tion. It must be sufficiently rigid to withstand possible short 5. Maintenance
circuit forces.
It is important to ensure that the mounting conditions do Inspect the motor at regular intervals, keep it clean and
not cause resonance with the rotational frequency and the ensure free ventilation air flow, check the condition of
doubled supply frequency. shaft seals and replace if necessary. Both electrical and
Only mount or remove drive components (pulley, coupling, mechanical connections must be checked and tightened if
etc.) using suitable tools, never hit the drive components necessary.
with a hammer as this will cause damage to the bearing.
The motor are balancing with half key, ensure that the drive
components are also the same.
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Motor Manual
Bearing size and type are specified on the rating plate. The table values are based on an ambient temperature of
Motor types HMA2 and HMC2 is as standard with lifetime 25°C. The values must be halved for every 15K increase in
greased bearing with motor size ≤225. bearing temperature.
Motor types MS and Y2E is as standard with lifetime greased Higher speed operations, e.g. frequency converter drive will
bearing with motor size ≤160. require shorter greasing intervals. Typically, doubling the
speed will reduce the values by 50%.
Typical duty hours for lifetime lubricated bearings.
Frame size Poles Typical lifetime

6. Special note for Atex Zone 22 motors.
56 – 160 2 – 8 40.000h Notice for the use of electrical equipment in areas with
180 2 35.000h combustible dust.
200 2 27.000h Designation of motor according to EC directive:
Ex II 3D T125°C, IP55.
225 2 23.000h
180 – 225 4 – 8 40.000h The dust hazardous 3-phase asynchronous motors are
in accordance with European standard EN 50281-1-1.
Motors with a re-greasing system must be lubricated with Combustible dust areas will be found in agricultural areas
high quality lithium complex grease, NLGI grade 2 or 3, with and in industrial environments.
a temperature range of between -40°C to +150°C. Only one electrical installation may be installed in one
specified area (zone).
Motors are normal fitted with a data plate with greasing
information; if it is missing use the following re-greasing Only certificated cable glands for category 2D may be used.
intervals. Unused glands must be closed.
Connections must be made in such a way as to ensure that
Frame Grease 2 pole 4 pole 6 pole 8 pole
a permanently safe electrical connection is maintained,
size (g) (h) (h) (h) (h)
both for the main supply and earth connection.
160 20 4200 7000 8500 8500 Installations must be in accordance with actual standards
180 20 4200 7000 8500 8500 for installation in the Zone 22 area.
200 25 3100 6500 8500 8500
It is recommended that EN 50281-2 is followed according
225 25 3100 6500 8500 8500
temperature and dust on the motor surface.
250 35 2000 6000 7000 7000 The use of motors with so much surface dust that the
280 35 2000 6000 7000 7000 motor temperature increases is not permitted.
315 50 1500 5500 6500 6500 Regularly cleaning is recommended.
The radial shaft sealing ring is part of the ATEX certification.
355 60 1000 4000 5000 6000
It is important that the ring is always intact.
400 80 800 3000 4000 6000 The shaft sealing must be regularly checked, and if dry
it must be lubricated. It is recommended that the seal is
Grease the motor while running, open the grease outlet plug re-lubricated regularly.
and let the motor run 1-2 hours before the outlet grease Always use the original seal ring when replaced.
plug is closed again. Replacing bearings also means replacing the seals.
Grease the motor for the first time during commissioning. All machines must be inspected regularly for mechanical
damage.
The following applies in general for both lifetime lubricated The user is responsible for changing parts in accordance
and re-lubricated bearings: with the lifetime of parts, in particular:
At 60Hz the time will be reduced by app. 20%. bearings, grease and lubrication of shaft sealing.
Data for vertically mounted motors are half of the above
values. Maintenance, repairs and replacement on zone 22 motors
must only be carried out by qualified specialists.
Hoyer Motors, Motor Manual, October 2011 3
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Svend Hoyer A/S · Over Hadstenvej 42 · DK-8370 Hadsten
T +45 86 98 21 11 · F +45 86 98 17 79 · svendhoyer@svendhoyer.com · svendhoyer.com
238/658
INSTRUCTIONS FOR SHELL & TUBE HEATER
Instruction Manual
for Aalborg MX
Table of contents for instruction manual
1. General Description......................................................................................... 1
2. Installation Space Requirements ..................................................................... 2
3. Storage............................................................................................................. 2
4. Mounting and Installation ............................................................................... 2
5. Connecting the Heat Exchanger ...................................................................... 3
6. Operation ......................................................................................................... 3
7. Conservation during shut down periods .......................................................... 4
8. Maintenance and Cleaning .............................................................................. 4
9. Dismantling and reassembling of the tube section .......................................... 5
10. Safety measures ............................................................................................... 5
11. Spare Parts ....................................................................................................... 7
Appendix: Spare Parts Drawing - Dimensional Drawing
1. General Description
Alfa Laval Aalborg MX heat exchangers are of the shell and tube type with u-
tubes.
The Aalborg MX heaters range from 0,5 m² to 60 m² heating surface with design
pressures 16 or 32 BAR. Other capacities may be manufactured at request.
All heaters may be delivered as immersion or outflow heaters for insertion in
tanks.
Aalborg MX heat exchangers are primarily used as fuel oil, lubrication oil, or
water heaters (JCW). The heating media used is either steam, hot water or ther-
mal oil.
Safety valve, thermometer, and pressure gauge may be mounted on a standard
outlet tube (optional).
Regulating equipment for either oil, steam or water is optional.
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Aalborg MX heat exchangers have been type approved by all major classifica-
tion societies.
2. Installation Space Requirements

2.1. Space allowance
When mounting the heater sufficient space must be allowed for withdrawal of
the tube insert for cleaning, inspection, or replacement purposes.
Please refer to dimensional drawing for withdrawal space requirements.
2.2. Installation surface

The heater must be placed on a level and stable surface.
3. Storage
3.1. Damp and humidity
Store the heater only in a dry storage room before installation. If the room is
damp the heater must be isolated with bags of silica gel. To avoid damage it is
recommended the heater be stored in the original packaging.
3.2. Hydrostatic testing

All Alfa Laval Aalborg heat exchangers have undergone hydrostatic pressure
testing before delivery. The testing fluid used contains a certain amount of corro-
sion protection (Castrol Rustilo Aqua 2); hence no further actions regarding stor-
age are required before installation.
3.3. Extended storage

When heat exchangers are to be kept in storage for an extended period of time
we recommend Castrol Rustilo Aqua 2 be used as protection against corrosion.
4. Mounting and Installation

The heat exchanger is designed for vertical or horizontal installations.
In case of horizontal installation, the inlet pipe and media outlet pipe must face
upwards.
If the heater is placed vertically the inlet and outlet tubes as well as the media
inlet must be at the bottom and the heater must be equipped with an air escape
screw at the top end.
The steam regulator (optional) must always be placed horizontally.
Instruction manual for heat exchanger type AALBORG MX 2/7

Manufactured in Aalborg, Denmark
APR. 2001, rev. 3 – Project specification deleted. OKT 2002, rev. 4 – Reference to steam replaced with
heating media. DEC 2005 T32 series torque added.
240/658
The steam trap (optional) should be mounted as close to the condensate outlet as
possible and somewhat lower. The steam trap is always to be placed horizon-
tally.
Place the heater on the surface and drill the holes for the foundation bolts. Place
the bolts into the holes and tighten up at one end, while the other is left suffi-
ciently loose to allow for movement caused by thermal expansion. The bolts at
the expansion end must be secured with counter nuts.
5. Connecting the Heat Exchanger

5.1. Preparation and pipe connection of the heat exchanger
Remove all plugs and cover flanges before connecting the heater. Make sure
sand and other impurities are removed from all connections. Set up the pipe con-
nections and make sure that no forces are transferred to the heat exchanger.
6. Operation
6.1. Commissioning
Before start-up it is important to make sure that all connections are securely
tightened.
Before start-up it is equally important that the heater is filled 100% with liquid
and that all connecting pipes are thoroughly air-vented.
NOTE: Remember to retighten the air ventilation plug.
6.2. Initial adjustments

The safety valve must be adjusted to maximum design pressure or lower.
6.3. Initial start-up

IMPORTANT: Fluid flow through the heat exchanger must be established be-
fore the heating medium is applied.
Tighten all main flange bolts according to below schedule. Operate the heater for
one hour, stop, and retighten all bolts according to schedule.
Heater main flange bolts tightening schedule (dry & smooth values) – T16 types
No bolts Size Torque [Nm] Tightening schedule
MX10 8 M16 50 14725836
MX15 8 M20 83 14725836
MX20 12 M20 79 1 7 11 4 9 2 6 12 5 10 3 8
MX25 12 M24 137 1 7 11 4 9 2 6 12 5 10 3 8
MX30 12 M24 186 1 7 11 4 9 2 6 12 5 10 3 8
MX40 16 M27 245 1 9 5 13 8 16 12 4 15 7 3 11 6 14 10 2

241/658
Heater main flange bolts tightening schedule (dry & smooth values) – T32 types
No bolts Size Torque [Nm] Tightening schedule
MX15 8 M16 164 14725836
MX20 12 M20 158 1 7 11 4 9 2 6 12 5 10 3 8
MX25 12 M20 234 1 7 11 4 9 2 6 12 5 10 3 8
MX30 12 M27 350 1 7 11 4 9 2 6 12 5 10 3 8
MX40 16 M27 350 1 9 5 13 8 16 12 4 15 7 3 11 6 14 10 2
Always use a torque wrench when tightening the flange bolts.
Both sides of the heater must be carefully vented and the circuits carefully in-
spected for leakage during the whole start-up period.
6.4. Output
The output of the heater is subject to the supply of heating media at the inlet
steam valve. The steam pressure/heating media temperature applied, is to be ac-
cording to heater size calculation.
The output is furthermore subject to correct type of steam trap being used. Cor-
rect layout of the condensate system avoids negative effect of counter pressure.
7. Conservation during shut down periods

Corrosion occurrences in shut down periods are mainly caused by oxygen. The
corrosion occurs if non-distilled or alkaline water remains in the heat exchanger.
However, even when fully emptied, heaters are exposed to corrosion caused by
water residues or condensation. Hence, heaters out of service should be protected
against corrosion.
If the heater is out of service for an extended period of time – in particular during
winter seasons with frost – it must be carefully emptied. Open the air escape
valve and check for clogging.
8. Maintenance and Cleaning

8.1. Regular cleaning periods
The heater should be cleaned regularly every six months by removing the tube
insert or at any time there is a decrease in output not related to other causes.
Note: The heat exchanger must be emptied before removing the tube section.
Check if any deposits have collected on the tubes.

242/658
8.2. Cleaning of tubes

Cleaning of the tube system from the outside is carried out after removing the
tube insert using a sharp liquid jet (citric acid or water).
Cleaning of the tube system from the inside is carried out after removing the
cover by flushing the tubes with e.g. citric acid.
8.3. Heavy contamination

If the heater is heavily contaminated with carbon deposits Alfa Laval Aalborg
recommends the heater chemically cleaned with a carbon remover.
After cleaning has been completed the heater must be flushed carefully with
fresh water and allowed to dry afterwards.
8.4. Checking the safety valves

Once every year the safety valve must be checked for correct set point.
9. Dismantling and reassembling of the tube

section
The tube section is inserted into the heater and fastened tightly between the shell
flange and the end flange. The back end of the tube section is not fixed.
The primary connection for heating media must be dismantled before disman-
tling the tube section for inspection, cleaning, etc. The tube flange has threaded
holes for dismantling screws and for mounting eyebolts for lifting devices.
Gasket surfaces are to be cleaned and protected against damage. New gaskets are
to be fitted every time the flange connection has been dismantled.
IMPORTANT: Fluid flow through the heat exchanger must be established be-
fore the heating medium is applied.
Tighten all main flange bolts according to schedule on page 3. Operate the heater
for one hour, stop, and retighten all bolts according to the schedule on page 3.
A pressure test should be carried out to prove tight joints.
Note: Pressure testing to be carried out only with insert mounted in shell.
Both sides of the heater must be carefully vented and the circuits carefully in-
spected for leakage during the whole start-up period.
10. Safety measures

During installation, commissioning, operation and maintenance, the following
measures must be observed:

243/658
10.1. Installation
10.1.1. Lifting
When lifting the heat exchanger, following methods are allowed:
a) Two or four point lifting with straps and shackles in the holes or lifting lugs
on the mounting brackets.
b) Two point lifting with wide support straps around the heater body.
Other ways of lifting the heat exchanger may damage it or cause risk of dropping
it.
10.1.2. Connecting the flanges

It is important that the connecting pipes are arranged in such a way, that no
forces other than short leg thermal expansion forces are transferred to the heater.
Pipe supports are to be placed adjacent to the nozzle flange connection, and any
vibrations in the system must be sufficiently damped. Excess force may cause
the nozzle weld to crack, with subsequent leakage of the fluid.
When tightening the bolts on the nozzle flanges, it is important that the applied
force corresponds to the gasket material used. If this is not observed, there is a
risk of leakage or gasket blow out. Flange connections which are not insulated
after installation should be fitted with blow out guards/screens.
10.1.3. Insulation
The heat exchangers are delivered with thermal insulation according to the scope
of supply stated in the contract. The main flanges are not insulated, since the
class stamps are placed on the rim of the flanges, neither are branch pipes, noz-
zles or connecting flanges, since this would hamper the installation process. In-
sulation of these parts should be completed during the commissioning phase,
Alfa Laval Aalborg recommend an insulation thickness of 50 mm mineral wool
or equivalent heat barrier. Any insulation delivered with the heat exchanger is
designed for a maximum surface temperature of 60°C at engine room conditions,
so no special warnings of hot surfaces is required.
10.2. Operation & maintenance
10.2.1. High pressure

The heat exchanger is a part of a large pressurised system, and does as such not
carry an individual warning sign. This is considered unnecessary, since there are
no quick opening devices on the pressure part and since safety valves and valves
for drain and venting must be installed with discharge piping.
10.2.2. Maintenance
During disassembly, inspection, reassembly and testing it is important that safety
measures of this manual as well as the ships safety procedures are observed. The
fluids in the systems can be both hot and flammable as well as posing a health
risk if ingested. Therefore it is important that proper depressurising, isolation and

244/658
draining is performed, as well as spillage control during disassembly and clean-

ing. Procedures for reassembly must be followed and the mandatory pressure test
be carried out with great care. Insulation and splash guards must be fitted during
recommissioning.
11. Spare parts

When ordering spare parts please state the serial number of the heat exchanger
(located on the nameplate).
For spare parts and further information please contact Alfa Laval Aalborg.

245/658
246/658
247/658

248/658
DATA SHEET
Vesta™ Heat Exchanger
Aalborg Industries Ref.: 0

Contact person 0
Customer & Ref.: mas GmbH 131M083-01

Contact person Katrin Engel
Date: 13 Feb 2014
Heat Exchanger Model: Vesta Shell & Tube Heat Exchanger

2-Pass design with U-tubes
Type/size: MX20 - L800

Class Workshop Hydro Static Pressure Test Certificate
Dimension sketch: 15 K
Fluid 1 Fluid 2
HFO 380 Steam
Shell Side Tube Side
Mass flow: 11.271 301 kg/h

Volume flow 12,70 64,72 m³/h
Inlet temperature: 117,0 175,4 °C
Outlet temperature: 142,0 175,4 °C
Fluid density: 888 - kg/m³
Opreating pressure: 16,00 8,00 bar g
Pressure drop: 0,11 - bar g
Fluid max. velocity 0,91 3,89 m/s
Nozzle size 65 25 /20 DN
Capacity: 169,9 kW
Overall Heat Transmission Coeff.: 795 W/m²K
LMTD Corrected: 44,7 °C
Gross Heat Surface: 4,9 m²
Fouling margin 1,9 %
Baffle distance 85 mm
Weight (empty) 160 kg
v1.3 b06.11-2
249/658
DATA SHEET
Vesta™ Heat Exchanger
Aalborg Industries Ref.: 0

Contact person 0
Customer & Ref.: mas GmbH 131M083-01

Contact person Katrin Engel
Date: 13 Feb 2014
Heat Exchanger Model: Vesta Shell & Tube Heat Exchanger

2-Pass design with U-tubes
Type/size: MX20 - L800

Class Workshop Hydro Static Pressure Test Certificate
Dimension sketch: 15 K
Fluid 1 Fluid 2
HFO 380 Steam
Shell Side Tube Side
Mass flow: 11.271 265 kg/h

Volume flow 12,70 56,96 m³/h
Inlet temperature: 120,0 175,4 °C
Outlet temperature: 142,0 175,4 °C
Fluid density: 888 - kg/m³
Opreating pressure: 16,00 8,00 bar g
Pressure drop: 0,11 - bar g
Fluid max. velocity 0,91 3,42 m/s
Nozzle size 65 25 /15 DN
Capacity: 149,5 kW
Overall Heat Transmission Coeff.: 796 W/m²K
LMTD Corrected: 43,5 °C
Gross Heat Surface: 4,9 m²
Fouling margin 12,5 %
Baffle distance 85 mm
Weight (empty) 160 kg
v1.3 b06.11-2
250/658
Motor control valve in two way form 421 4/5.. E
with PTFE-V-ring sealing Page 1 of 2
EN-GJS-400-18-LT (GGG-40.3), PN 16/25
Body: EN-GJS-400-18-LT (GGG-40.3), two way form

for water and steam
Spindle sealing: spring-loaded PTFE-V-ring unit
for media temperatures up to 250°C
Alternatively: graphite-packing
for media temperatures up to 350°C
Flow characteristic: equal percentage
Positioning ratio: 50:1
Thrust: 2000 N
Power input: 12 VA
Other Kvs- values (see page 4214/5red1/2)
Order text:
Motor control valve in two way form
EN-GJS-400-18-LT (GGG-40.3), PN . ., DN . ., Kvs . . .
Spindle sealing with PTFE-V-ring unit

by: -10…120 150 200 250 300 350 °C*
PN 16 16 15,5 14,7 13,9 12,8 11,2 bar
PN 25 25 24,3 23 21,8 20 17,5 bar
* = max. 250°C for spindle sealing with PTFE-V-ring unit

PN 16 PN 25 m³/h mm sec 2000N 4000N 5500N
15 421 400 421 500 4 20 66 25,0
20 421 401 421 501 6,3 20 66 25,0
25 421 402 421 502 10 20 66 25,0
32 421 403. 421 503. 16 20 66 17,3 25,0
40 421 404. 421 504. 25 20 66 10,8 25,0
50 421 405. 421 505. 40 20 66 6,6 16,0 23,0
65 421 406. 421 506. 63 30 100 3,4 9,1 13,3
80 421 408. 421 508. 100 30 100 2,0 5,8 8,6
100 421 410. 421 510. 160 30 100 1,1 3,5 5,4
125 421 412. 421 512. 230 60 198 2,1 3,3
150 421 415. 421 515. 330 60 198 1,3 2,1
* for higher closing pressures see page 4214/5Heh, bigger DN on request

251/658
Motor control valve in two way form 421 4/5.. E
with PTFE-V-ring sealing Page 2 of 2
EN-GJS-400-18-LT (GGG-40.3), PN 16/25
ø153 Place required

Actuator type: 145 to remove
2,0 kN: 4e1230* (with 49sr5 or 49r: 190) the bonnet
4,0 kN: 4e1430*
5,5 kN: 4e1630*
Bonnet
Motor
Limit switch
Gear
Spring plate unit H**
Spindle (actuator)
Hand wheel
Mounting rod
staggered
V-ring unit drawn
Spindle
Plug
Valve body type: 6a21...

L
DN 15 20 25 32 40 50 65 80 100 125 150

Height H** 491 505 499 506 511 513 556 557 564 720 735
Length L 130 150 160 180 200 230 290 310 350 400 480
Weight kg 14 15 16 17 18 21 35 38 48 100 109
* = only for DN 15-100; actuators for DN 125-150: 4e1466 (4kN) and 4e1666 (5,5kN)
** = add. 45mm for actuators with positioner 49sr5 or controller 49r
Electrical wiring:
Basic version: Accessories*** (optionally):
230/115/24 V 50...60 Hz 24 V DC

for position: valve
CLOSE OPEN
1 2 3 4 5 1 2 3 4 5 6 11 12 13 14 15 16 21 22 23 24 25 26 31 32 33 34 35 36 40 41
N L L L+ L- L+ L-
L on 2 = valve closes 24V on 1/2 = valve opens *** = for actuators with positioner 49sr5 or controller 49r
L on 3 = valve opens 24V on 3/4 = valve closes see electrical wiring on page 49sr5 or 49r

252/658
Installation and operating manual B4E
for motor control valves Page 1 of 1
Installation:
Attention: - Installation, operation and maintenance should be done only by qualified personnel.
- Disconnect supply voltage before working on the valve and make sure, that it is impossible to switch
the power on unintentionally (death and injury hazards)
- It is not permitted to work on the valve body and to exchange the actuator as long as
the valve is subjected to pressure and temperature.
- Crushing and injury hazard because of rotating and moving parts
The mounting site should be easily accessible and have sufficient clearance for maintenance and for removing
the actuator. Ensure that the pipe line axes are flush and connection flanges are parallel. Provide suitable
measures to absorb possible tensile and pressure forces. The valve must not serve as a fixed point.
It must be carried by the piping.
Clean pipelines thoroughly prior to installing the control valves in order to avoid damage through residual
installation material, welding beads or forging scale. If possible, provide a dirt trap in front of each control valve.
Installation position should be vertical to horizontal. Ensure that the installation direction is correct (directional
arrows of the flow on the valve housing). Observe a 10 x DN spacing to flanges, elbows, etc., to avoid an
impaired valve function.
Remove flange covers before the installation. Use suitable handling and lifting equipment for installing the valve
(see corresponding data sheet for the weights).
Regard the permitted max. operating pressure and temperature as described in the corresponding valve data sheet.
Observe the ambient temperature limits (-20...+60°C), if necessary, provide a drive heater at lower temperatures
and for higher temperatures insulate the pipeline, provide conductive plates or cooling possibilities.
An additional protecting cover for the actuator is necessary, if the valve is installed outdoors.
Retighten the screws of all flange connections (also cover and connection piece flanges) prior to
commissioning/start-up and following initial heat-up.
Electrical connection:
Check supply voltage according to the rating plate, loosen screws on the motor hood and remove hood.
Route signal and control lines separately from high-voltage lines, if necessary, run in screened cables.
Insert cables (1.5 mm²) through a twisting sleeve or cable gland.
Perform electrical connection with the supply voltage switched off according to the connection diagram
(observe VDE, EVU and regional electrical regulations).
In the event of deviations, the connecting diagram in the motor hood has precedense.
Maintance:
Following the initial temperature and pressure load, retighten the screws of all flange connections (also cover
and connection piece flanges), the valve cone should be located in the centre.
Attention: - Never loosen the lid and flange screws as long as the fittings are subjected
to pressure and temperature.
Protect valve spindle against soiling, if necessary, clean it in order to protect stuffing boxes and PTFE-V-rings
against increased wear.
Retighten stuffing box seals slightly in the event of leaks.
No further maintenance work is required for fittings with PTFE-V-rings or bellows.
Undertake maintenance on the actuator in accordance with the corresponding information in the separate
operating instructions.
data subject to alteration 4_b_e.DOC 1011526

253/658
Parts list vg21-t E
Control valve in two way form, type 21, GGG-40.3, PN16/25 Page 1 of 2
01
02
03
04
05
06
07
08
09
10
11

01 Screw joint with scraper 6a21dv..
02 Gasket 6a21sd..
03 V-rings 6a21dm
05 Guiding bush 6a21gb
06 Spring 6a21f
08 Gasket 6a21dd..
09 Plug with spindle 6a21ks..
10 Seat ring 6a21s..
11 Valve body 6a21vg..
data subject to alteration Vg21-te.doc / 0104518
254/658
n
c
e
s
g
E
w
A
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ie
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r

Page 1 of 2
Electric actuator for valves

with integrated manual emergency
Controlling device: 3-point step controller r
Power supply: 230V / 50...60Hz
alternatively: 115V / 50...60Hz (option 49u1)
24V / 50...60Hz (option 49u2)
24V DC (option 49u8)
Thrust: 2000 N
Power input: 10 VA
alternatively: 4000/5500 N / 20 VA
Positioning time: 3,3 s/mm
alternatively: 2,2 s/mm (option 49t12)
Stroke: 41 mm
alternatively: 60 mm (on request)
Protection class: IP 65
Limit switches: 1 changeover switch for each limit position,
load dependent, ratings: 250V / 2A
Mounting position: any, avoid hanging position
(damaging by effluent media possible)
Max. ambient temperature: -15...60° C
Accessories, special designs:

Add. load dependent signal switches (see page 49e)
Add. travel dependent signal switches (see page 49w)
Order text:
Electric actuator, thrust . . ., power supply . . .,
pos. time . . ., mounting rod lenght . . .,
List-No. 4e1 . . .
List-No. Thrust Mounting rod* Pos.time Weight

N mm s/mm kg
4e1134 1500 195 3,3 6
4e1230 2000 200 3,3 6
4e1231 2000 218 3,3 6
4e1232 2000 231 3,3 6
4e1235 2000 250 3,3 6
4e1430 4000 200 3,3 7
4e1431 4000 218 3,3 7
4e1432 4000 231 3,3 7
4e1435 4000 250 3,3 7
4e1630 5500 200 3,3 7
4e1631 5500 218 3,3 7
4e1632 5500 231 3,3 7
4e1635 5500 250 3,3 7
* = other rod lenghts on request
Electrical wiring: Accessories (optionaly):
Limit switches Potentiometer Signal switches

M load dependent travel dependent
for valve position
DOWN UP
1 2 3 4 5 11 12 13 14 15 16 21 22 23 24 25 26 31 32 33 34 35 36
N L on 2 = stroke downwards
L on 3 = stroke upwards
Page 2 of 2
153 Space required to

Bonnet remove the bonnet h
Motor
Gear
Limit switch for

valve end position
“down”
H
Terminal bar
Mounting plate with

wiring diagram
Limit switch for

valve end position
“up”
Base plate
Cable bushing
Spring housing
Disc spring unit

A
Spindle
Mounting rod
Stroke
Hand wheel with
blocking lever Cmax
Coupling nut Cmin

100
Screw collar ring
Type Thrust A Cmin Cmax H h G g

N mm mm mm mm mm mm mm
4e1134 1500 195 40 81 146 145 M12 24
4e1230 2000 200 45 86 146 145 M16 32
4e1231 2000 218 63 104 146 145 M16 32
4e1232 2000 231 76 117 146 145 M16 32
4e1235 2000 250 95 136 146 145 M16 32
4e1430 4000 200 45 86 191 190 M16 32
4e1431 4000 218 63 104 191 190 M16 32
4e1432 4000 231 76 117 191 190 M16 32
4e1435 4000 250 95 136 191 190 M16 32
4e1630 5500 200 45 86 191 190 M16 32
4e1631 5500 218 63 104 191 190 M16 32
4e1632 5500 231 76 117 191 190 M16 32
4e1635 5500 250 95 136 191 190 M16 32
Attention:
- Adjustment of and work on the actuator may only be done by skilled labour
- Disconnect power supply before removing the cover
- Observe local instructions and terminal diagram
Actuator disassembly: Actuator assembly:

- disconnect supply - lift actuator onto valve connection and secure nuts (18)
- loosen fixing screw (21) (see Fig.1)
(see Fig.1) - tighten (19) coupling nut and fixing screw (21)
- unscrew coupling nut (19) - connect lines acc.to wiring diagram
- unscrew nuts (18) - if necessary, move actuator in both limit positions and
- take off actuator from valve connection adjust stroke indikators (17) on mounting rod
Maintenance: the spindle has to be kept cleen and lubricated, if necessary, lubricate the spindle with
molykote including grease
Limit switches:
Attention! The limit switches work load dependent and turn off automatically when the valve drives in
end position, so that a readjustment, as for travel dependent limit switches, is not necessary
and not allowed. Change of the factory adjustment endangers correct operation, no warranty
will be given and no liability will be accepted in case of damage of the varnish sealing.
If for extraordinary reasons, for instance by previous damages, a readjustment is exceptionally
necessary, the actuator should preferably be sent in for new factory adjustment. Only if this is
exceptionally not possible, a new coarse adjustment can be directly done, with our agreement
and acc. to the following operating instruction.
Special information for actuators with integrated positioner:

No reaction of limit switch can occur when the positioner turns off the actuator to early,
before the valve is in the end position. Don’t readjust limit switch in this case, control
at first adjustment of positioner and correct it if necessary.
Upper limit switch
Add. upper switch

Add. lower switch
Lower limit switch

Lower limit switch
Fig.1

257/658
01
02
03
04
05
06
07
08
09
10
11
12
13
detail X
14
15
16
17
19
20
X
18
Fig.2

01 Bonnet: 2kN / 4kN e3h136 / e3h180
02 Motor 230V / 50/60Hz: 2kN / 4kN*** e2m220 / e2m220.4
02a Capacitor: 2kN / 4kN e2k033 / e2k068
03 Gear: pos. speed 3,3s/mm / pos. speed 2,2s/mm e2g1875 / e2g1250
04 Limit switch for spindle position "down" eheo
05 Mounting plate for motor e3zp
06 Terminal bar e6k12
07 Gear wheel e3zr75
08 Mounting plate with wiring diagram e3hb
09 Limit switch for spindle position "up" eheu
10 Base plate e3gp
11 Screw-type cable bushing PG11 e1kv11
12 Spring housing e3fg
13 Set of disc springs e5ft355+e5fs335
14 Spindle e3s
15 Mounting rods e3s... / e3s...n
16 Hand wheel with blocking lever ehhr
17 Stroke indicator e5ak
18 Hexagonal nut M16 e8mv16
19 Coupling nut e5vk
20 Screw collar ring e3sr...
*** = only for standard actuator: voltage 230V / 50/60Hz

258/658
259/658
260/658
Accessories for electric actuators 49e.E
Additional load dependent signal switch Page 1 of 2
Electric actuators type 4e... can be equipped with an additional load dependent limit switch for
valve positon "up" and/or "down". The zero-potential change over switches have a contact rating
of 250V / 2A (ohmic load).
Adjustment screw
Mounting plate
Additional upper limit switch
for valve position "down"
Additional lower limit switch

for valve position "up"
Lateral view Mounting plate
upper limit switch Adjustment screw
Additional terminals:
11 12 13 14 15 16
Upper switch for valve position "down" Lower switch for valve position "up"
Summary of types: List-No.
1 add. upper limit switch for valve position "down" 49eo

1 add. lower limit switch for valve position "up" 49eu
1 upper and 1 lower additional limit switch 49ev
data subject to alteration 49E-E.DOC / 0103506

261/658

262/658
Technical Manual
Instructions for installation,

operation and maintenance
761
VISCOSENSE®2
Viscosity Sensor & Interface box
Valid for ViscoSense®2 (serial numbers from 87600)
Publication nr TIB-761-GB-0412
Supersedes TIB-761-GB-0312
263/658
CONTENTS
1. PREFACE ....................................................................................... 3
1.1 General ........................................................................................................ 3
1.2 Symbols ....................................................................................................... 3
1.3 Copyright ..................................................................................................... 4
2. SYSTEM DESCRIPTION................................................................ 5
2.1 System description....................................................................................... 5
2.2 System components .................................................................................... 6
2.3 Principle of operation ................................................................................... 7
3. TECHNICAL SPECIFICATION ....................................................... 8
3.1 Sensor ......................................................................................................... 8
3.2 Sensor housing ............................................................................................ 8
3.3 Interface box ................................................................................................ 9
4. SAFETY INSTRUCTIONS .............................................................. 9
4.1 Safety precautions ....................................................................................... 9
5. UNPACKING ................................................................................ 10
6. INSTALLATION ............................................................................ 10
6.1 To record nameplate data .......................................................................... 10
6.2 Conditions for correct working of the ViscoSense®2 sensor ...................... 11
6.3 General installation recommendations ....................................................... 12
6.4 Mechanical installation ............................................................................... 12
6.4.1 ViscoSense®2 interface box .............................................................. 12
6.4.2 ViscoSense®2 housing ...................................................................... 12
6.4.3 To assemble ViscoSense®2 sensor .................................................. 14
6.5 Electrical installation .................................................................................. 16
6.6 Connection of sensor to interface box........................................................ 17
7. OPERATING INSTRUCTIONS ..................................................... 18
7.1 Initial start-up ............................................................................................. 18
7.2 Shut-down on heavy fuel oil ....................................................................... 18
7.3 Shut-down on diesel oil .............................................................................. 18
7.4 Routine start-up ......................................................................................... 18
8. MAINTENANCE ............................................................................ 19
8.1 Routine maintenance ................................................................................. 19
8.2 To clean the ViscoSense®2 sensor ............................................................ 19
8.2.1 General procedure ............................................................................ 19
9. REPAIR OR REPLACEMENT ...................................................... 20
9.1 Repair ........................................................................................................ 20
9.2 Replacement .............................................................................................. 20
10. TAKE OUT OF SERVICE ......................................................... 21
11. REMOVAL AND STORAGE OF EQUIPMENT ......................... 22
264/658
12. MALFUNCTION AND SEND FOR REPAIR ............................. 22
13. ENVIRONMENT ....................................................................... 22
14. DISPOSAL ................................................................................ 22
15. TROUBLE SHOOTING ............................................................. 23
15.1 Disconnection the sensor ........................................................................ 23
15.2 General trouble shooting ......................................................................... 24
15.3 PI setting errors (for additional viscosity controller)................................. 25
15.4 How to take a HFO sample for analysis .................................................. 26
15.5 Diagnostic information ............................................................................ 26
16. CERTIFICATES ........................................................................ 29
17. DRAWINGS .............................................................................. 30
17.1 ViscoSense®2 sensor and sensor housing ............................................. 30
17.1.1 ViscoSense®2 sensor housing with sensor installed ......................... 30
17.2 ViscoSense®2 interface box .................................................................... 34
17.2.1 ViscoSense®2 interface box .............................................................. 34
18. ABBREVIATIONS ..................................................................... 35
19. PARTS LISTS ........................................................................... 36
19.1 ViscoSense®2 sensor ............................................................................. 36
20. WARRANTY CONDITIONS ...................................................... 37
21. ENCLOSURE ........................................................................... 39
21.1 Recommendations for a good working booster unit ................................ 39
2
265/658
1. PREFACE
1.1 GENERAL
This manual contains instructions for installation, operation and maintenance (IOM) of the VAF
ViscoSense®2 viscosity sensor and interface box.
For IOM information of associated equipment supplied by VAF Instruments, refer to the separate
manual supplied with those products.
This manual contains important information for the installer, the operator and for your maintenance
department.
To ensure safe and correct installation and operation, read this manual completely
before installing the equipment and starting operations.
ViscoSense®2 sensor (from serial numbers 70000) and interface box (from serial
numbers 1480000) are not interchangeable with previous model ViscoSense®.
For any additional information contact:
VAF Instruments B.V. Tel. +31 78 618 3100

Vierlinghstraat 24, 3316 EL Dordrecht Fax +31 78 617 7068
P.O. Box 40, NL-3300 AA Dordrecht E-mail: sales@vaf.nl
The Netherlands Internet: www.vaf.nl
Or your local authorized VAF dealer.

Their addresses can be found on www.vaf.nl
1.2 SYMBOLS
The following symbols are used to call attention to specific types of information.
A warning to use caution! In some instances, personal injury or damage to the

ViscoSense®2 unit or control system may result if these instructions are not followed
properly.
An explanation or information of interest.
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1.3 COPYRIGHT
This technical manual is copyrighted with all rights reserved.
While every precaution has been taken in the preparation of this manual, no responsibility for errors or
omissions is assumed. Neither is any liability assumed for damages resulting from the use of the
information contained herein. Specifications can be changed without notice.
ViscoSense® is a registered trademark of VAF Instruments B.V.

Teflon® is a registered trademark of Dupont.
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2. SYSTEM DESCRIPTION
2.1 SYSTEM DESCRIPTION
ViscoSense®2 is, besides other applications, intended for use in fuel oil treatment systems to obtain a
correct measurement and control of the fuel oil viscosity.
Figure 1 shows a typical fuel treatment system with return line from the engine. In this system, the
degassing/mixing tank operates as a fuel buffer, ensuring gradual changes of viscosity which results
in a stable control of the viscosity. The ViscoSense®2 sensor is used to measure the actual viscosity
of the fuel oil. The signal from the sensor is compared to the setpoint of a viscosity controller, which
regulates the output of the fuel heater via a control element (steam or thermal oil valve, or electric
heater cabinet).
Figure 1 Typical example of an automatic control system using steam or thermal oil heater
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2.2 SYSTEM COMPONENTS
The ViscoSense®2 viscosity system consists of:
 the combined viscosity and temperature measuring sensor
 the sensor housing
 Interface box
The sensor housing is made of ductile iron and has flanges for direct mounting in the fuel line. The
sensor itself is made of stainless steel and is mounted in the housing. The sensor head has a special
Teflon® coating and it is mechanically protected by a stainless steel flowtube with 3 oval slits. It is
supplied with 5 metres of signal cable for connection to the interface box. The ViscoSense®2 Interface
box is a wall mount electronic unit, processing the signals to and from the sensor. It provides 4..20
mA signals for remote read-out of viscosity and temperature for a controller or other system elements.
See separate technical manuals for a description of these components.
Figure 2 ViscoSense®2 components
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2.3 PRINCIPLE OF OPERATION
The operating principle of the sensor is that of a torsion pendulum. The sensor consists of a stainless
steel driver / sensor head (1), attached to the base plate (2) by means of a tubular torsion spring (3).
In the head, one pair of piezo elements (driver piezos) (4) actuates the pendulum at its torsional
resonance frequency, while another pair (the receiver piezos) probes the actual movement of the
head. In a low viscosity medium, like air the resonance frequency is in the range of 1600 Hz. In a high
viscosity medium the movement of the head is damped by the liquid. Consequently, the resonance
frequency slightly shifts towards lower frequencies, whilst the width of the resonance peak increases,
which is a measure for the viscosity.
A flow tube (5) is placed around the pendulum, to protect it against mechanical damage.
The flowtube is machined with a smooth surface, as well as with a triplet of oval slits. These slits
increase the refreshing rate between sensor and flowtube.
Figure 3 ViscoSense®2 sensor
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3. TECHNICAL SPECIFICATION
3.1 SENSOR
Viscosity range 0 .. 25/50 mPa.s (other ranges on request)
Maximum operating temperature 180C
Temperature transmitter PT 100 element
Accuracy
Viscosity +/- 2% instantaneous or 0.5 mPa.s
Temperature ± 1C
Measuring range 0-200C
Material
Sensor Stainless steel 316L
Coating Teflon®
Signal cable length 5 metres, integrated with sensor
Protection class IP65
Weight 1 kg
Warning
For hazardous zone I and II, the ViscoSense® Ex d version is required.
(See separate technical manual TIB-769)
3.2 SENSOR HOUSING

Material housing ductile iron
Flange connections DN 50 mm (2”), DIN, ANSI or JIS

DN 65 mm (2,5”), DIN, ANSI or JIS
DN 80 mm (3”), DIN, ANSI or JIS
DN 100 mm (4”), DIN, ANSI or JIS
Maximum pressure rating 40 bar
Weight 2” approx. 10 kg
2,5” approx. 11 kg
3” approx. 12 kg
4” approx. 13 kg
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3.3 INTERFACE BOX
Supply voltage 115/230 VAC, 50/60 Hz selectable
(Fluctuations should not exceed ±10% of the nominal value)
Power consumption 17…25 Watt
Output
Viscosity Active output 4…20 mA, current loop
Range 0-25/50 mPa.s (depending on range ViscoSense®2)
maximum load 400 Ohm
Temperature Active output 4…20 mA, current loop
Range 0-200° C, maximum load 400 Ohm
Response time Less than 1 minute
Resolution 0.1 mPa.s
Ambient temperature -20… + 55 C
Humidity range 0-95% RH
Protection class IP 65
Mounting Wall mounting
Cable connections
Power supply Cable dia. 6-12 mm
Output signals Cable dia. 5-10 mm
Wiring supply 1.5 mm²
Output 24 AWG or 0.25 mm2
Installation category I acc. to IEC 1010-1
Pollution degree 1 acc. to IEC 664
Ventilation requirements no special requirements
Weight 2,9 kg
4. SAFETY INSTRUCTIONS
4.1 SAFETY PRECAUTIONS
To ensure the safety of personnel and equipment:
 Always follow the safety and installation recommendations in this manual.
 Always use personal protective means when working with hot, aggressive and toxic process
liquids.
 Always use insulated tools when working on electrical installations.
 Ensure that local safety regulations are met when installing and operating the equipment.
 All personnel who operate and service the equipment should read this manual completely and
make themselves acquainted with the equipment before installing or operating the equipment.
 The ViscoSense®2 sensor body will heat up to the process temperature; do not touch the body
housing while process is running!
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5. UNPACKING
Let the instruments acclimatize in the location where they are going to be installed for at least
one hour inside their shipment box. This is to avoid moisture buildup inside the instrument, or on the
connectors and wires.
When the equipment is taken out of the box, please leave the transport locking cap and the outside
protection, in place as long as possible to avoid any damage.
The ViscoSense®2 sensor has a special Teflon® coating on the pendulum.
Damage of the coating will influence the working of the sensor.
Special care should be taken not to scratch or damage the Teflon® coating.
The transport locking cap and the outside protection should be stored, in the unlikely event the
equipment has to be returned for repair.
Dispose of the packing material should be done according to the laws of the country where the
equipment is installed, or according to the rules that are applicable on the vessel.
Figure 4 Transport locking cap Figure 5 Outside protection
6. INSTALLATION
6.1 TO RECORD NAMEPLATE DATA
Before installing a ViscoSense®2 system, record type and serial numbers as stamped on the
ViscoSense®2 sensor and interface box.
Always quote the instrument serial number and the variant number when contacting the
factory or local service representative.
A ViscoSense®2 unit may be part of a complete VAF viscosity control system. For information and
instructions covering the other components of this system, refer to the separate technical manuals as
supplied with these components.
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For identification purposes it is recommended to record also nameplate data of other ViscoSense®2
system components here.
Housing:
Serial number: __________________
Variant: __________________
Sensor:
Serial number: ________________
Interface Box:
Serial number: ________________
Model: ________________
6.2 CONDITIONS FOR CORRECT WORKING OF THE VISCOSENSE®2 SENSOR

The flow is recommended to be in-between the maximum and minimum fluid flow rate as mentioned
in chapter 21.1.
The ViscoSense®2 housing should be placed in such a way, that no air can be trapped in the housing.
This can easily happen if the inner diameter of the piping is smaller than the inner diameter of the
ViscoSense®2 housing, if it has been installed horizontally.
If the inner diameter of the piping is smaller than the inner diameter of the ViscoSense®2 housing, the
transitions between the two diameters should be tapered. The inner diameter of the ViscoSense®
housing should not be smaller than the piping.
The fluid should be homogenous.
It should not contain any air bubbles or foam.
THE FLUID SHOULD NOT CONTAIN ANY CHEMICALS OR SOLID PARTICALS THAT
CAN DAMAGE TEFLON®.
THE FUEL SHOULD BE IN COMPLIANCE WITH ISO 8217:2010

(SPECIFICATIONS OF MARINE FUELS).
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6.3 GENERAL INSTALLATION RECOMMENDATIONS
 Mount the ViscoSense®2 housing as low as possible, in the fuel system.
 Compare your process variables with the specifications. Make sure these are compatible!
 Pressure pulsations and variations should be avoided as much as possible.
 Mechanical vibrations should be avoided as much as possible.
 No special tools are required to install the ViscoSense®2. Ensure that your standard tools
are fit for the job.
 Make sure that the working environment is clean. Ensure that no dirt can enter the sensor.
 Insulate the pipes and the sensor housing well, to avoid any temperature loss of the fluid.
 When fuel viscosity is 500 mPa·s or thicker it is recommended to wrap steam tracing with
sufficient capacity, or 20 Watts/metre resistance wiring around the ViscoSense®2 housing.
 VAF ViscoSense®2 sensor and interface box are precision instruments. Handle them with
care.
Do not unscrew the cable gland on the top of the ViscoSense®2 sensor or disconnect the
cable from the sensor. This will violate the correct operation of the ViscoSense®2 sensor.
Take care that the pendulum is not damaged and the torsion tube not bent by
mechanical force.
This will violate the ViscoSense®2 signal.
6.4 MECHANICAL INSTALLATION

6.4.1 ViscoSense®2 interface box
1. Install the ViscoSense®2 interface box in a suitable location, free from excessive vibrations,
humidity and excessive temperature variations.
2. The maximum distance between sensor and the interface box is determined by the cable length
from the sensor, being approx. 5 metres.
3. Allow sufficient space for installation of cables and for servicing.
6.4.2 ViscoSense®2 housing

1. Remove dust caps from sensor housing and install housing stress-free, with shut-off valves and
bypass valve in the fuel piping as illustrated in Figure 6. Take care that the flow direction is in
accordance with the indication on the housing (inlet, outlet and arrow) as illustrated in figure 8.
Support inlet and outlet piping sufficiently.
These shut-off valves and bypass valve are not furnished by VAF Instruments.
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2. Note that the distance between fuel heater and sensor housing inlet should not exceed 4 metres.
3. To protect the instrument from excessive vibrations, which can cause malfunctioning of the
instrument, it is recommended to:
Install the ViscoSense®2 as low as possible in the fuel system close to a solid structure or beam.
Install suitable pipe clamps at both sides of the ViscoSense®2 sensor.
4. Allow at least 50 cm clearance to the sensor housing, to be able to take out the measuring sensor
for service.
5. The sensor needs a stable environment to act as a counterweight for the pendulum movement.
The support must prevent movement and excessive vibrations of the ViscoSense®2 housing,
especially movement in the direction of the pendulum movement (see drawing- angular movement
around the sensor axis). Therefore there must be two supports to the inlet and outlet perpendicular
to the pipe and perpendicular to the ViscoSense®2. If one support would be used the lateral
vibrations would be converted to angular vibrations and the situation would be made worse instead
of better.
Figure 6 Sensor installation diagram
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The angular position of the supports must always be 90° in relation to the sensor.
The distance from the flange to the support should be two times the diameter of the pipe.
ViscoSense®2 size T. Max. L. Max.
50 mm (2”) 350 mm 150 mm

65 mm (2 ½”) 400 mm 160 mm
80 mm (3”) 400 mm 165 mm
100 mm (4”) 450 mm 185 mm
Figure 7 Sensor installation diagram
6.4.3 To assemble ViscoSense®2 sensor

1. Check the O-ring for damage, before installing the ViscoSense®2 sensor. Replace if necessary.
Make sure only one original o-ring is installed.
2. Remove transport locking cap from bottom side of flowtube.
3. Please make sure not to damage the Teflon® coating during installation.
Without the transport locking cap the sensor is not protected against excessive
mechanical shocks which can occur during handling.
4. Install sensor carefully in housing with the closed surface facing the flow, illustrated in figure 8.
Make sure the flow tube closed surface is pointing towards the inlet of the sensor
housing, see figure 8.
The sensor will not work correctly if installed wrongly.
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Check if the position of the hole inside the housing and the fixation pin on the sensor
match.
5. Tighten the nut (1) by hand. If there is a temperature difference between the sensor and the
housing you should wait until they have the same temperature before tightening the nut.
6. Tighten the nut (1) with a wrench with a recommended torque of 100 Nm.
Make sure that all flange bolts and nuts are tightened correctly before re-pressurizing the
system.
See chapter 15.1
7. The ViscoSense®2 system is now ready for electrical installation.
Figure 8 ViscoSense®2 sensor assembly
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6.5 ELECTRICAL INSTALLATION
Provide correct supply power to the interface box.
In order to maintain proper EMC protection a shielded cable should be used for 4-20 mA
output signals. Recommended cable: twisted pair individually screened conductor (24
AWG or 0.25mm²) stranded wire, overall screen and PVC insulated.
For correct installation a suitable isolation switch shall be installed in the supply line as
near as possible to the equipment. Maximum fuse current 16A.
To avoid signal grounding problems it is not recommended to connect more than one
device to each 4-20 mA output of the interface box.
1. Remove cover from interface box.
Check power selector switch for correct position in accordance with the power source to
be supplied.
Figure 9
2. Feed cable from ViscoSense®2 sensor through gland and connect wires to terminal J6 in
accordance with Figure 12.
3. Feed cable for 4-20 mA viscosity and temperature output signals through the cable glands and
connect wires to terminal J1 in accordance with Figure 12. When no temperature output is
connected to 4 and 5 on J1 (Figure 12), terminals 4 and 5 must be connected together with a wire
link.
4. Feed cable for main power supply through cable gland and connect wires to terminal J2 in
accordance with Figure 12.
To maintain proper EMC protection the cable glands provided with the interface box
should not be exchanged for cable glands of any other make/type.
5. Make sure that all connectors are properly seated before closing the cover again.
6. Close the cover of the interface box.
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6.6 CONNECTION OF SENSOR TO INTERFACE BOX
Figure 10 Tighten the cable gland with a spanner Figure 11 Install the numbered wires in the
appropriate terminals of Terminal J6,
see figure 12
Figure 12 External connections at interface box
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7. OPERATING INSTRUCTIONS
Figure 13
7.1 INITIAL START-UP

The initial start-up should always be done with diesel oil.
1. Fill the complete fuel system with diesel oil.
2. Open block valves (K and M) and bypass valve (L)
3. Allow diesel oil to enter the fuel system
4. Vent the fuel system
5. Start the booster pump in the fuel system and after approximately 15 minutes close bypass valve
(L)
6. Switch on power supply to the ViscoSense®2 system. Depending upon the viscosity of the liquid it
can take up to 30 seconds, before the first reading appears. This is due to the automatic signal
gain control.
7. Gradually change over to HFO.
7.2 SHUT-DOWN ON HEAVY FUEL OIL

Maintain heat tracing on the ViscoSense®2 sensor housing after shut-down, to prevent clogging of the
fuel to the sensor internal parts.
7.3 SHUT-DOWN ON DIESEL OIL

No special actions on the ViscoSense®2 unit are required.
7.4 ROUTINE START-UP

Make sure that the power is on.
No other special actions on the ViscoSense®2 unit are required.
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8. MAINTENANCE
8.1 ROUTINE MAINTENANCE
Under normal conditions the ViscoSense®2 interface box requires no maintenance.
“Normal” means;
 A clean operating environment
 ViscoSense®2 interface box installed in accordance with the installation instructions given.
 Operation of the ViscoSense®2 interface box and related control system in accordance with this
manual and other related publications
 Uninterrupted power supply at normal specified values.
8.2 TO CLEAN THE VISCOSENSE®2 SENSOR
When removing a ViscoSense®2 sensor from the piping system precautions must be
taken to prevent personal injuries and damage to the sensor and process installation.
See chapter 15.1.
8.2.1 General procedure

1. Change over to manual viscosity control.
2. Shut off flow through the ViscoSense®2 sensor, by closing the valves on both side of the sensor
housing.
3. Switch off power supply to the ViscoSense®2 interface box.
4. If possible drain and empty the piping system.
Although the flow has been shut off, the ViscoSense®2 housing can still be under
pressure and hot. If the sensor is removed from a sensor housing which has not been
de-pressurized, hot oil will spray out.
5. Unscrew the ViscoSense®2 sensor from its housing by loosening nut 1 (Figure 8 ViscoSense®2
sensor assembly).
6. Take out the ViscoSense®2 sensor.
7. Do not remove the flow tube, do not stick any object in between the flow tube and pendulum.
8. Flush the space between the tube and the pendulum with diesel oil or non aggressive cleaning
detergent.
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Take care that the pendulum is not damaged or the torsion tube bent by mechanical
force.
NEVER use abrasive materials like sandpaper, files etc., to clean the flow tube.
9. For the re-installation of the sensor in the sensor housing please follow the instructions in chapter
6.
As it is important to install only one original o-ring, please verify that no parts of the old
o-ring are left behind in the housing. Using other o-rings than original VAF o-rings can
cause misreading of the sensor.
9. REPAIR OR REPLACEMENT
9.1 REPAIR
The ViscoSense®2 sensor and interface box can not be repaired on site.
They will be either exchanged for a spare unit or send back to VAF Instruments.
9.2 REPLACEMENT
When the sensor or interface box is replaced, we refer to chapter 5 and 6 for unpacking and
installation instructions.
If the sensor is replaced, this will require that the correct settings for this sensor are made in the
interface box. To make the correct settings, a spare sensor is supplied together with a dongle, which
can be connected into the interface box.
Please note that the power supply should be connected to the interface box, when
using the dongle.
Please take necessary precautions to avoid personal injury.
Procedure for using the ViscoSense®2 dongle:

1. Open the interface box
2. Insert the dongle into the interface box in the 9-pin serial connector (fig. 14)
Figure 14
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3. Switch on the dongle (fig. 15). The red LED indicator on the dongle will burn now.
Figure 15
4. Wait until the green LED indicator on the dongle starts blinking and switch off the dongle. If the
green LED indicator does not start blinking, please repeat steps 2 – 4.
5. Close the interface box and the system is ready for use. The dongle is meant to be used for 1
sensor only, and can be disposed according to local rules. The dongle contains electronic
components and a small battery.
10. TAKE OUT OF SERVICE

Disconnect the power to the interface box. The ViscoSense®2 sensor should be taken out of the
sensor housing and cleaned. See maintenance section for cleaning instructions. To protect the
pendulum from damage due to mechanical shocks, the transport locking cap should be carefully
placed in-between the flow tube and the pendulum.
Figure 16
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11. REMOVAL AND STORAGE OF EQUIPMENT
Disconnect the power to the interface box. Disconnect the electrical connections of the sensor,
outputs and power inside the interface box. The ViscoSense®2 sensor should be taken out of the
sensor housing and cleaned. See maintenance section for cleaning instructions. To protect the
pendulum from damaged due to mechanical shocks, the pendulum protection tube should carefully be
placed in-between the flow tube and the pendulum. The sensor must be wrapped in protection
material (preferably where it was shipped in) to protect it from damage.
Both the sensor and the interface box must be stored in a cool and dry place.
12. MALFUNCTION AND SEND FOR REPAIR

If the sensor or the interface box fails, they should be sent back to VAF Instruments for repair.
13. ENVIRONMENT
There are several electronics inside the Interface box. The sensor has Teflon® coating on the sensor
head. During normal use all these components can not cause any harm to the environment.
14. DISPOSAL
Laws and restrictions for disposal of equipment will be different in most countries. If in doubt or unable
to dispose the equipment it can be send back to VAF Instruments.
VAF Instruments will dispose the equipment in a correct way.
The ViscoSense®2 equipment has the following possible environmentally unfriendly components in
minor quantities.
Sensor Teflon® coating on the sensor head.

Sensor cable Electrical cable with Teflon® coating.
Interface box Electronic components.
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15. TROUBLE SHOOTING
15.1 DISCONNECTION THE SENSOR
Figure 17
The sensor and electric wire are moulded together.
NEVER TRY TO OPEN THE BACK OF THE SENSOR.

THIS WILL DAMAGE THE WIRE AND SENSOR BEYOND REPAIR.
The sensor can only be disconnected at the interface box.
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15.2 GENERAL TROUBLE SHOOTING
Problem Possible cause Corrective action
No viscosity signal No supply to interface box Check supply.

Check fuses.
Check electrical connections.
Current loop connection broken Check electrical wiring of 4-20

mA output signal
Air entrapped in the fuel system Vent the system
ViscoSense®2 malfunctioning Check diagnostic led
No temperature signal No supply to interface box Check supply.

Check fuses.
Check electrical connections.
Current loop connection broken Check electrical wiring of 4-20

mA output signal
ViscoSense®2 malfunctioning Check diagnostic led
Viscosity output is lower Actual viscosity is lower than None (For laboratory check of
than expected expected. viscosity take sample according
E.g. bunker calculator only gives instructions in chapter 15.4).
approx. value.
Dilution with MDO.
Temperature is higher than expected.
Range settings ViscoSense®2 and Check mA signal and range

readout unit do not match settings
Air entrapped in the fuel system Vent the system
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Viscosity output is higher Actual viscosity is higher than None (For laboratory check of
than expected expected. viscosity take sample according
E.g. bunker calculator only gives instructions in chapter 15.4).
approx. value.
Temperature is lower than expected.

Fuel is not pure, well mixed liquid None

(see chapter 6)
Sensor is damaged or fouled Clean and inspect the sensor

(see chapter 8)
Viscosity output is max The viscosity in the sensor housing is Heat up the fluid
range higher than the max range
Actual viscosity is higher than None

expected.
E.g. bunker calculator only gives
approx. value.
ViscoSense®2 interface box is Check diagnostic led

malfunctioning
ViscoSense®2 sensor is
malfunctioning

Sensor is damaged or fouled Clean and inspect the sensor

(see chapter 8)
15.3 PI SETTING ERRORS (FOR ADDITIONAL VISCOSITY CONTROLLER)

The heaters in the booster system are controlled by a viscosity controller.
In order to get a good working viscosity system an optimum adaptation of the control parameters (P,I)
is necessary.
P = Proportional band Pb (%)

I = intergral action time Ti (min)
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Oscillating temperature with Pb too low Increase Pb

distinct initial overshot
Set point is reached very slowly Pb too high Decrease Pb

after initial exceeding
The set value is reached very Ti too high Decrease Ti

slowly without overshooting
High initial overshot followed by Ti too low Increase Ti

fading oscillation
15.4 HOW TO TAKE A HFO SAMPLE FOR ANALYSIS

The HFO sample must always be taken from the circulation system as close as possible to the
viscosity sensor. Never take a sample from the bunker, settle or day tank.
The HFO sample must be collected and stored in a clean bottle or sample container. The bottle or
sample container must be sealed in order to prevent contamination with other products. The sample
quantity must be at least 200ml.
Write down the actual viscosity and temperature reading when the sample is taken. Send the sealed
bottle or sample container with actual readings to a qualified laboratory or to VAF Instruments B.V. for
analysis.
15.5 DIAGNOSTIC INFORMATION

The printed circuit board inside the ViscoSense®2 controller has a provision for diagnostic indication.
Failures and errors are displayed by a blinking digit or character on a 7 segment LED. Dependent on
the type of failure, error or warning, the viscosity and/or temperature outputs will go to 0, 4 or 20 mA,
or will remain functioning normally.
If there is no failure, error or warning, the display indicates the state of the program by displaying a
symbol (not blinking) on the display.
The following symbols are displayed during normal operation:
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Display Description Display Description
Power on Changing U-send_setpoint
Initializing hardware measuring at + 45 degrees

(left -3 dB point)
VCO frequency measurement while measuring at - 45 degrees

phase is +45 degrees (left +3 dB point)
Waiting for U_receive to settle after Adjusting phase

changing setpoint
The decimal point at the bottom of the display is always on after power is on. This point is only turned
off while the ViscoSense®2 is writing to EEPROM, and if no measurement is possible due to extensive
external vibrations.
Normally the ViscoSense®2 electronics will try to restart the unit if a faulty situation occurs. However,
if the fault is persistent contact VAF Instruments or your local authorised VAF dealer and give a
detailed description of the problem that occurred and the diagnostic information indicated at the 7
segment LED.
The faults, indicated in the table below, are listed in order of priority. The faults on top of the list have the
highest priority. This means that faults with a lower priority can be overwritten by faults of a higher
priority.
At power-on the system is explicitly tested for failures indicated by display messages 1, 2, 3, 4, 5, 6
and 7. During normal operation these tests (except 2) run at the background.
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Followed by:
or or
Display Viscosity Temperature Recovery action Fault description

message output [mA] output [mA] (attempt)
0 0 Delay & retry 15 V power failure. Supply drops below 13 V
0 Actual Delay & retry Pendulum not oscillating
4 Actual Delay & retry Oscillation error
4 20 None Temperature out of range (overflow)

4 4 None Temperature out of range (underflow)
20 Actual None Viscosity out of range (overflow)

4 Actual None Viscosity out of range (underflow)
Actual Open loop None Temperature output open loop

Open loop Actual None Viscosity output open loop
Not all segments

working after Actual Actual Not applicable 7 - segment display defective
power on
Any other figure or letter indicates an error in the electronics or software.
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16. CERTIFICATES
Certificates are delivered separately.
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17. DRAWINGS
17.1 VISCOSENSE®2 SENSOR AND SENSOR HOUSING
17.1.1 ViscoSense®2 sensor housing with sensor installed
Figure 18 Dimensions of ViscoSense®2 sensor (All dimensions in millimetres)
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17.2 VISCOSENSE®2 INTERFACE BOX
17.2.1 ViscoSense®2 interface box
Figure 22 Dimensions of ViscoSense®2 interface box (All dimensions in millimetres)
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18. ABBREVIATIONS
ANSI American National Standards Institute

AWG American Wire Gauge
dia Diameter
DIN Deutsches Institut für Normung
DN Diameter Nominal
EEPROM Electrically Erasable Programmable Read-Only Memory
EPROM Erasable Programmable Read-Only Memory
Hz Hertz (Frequency)
IEC International Electrotechnical Commission
IOM Installation, Operation and Maintenance
JIS Japanese Industrial Standard
Kg Kilograms
LED Light Emitting Diode
mPa.s Millipascal second
PAL Programmable Array Logic
PT100 Temperature Sensor
RAM Random Access Memory
RH Relative Humidity
VAC Volt Alternating Current
ºC Degrees Centigrade
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19. PARTS LISTS
Spare parts:
0279-0096PH consisting of 0279-0096 ViscoSense®2 sensor
0279-0102 dongle
19.1 VISCOSENSE®2 SENSOR
Figure 23 Parts list
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20. WARRANTY CONDITIONS
1. Without prejudice to the restrictions stated hereinafter, the contractor guarantees both the
soundness of the product delivered by him and the quality of the material used and/or delivered for
it, insofar as this concerns faults in the product delivered which do not become apparent during
inspection or transfer test, which the principal shall demonstrate to have arisen within 12 months
from delivery in accordance with subarticle 1A exclusively or predominantly as a direct
consequence of unsoundness of the construction used by the contractor or as a consequence of
faulty finishing or the use of poor materials.
1A. The product shall be deemed to have been delivered when it is ready for inspection (if
inspection at the premises of the contractor has been agreed) and otherwise when it is ready
for shipment.
2. Articles 1 and 1a shall equally apply to faults which do not become apparent during inspection or
transfer test which are caused exclusively or predominantly by unsound assembly/installation by
the contractor. If assembly/installation is carried out by the contractor, the guarantee period
intended in article 1 shall last 12 months from the day on which assembly/installation is completed
by the contractor, with the understanding that in this case the guarantee period shall end not later
than 18 months after delivery in accordance with the terms of subarticle 1A.
3. Defects covered by the guarantee intended under articles 1, 1a and 2 shall be remedied by the
contractor by repair or replacement of the faulty component either on or off the premises of the
contractor, or by shipment of a replacement component, this remaining at the discretion of the
contractor. Subarticle 3A shall equally apply if repair or replacement takes place at the site where
the product has been assembled/installed. All costs accruing above the single obligation described
in the first sentence, such as are not restricted to shipment costs, travelling and accommodation
costs or disassembly or assembly costs insofar as they are not covered by the agreement, shall be
paid by the principal.
3A.If repair or replacement takes place at the site where the product has been assembled/installed,
the principal shall ensure, at his own expense and risk, that:
a. the employees of the contractor shall be able to commence their work as soon as they have
arrived at the erection site and continue to do so during normal working hours, and
moreover, if the contractor deems it necessary, outside the normal working hours, with the
proviso that the contractor informs the principal of this in good time;
b. suitable accommodation and/or all facilities required in accordance with government
regulations, the agreement and common usage, shall be available for the employees of the
contractor;
c. the access roads to the erection site shall be suitable for the transport required;
d. the allocated site shall be suitable for storage and assembly;
e. the necessary lockable storage sites for materials, tools and other goods shall be available;
f. the necessary and usual auxiliary workmen, auxiliary machines, auxiliary tools, materials and
working materials (including process liquids, oils and greases, cleaning and other minor
materials, gas, water, electricity, steam, compressed air, heating, lighting, etc.) and the
measurement and testing equipment usual for in the business operations of the principal,
shall be available at the correct place and at the disposal of the contractor at the correct time
and without charge;
37
300/658
g. all necessary safety and precautionary measures shall have been taken and adhered to, and
all measures shall have been taken and adhered to necessary to observe the applicable
government regulations in the context of assembly/installation;
h. the products shipped shall be available at the correct site at the commencement of and
during assembly.
4. Defects not covered by the guarantee are those which occur partially or wholly as a result of:
A. non-observance of the operation and maintenance instructions or other than foreseeable normal
usage;
B. normal wear and tear;
C. assembly/installation by third parties, including the principal;
D. the application of any government regulation regarding the nature or quality of the material
used;
E. materials or goods used in consultation with the principal;
F. materials or goods provided by the principal to the contractor for processing;
G. materials, goods, working methods and constructions insofar as are applied at the express
instruction of the principal, and materials or goods supplied by or on behalf of the principal.
H. components obtained from third parties by the contractor insofar as that party has given no
guarantee to the contractor.
5. If the principal fails to fulfil any obligation properly or on time ensuing from the agreement
concluded between the principal and the contractor or any agreement connected to it, the
contractor shall not be bound by any of these agreements to any guarantee regardless of how it is
referred to. If, without previous written approval from the contractor, the principal commences
disassembly, repair or other work on the product or allows it to be commenced, then every
agreement with regard to guarantee shall be void
6. Claims regarding defects must be submitted in writing as quickly as possible and not later than 14
days after the discovery of such. All claims against the contractor regarding faults shall be void if
this term is exceeded. Claims pertaining to the guarantee must be submitted within one year of the
valid complaint on penalty of invalidity.
7. If the contractor replaces components/products under the terms of his guarantee obligations, the
replaced components/products shall become the property of the contractor.
8. Unless otherwise agreed, a guarantee on repair or overhaul work carried out by the contractor or
other services shall only be given on the correctness of the manner in which the commissioned
work is carried out, this for a period of 6 months. This guarantee only covers the single obligation
of the contractor to carry out the work concerned once again in the event of unsound work. In this
case, subarticle 3A shall apply equally.
9. No guarantee shall be given regarded the inspection conducted, advice given and similar matters.
10.Alleged failure to comply with his guarantee commitments on the part of the contractor shall not
absolve the principal from his obligations ensuing from any agreement concluded with the
contractor.
11.No guarantee shall be given on products which form a part of, or on work and services on, goods
older than 8 years.
38
301/658
21. ENCLOSURE
21.1 RECOMMENDATIONS FOR A GOOD WORKING BOOSTER UNIT
In order to get a good working booster unit we would like to point out a few things that are important.
Circulation
 The capacity of one circulation/booster pump should be 2,5 to 4 times the max fuel
consumption
 The capacity of one feeder pump should be 1,5 to 2 times the max fuel consumption
Fuel velocity
Fuel velocity depends on the capacity of the circulation/booster pump and the inner diameter of the
pipe that is used. A larger inner diameter will give a slower fuel velocity.
 The recommended fuel velocity in the booster unit is 1 - 2 m/sec

 The recommended fuel velocity to and from the engines is 0,25 – 0,5 m/sec
Remarks:
 A too high fuel velocity will result in larger pressure losses within the booster unit.
 A too high fuel velocity can result in unstable viscosity measurements.
 A too low fuel velocity will result in a slow and possibly unstable viscosity control
VAF Instruments delivers the ViscoSense®2 with housing. Refer to the table below for flow rate
corresponding to the size of housing:
Fluid flow rate in piping All at 0-50 mPa.s

(Recommended for correct control function) 2” - Max 20 m3/h, Min 7m3/h
2.5” - Max 34 m3/h, Min 12m3/h
3” - Max 51 m3/h, Min 18m3/h
4” - Max 80 m3/h, Min 28m3/h
For lower flowrates a smaller pipe diameter is
recommended.
Mixing tank
The mixing tank is an important part of the booster system that has several functions.
 The mixing of MDO and HFO to a homogeneous emulsion.

 The mixing of hot ( +/- 130° C ) with colder (+/- 80 °C ) fuel, to a fuel with a single temperature
 Compensation of pressure pulses
 Prevention of a thermal shock of the engine when changing over from HFO to MDO.
Remarks
 If hot and cold HFO is not mixed well, it can result is incorrect viscosity measurements, which
will result in an incorrect viscosity control of the system
 High or constant pressure pulses in the system can lead to damage to the ViscoSense®2 or
other components of the booster unit.
39
302/658
Fuel filters
There should be two fuel filters, placed parallel. One should be clean and on standby.
Fuel filters should be placed in the HFO supply to the booster.
 The fuel flow is less; therefore the filter can be smaller.
 The fuel temperature is lower and the fuel is more stable.
Heaters
Heaters can be steam, or electric.
There must be two heaters placed parallel in the system. Only one heater should be switched on. The
other one should be clean and on standby.
Booster pump
There should be two booster pumps.
One active and the other one on standby

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303/658
304/658
Operating instructions for duplex filter
Type 2.06.5.4
Nominal diameter DN 65 - DN 80
Filter element Multimantle element
Print document on both sides
NOTE:
Translation of the original operating instructions
Siemensstraße 10 - 14
50170 Kerpen
Germany
www.bollfilter.de
Date Version Language Order No. Item No.

06.2013 001 en 4015080 01
1/50
305/658
2 / 50 Operation Instruction 2.06.5.4
306/658
Table of Contents
1 Preamble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.2 Warning signs and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.4 Obligations of the user/operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.5 Selection and qualifications of staff . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1.6 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.6.2 Maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.7 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.7.1 Filtered media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.1.7.2 Cleaning agent. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Transportation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Packaging material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Overview of assembly groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1 Special safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.2 Filter installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.2.1 Floor fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.2.2 Identifying the flow direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2.3 Filter inlet/outlet pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.2.4 Filter heating (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.2.5 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2.6 Potential equalisation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1 Functional description of the filter . . . . . . . . . . . . . . . . . . . . . . . . . . 23
7.1.1 Housing cover safety device (optional) . . . . . . . . . . . . . . . . . . . . . . 23
7.1.2 Differential pressure monitoring (optional) . . . . . . . . . . . . . . . . . . . . 24
7.2 Filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.2.1 Multimantle element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
7.2.2 Functional description of the multimantle element. . . . . . . . . . . . . . 26
7.3 Filter switch-over . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.3.1 Position of the pressure compensation valve . . . . . . . . . . . . . . . . . 27
7.3.2 Segmented plug valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.3.3 Operating the pressure compensation valve . . . . . . . . . . . . . . . . . . 29
7.4 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Operation Instruction 2.06.5.4 3 / 50
307/658
7.4.1 Filter in pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
7.4.2 Filters in suction lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.5 Removal from service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
7.6 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
8 Maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.1 Special safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
8.2 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.3 Special tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.4 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8.5 Cleaning/replacing filter elements . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.5.1 Preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.5.2 Removing the multimantle element . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.5.3 Cleaning the multimantle element . . . . . . . . . . . . . . . . . . . . . . . . . . 36
8.5.3.1 Cleaning the multimantle element in case of stubborn soiling . . . . . 37
8.5.4 Installing the multimantle element . . . . . . . . . . . . . . . . . . . . . . . . . . 38
8.5.5 Concluding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.5.5.1 Filter in pressure lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
8.5.5.2 Filters in suction lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
9 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.1 Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.1.1 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
9.1.2 Technical data sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9.1.3 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.1.3.1 Spare parts drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
9.1.3.2 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
9.2 Differential pressure indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2.1 Technical data sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2.2 Spare parts list . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.3 Supplier's documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.4 Cleaning devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
9.5 BOLL CLEAN 2000 cleaning agent product information . . . . . . . . . 48
9.6 Worldwide sales and service network, subsidiaries and
representatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
308/658
1 Preamble
1.1 General
These operating instructions are designed to make it easier to get to know the
BOLL & KIRCH filter and make use of its proper intended uses.
The operating instructions contain all important instructions on how to operate
the filter safely, properly and economically. Adherence to the operating
instructions helps to prevent hazards, repair costs as well as to reduce down
times, increase the reliability and even the serviceable life of the filter. Read the
operating instructions carefully and attentively.
Supply the operating instructions with any instructions required due to existing
national and international regulations for the prevention of accidents and
environmental protection. Make sure that the operating instructions are always
available in the place of use for the filter. The operating instructions must be read
and applied by every person given the task of performing the following work:
• transportation,
• installation,
• operation,
• maintenance and servicing,
• Disposal.
1.2 Warranty and liability

The "General Terms and Conditions" of BOLL & KIRCH Filterbau GmbH apply.
BOLL & KIRCH Filterbau GmbH shall not recognise any warranty or liability
claims for personal and material damages if they can be attributed to one or more
of the following causes:
• improper use of the filter,
• failure to comply with the information and instructions in the operating
instructions,
• arbitrary constructional modifications to the filter,
• insufficient monitoring of parts which are subject to wear and tear,
• maintenance/repair work performed improperly or too late,
• disasters caused by external influences or an act of God.
All the information in these operating instructions is provided to the best of our
knowledge based on our prior experience. We reserve the right to make technical
changes as part of further technical development.
The text and graphic illustrations do not necessarily correspond exactly to the
actual delivery. Reference to any deviations is made in the respective place if
required for comprehension. The graphic illustrations are not true to scale.
A list of spare parts is enclosed with the operating instructions for spare parts
orders.
309/658
1.3 Copyright
These operating instructions are a certified document as per the terms of the law
against unfair competition.
The copyright of the document is held by

BOLL & KIRCH Filterbau GmbH
Siemensstraße 10 - 14
50170 Kerpen
Germany
These operating instructions are for the user of the filter and the user's staff. They
contain text and drawings which, without the express permission of the
manufacturer must not be
• reproduced,
• distributed or
• otherwise made available to others, either in full or in part.
Failure to comply will require compensation.
310/658
2 General safety instructions
2.1 Basic safety instructions
2.1.1 Proper use
The filter is constructed with state-of-the-art technology and according to the

recognised rules of safety. However, use of the filter may result in risks to the life
and limb of the user or third parties and/or damage to the filter or other objects of
material value.
Only use the filter if it is in a technically perfect condition and only use it properly;
paying due attention to safety and hazards, and in adherence to the operating
instructions. It is particularly important to remedy any faults (or have them
remedied), which may compromise safety.
The filter is designed only for liquid media filtration. The filter is designed for
installation in pipes. The type of medium agreed in the order, and the limit values
for operating pressure and temperature as set out in the "Technical data", must
be adhered to. Any other type of use or use going beyond this use, is regarded
as improper use. The manufacturer/supplier shall not be liable for any damage
caused as a result of improper use. The user bears the sole risk.
Proper use includes observance of the operating instructions and adherence to
the inspection and maintenance conditions.
Operationally safe function is only ensured if all the instructions, settings and
performance limits for the filter, are adhered to.
2.1.2 Warning signs and symbols
The following designations and symbols are used in the operating instructions to
denote particularly important information:
DANGER!
Denotes immediate hazard with high risk which will cause death or serious
physical injury if not avoided.
WARNING!
Denotes possible hazard with medium risk which may cause death or serious
physical injury if not avoided.
CAUTION!
Denotes a hazard with low risk which could cause light or medium physical injury
or material damages if not avoided.
NOTE
Denotes special user tips and other particularly useful or important information.
DISPOSAL
Denotes special measures for environmental protection.
311/658
2.1.3 Target group
The operating instructions apply for use by qualified specialist staff only.
2.1.4 Obligations of the user/operator
• Always keep the operating instructions at hand at the place of use of the filter.
• Adhere to general legal and other binding accident prevention regulations
and environmental protection, and provide supplementary instructions in the
operating instructions accordingly. This type of obligation can apply to the
handling of hazardous substances or the provision / wearing of personal
safety clothing and equipment, for instance.
• Supplement the operating instructions with your own instructions, including
supervision and reporting obligations for specific operational matters, e.g.
with regard to organisation of work, working sequences and the appointed
staff.
• Observe all existing safety instructions and hazard warnings on the filter.
• Keep all existing safety instructions and danger signs on the filter complete
(in number) and in a legible condition.
• Do not make modifications of any kind to the filter which may compromise
safety, without the permission of the manufacturer.
• The spare parts which are used must comply with the technical requirements
set out by the manufacturer. This is always guaranteed by the use of original
spare parts.
• The user is responsible for the selection of materials and the chemical
resistance of the installed components, internal linings and coatings. The
user must specify the technical details when ordering the filter.
2.1.5 Selection and qualifications of staff
• All work on the filter must be performed exclusively by reliable staff. Staff
must not be under the influence of drugs or medication. Adhere to the legal
minimum age requirement.
• Only employ qualified or trained staff. Clearly define the staff responsibilities
for assembly, operation, as well as maintenance and servicing.
312/658
2.1.6 Organisational measures
2.1.6.1 General
• Follow the respective valid national and international accident prevention

regulations.
• Avoid direct contact with the surfaces. Depending on the operating
temperature, there may be a risk of burns.
2.1.6.2 Maintenance and servicing
• Adhere to the maintenance tasks and intervals set out in the operating
instructions, including instructions on the replacement of parts/equipment.
• Only use original spare parts.
• If the filter is subject to a regular inspection by an inspection and testing
organisation, with regard to temperature, steam pressure and the
dangerousness of the medium, the inspection periods must be adhered to by
the user.
2.1.7 Consumables
• Observe the regulations for environmental protection. Make sure that

consumables are disposed of properly and in an environmentally friendly
manner.
2.1.7.1 Filtered media
• When handling media which are to be filtered, make sure you follow the
respective safety regulations for the media.
2.1.7.2 Cleaning agent
• When handling the cleaning agents, make sure you follow the respective
safety regulations for the cleaning agents.
313/658
314/658
3 Transportation and storage
3.1 Transportation
DANGER!
Risk of accidents from falling loads
During transportation of the filter, accidents may occur due to sizes and weights.
• Exercise extreme caution when transporting the filter in order to prevent
damage to or deformation of the filter.
• Only use suitable means of transport and lifting gear with sufficient load-
bearing capacity.
• Do not stand underneath suspended loads. Do not work underneath
suspended loads.
• Wear the appropriate safety equipment and clothing.
3.2 Storage
CAUTION!
Improper storage will cause damage to the filter and filter elements
If stored incorrectly and improperly, moisture and contamination, for example,
may cause damage to the filter and the filter elements.
• Protect the filter and filter elements from moisture and contamination during
storage.
• Do not store the filter and filter elements below the frost line.
• If the filter and the filter elements have been stored for more than one year,
check that all seals are fully functional before installation.
3.3 Packaging material

CAUTION!
Risk of explosion from electrostatic charge
Packaging material, such as paper or plastic, can become statically charged and
generate sparks when discharged.
• Remove the packaging material before transportation into an explosion
protected zone.
DISPOSAL
Observe the regulations for environmental protection. Make sure that the
packaging material is disposed of properly and in an environmentally friendly
manner.
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4 Scope of delivery
Immediately after receiving the delivery, check that the content is not damaged
and that it corresponds to the scope of the order. In case of discrepancies,
contact the manufacturer.
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5 Technical data
NOTE
You will find the technical data in the appendix of these operating instructions.
5.1 Type plate

The type plate is placed on the filter. You can read the maximum permitted
operating pressure and the maximum / minimum operating temperature from the
type plate.
NOTE
When making enquiries or ordering spare parts, always indicate the information
mentioned on the type plate.
5.2 Overview of assembly groups

NOTE
The description of assembly groups can be found in the "Operation" chapter of
these operating instructions.
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2 1 2 6 5
3
3 7
8 9
10
11 12
Fig. 5-1 Overview of assembly groups
1 Pressure compensation 7 Flange

2 Cover 8 Draining
3 Housing 9 Drain (only housing-
 195 mm)
4 Filter element 10 Differential pressure
monitoring (optional)
5 Vent (only housing- 195 mm) 11 Reversing lever
6 Vent 12 Segmented plug valve
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6 Installation
6.1 Special safety instructions
DANGER!
Risk of accidents from improper installation
Incorrect installation and failure to observe the listed safety instructions can lead
to accidents or damage to property.
Make sure of the following:
• The filter must be installed by qualified specialist staff or persons who have
received appropriate instruction.
• Wear the appropriate safety clothing.
• Only use suitable lifting gear with sufficient load-bearing capacity.
• Only use lifting gear on the provided suspension points (if available).
• Use lifting gear in such a way that the filter does not become damaged.
• Raise the filter evenly. Avoid tilting.
• Do not stand underneath suspended loads. Do not work underneath
suspended loads.
• Additional devices to prevent maximum temperatures being exceeded and
temperatures dropping below the minimum and for compensation and relief
of overpressure, must be provided by the user throughout the entire system
of the plant. Observe the minimum and maximum permitted operating
temperatures and pressure values for the filter.
• Additional devices for monitoring the ambient temperature of the filter must
be provided by the user throughout the entire system of the plant.
• Install a ground cable with a cross section of at least 10 mm² as a potential
equalisation for the filter.
NOTE
Contact the manufacturer with any special questions you may have regarding
installation. The contact data for the respective national subsidiaries can be
found in the appendix of the operating instructions.
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6.2 Filter installation
CAUTION!
Risk of damage to the filter housing
The filter housings are designed exclusively for internal overpressure.
• The housing and connection flanges of the filter must not be exposed to any
external force or moment.
6.2.1 Floor fastening
Fig. 6-1 Filter with support leg for floor fastening
1 Fastening point
2 Support leg
 Make sure the foundation has sufficient load bearing capacity.

 Make sure that there is sufficient space in the vicinity of the filter for
maintenance and servicing work.
 Align the filter.
 Screw the filter housing to the fastening points. When fastening the filter in
place, the filter housing must not be twisted.
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6.2.2 Identifying the flow direction
NOTE
• The connections for the filter inlet / outlet depend on the filter element in use.
• The inlet / outlet are indicated by the inscriptions (Ein/In), (Aus/Out) on the
connection flanges.
Fig. 6-2 Flow direction
6.2.3 Filter inlet/outlet pipe connections
 Establish the connections between the filter and piping.

 Use the appropriate seals.
 The pipes for the filter inlet and outlet may need to be provided with additional
supports, depending on the installation conditions. When installing the piping,
the filter housing must not be twisted.
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6.2.4 Filter heating (optional)
Fig. 6-3 Filter heating (optional)
1 Filter heating (optional)

2 Piping
The filter heating is used during the filtering process to cover heat loss in the filter
and before starting up the plant in order to heat up the medium in the filter. The
filter can be heated with water vapour, hot water or thermal oil.
DANGER!
Risk of accidents from expelled hot medium
Too much pressure in the heating system can cause hot medium to be expelled
and lead to damage to the filter and accidents.
• Adhere to the maximum permitted operating temperature and operating
pressure for the filter heater.
 Connect the medium-carrying pipes to the filter heating on the plant side.
Welded joints must be made in line with the valid regulations.
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6.2.5 Electrical connections
DANGER!
Risk of accidents from electric shock
When connecting to the power supply, the supply voltage can cause accidents
from electric shock.
• All the electrical connections on the filter must be made by a qualified
electrician and in line with the rules of electrical engineering.
Filter heating, electrical (optional)

The filter heating is used during the filtering process to cover heat loss in the filter
and before starting up the plant in order to heat up the medium in the filter. The
filter is heated electrically.
 Connect the filter heating to the electrical power supply.
Differential pressure monitoring, electrical (optional)
NOTE
You will find more detailed information on the differential pressure monitoring
system in the appendix of these operating instructions or in the manufacturer's
documentation.
NOTE
BOLL & KIRCH Filterbau GmbH differential pressure indicators have potential-
free contacts.
6.2.6 Potential equalisation
 For potential equalisation, install a ground cable with a cross section of at

least 10 mm² on the filter.
 Connect the ground cable to the fastening screw on the filter. If necessary,
prior to the installation of the ground cable, remove the paint from the
fastening point to ensure sufficient electrical contact.
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7 Operation
7.1 Functional description of the filter
The filter is used to filter particles from media in order to protect the downstream
parts of the plant.
It can be installed in a pressure line or in a suction line. Duplex filters are used in
cases in which the soiled filter elements have to be regenerated without
interrupting the filtering process.
Switchable duplex filters comprise two filter housings which are arranged in a
parallel circuit by a dual-stage switching organ. The filter housings are designed
in line with its pressure stage and in accordance with the respective regulations.
The medium being cleaned flows through the filter inlet of the filter housing into
the filter chamber where it flows through the filter element. The cleaned medium
exits from the filter outlet.
The double-stage filter switch-over mechanism ensures the switch-over is
performed without pressure surges. The construction of the filter switch-over
mechanism prevents both filter chambers from being shut down at the same
time.
In normal operation mode, one filter chamber is in operation whilst the other filter
chamber is available as a reserve.
For media with a high ferrite content the drain screws can be fitted with optional
magnetic inserts.
7.1.1 Housing cover safety device (optional)
1 2 3 4
A B
Fig. 7-1 Housing cover safety device (optional)
1 Threaded connector
2 Vent
3 Cover
4 Housing cover safety device (optional)
A Cover secured
B Housing cover safety device pivoted to the side
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The housing cover safety device has the task of preventing pressurised medium
from being expelled uncontrollably in case of incorrect operation. The cover
sheet covers a minimum number of cover screws so that the cover cannot be
removed without opening the vent to bleed the system.
The filter chamber is relieved via the vent. When the filter is shut off, the operating
pressure is immediately relieved and hardly any medium is expelled. Otherwise,
close the vent immediately and the expulsion of medium is limited.
DANGER!
Risk of accidents from expelled medium
Hot medium may be expelled when opening the vent.
• Proceed with extreme caution.
DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is disposed
of properly and in an environmentally friendly manner.
7.1.2 Differential pressure monitoring (optional)
The differential pressure monitoring system measures the differential pressure

between the filter inlet and filter outlet. As the soiling increases, the differential
pressure in the filter also increases.
The differential pressure monitoring system indicates the differential pressure
optically and/or provides electrical signals for further processing.
NOTE
• You will find more detailed information on the differential pressure monitoring
system in the appendix of these operating instructions or in the
manufacturer's documentation.
• The control line to the differential pressure monitoring system can be fitted
with optional shut-off valves (e.g. ball valves).
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7.2 Filter insert
7.2.1 Multimantle element
2
3
Fig. 7-2 Construction of the multimantle element
1 Filter element anchor

2 Nut or magnetic secondary filter (optional)
3 Lifting ring
4 Seal
5 Individual filter elements (number depends on the overall size)
6 Magnetic primary filter (optional)
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7.2.2 Functional description of the multimantle element
Multimantle elements are used for filtration. The flow runs from the outside to the
inside.
Particles of dirt in the flow are thus filtered off by the individual sieve elements.
The cleaned medium exits from the top of the multimantle elements and is fed
back into the plant.
The multimantle elements consist of several filter elements slotted into one
another. The points of contact between the individual sieve elements are sealed
with seals in order to prevent short-circuiting.
The dirty side is sealed off from the clean side by the seal on the outermost sieve
element.
Construction and function of the magnetic primary filter / magnetic

secondary filter (optional)
For media with a high ferrite content, it is recommendable to equip the
multimantle element with a magnetic insert as a preliminary and secondary filter.
The magnetic insert comprises several individual magnets which are fastened to
a section tube.
The magnetic primary filter / magnetic secondary filter is removed for cleaning
and the collected dirt particles can be easily removed.
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7.3 Filter switch-over
7.3.1 Position of the pressure compensation valve
CAUTION!
Risk of damage to the filter if the pressure compensation valve is
positioned incorrectly
With a closed pressure compensation valve, the medium may be subject to heat
expansion and cause an increased build-up of pressure in the filter chamber
which is shut off.
• The pressure compensation valve must always remain open during
operation.
• The pressure compensation valve must only be closed when cleaning the
filter element.
7.3.2 Segmented plug valve
2 1 7
Fig. 7-3 Overview of assembly groups (cross sectional view)
1 Pressure compensation 5 Segmented plug valve

2 Reversing lever 6 Valve housing
3 Retaining ring 7 Drain plug
4 Seal
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Functional description of the segmented plug valve circuit
The segmented plug valve circuit is used to switch between the filter's filter
chambers.
The special shape of the segmented plug valve prevents breaks in the flow of
medium and pressure surges when switching over and, at the same time,
guarantees ease of movement due to lower levels of frictional force.
The segmented plug valve only requires seals in two positions.
Operating the segmential plug valve circuit
A B
2 3
Fig. 7-4 Switch position indicator
1 Reversing lever A Filter chamber in operation

2 Symbols B Stand-by filter chamber
3 Position pointer
The position pointer, comprising the position pointer and symbols, indicates the
direction of flow and which filter chamber is in operation. Before switching over
from one filter chamber to the other, you must check whether the pressure
compensation valve is open. Then turn the segmented plug valve all the way to
the right or left using the reversing lever. In the middle position both filter
chambers are in operation.
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7.3.3 Operating the pressure compensation valve
Fig. 7-5 Pressure compensation
1 Pressure compensation plug valve

2 Segmented plug valve
3 Crossways drilled hole
The pressure compensation valve must remain open at all times whilst the filter
is in operation in order to prevent overpressure in the filter chambers.
The pressure compensation valve must only be closed when cleaning the filter
chamber.
A hole drilled crossways in the plug valve is used for pressure compensation and
filling a drained filter chamber. The crossways drilled hole is sealed and opened
using a pressure compensation plug valve which can be screwed in and out.
NOTE
Opening the pressure compensation valve - turn anti-clockwise
Close pressure compensation valve - turn clockwise
Always open and close the pressure compensation valve completely.
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7.4 Commissioning
CAUTION!
Risk of damage to the filter from improper filling
If the filter is filled improperly, the filter elements may be damaged.
• Filling the filter against the indicated direction of flow of the filter elements is
not permitted.
7.4.1 Filter in pressure lines
 Check whether all connections have been made properly.

 Check that the filter switch-over mechanism moves easily by switching it
several times.
 Put both filter chambers into operation by placing the reversing lever in
middle position.
 Open the pressure compensation valve.
 Open the shut-off valves (if available) in the control line to the differential
pressure monitoring system (if available).
 Put the filter heating (if available) into operation.
DANGER!
DISPOSAL
 Open the vents on both filter chambers or the vents on the housing cover
safety devices (if available).
 Slowly put the plant into operation.
 Close the vents as soon as medium is expelled from the vents without any
bubbles.
 Put one of the two filter chambers into operation by shifting the reversing
lever. The pressure compensation valve remains open during operation.
 The filter is ready for operation. Whilst medium is flowing through one filter
chamber, the deactivated filter is on stand-by.
DISPOSAL
 After each time you commission the filter, check the filter for leaks and
eliminate them as necessary.
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7.4.2 Filters in suction lines
 Check whether all connections have been made properly.

 Check that the filter switch-over mechanism moves easily by switching it
several times.
 Open the shut-off valves (if available) in the control line to the differential
pressure monitoring system (if available).
 Remove the housing cover safety devices (if available).
 Unfasten the screw connection on the covers.
 Lift the covers off the housing.
 Fill and bleed the filter chambers.
 Check the seals for damage. Replace any damaged seals as necessary.
 Place the cover on the housing. Make sure that the seals are properly in
place.
 Screw the covers to the housings. Tighten the screw connection evenly,
gradually tightening opposite screws step-by-step.
 Fit the housing cover safety devices (if available).
 Select which of the two filter chambers to put into operation by shifting the
reversing lever.
 Open the pressure compensation valve.
 Put the filter heating (if available) into operation.
 Slowly put the plant into operation.
 The filter is ready for operation. Whilst one filter chamber is being used to
filter medium, the deactivated filter is on stand-by.
DISPOSAL
 After each time you commission the filter, check the filter for leaks and
eliminate them as necessary.
335/658
7.5 Removal from service
NOTE
When removing the filter and taking it out of service for longer periods, pay
attention to the following points:
• The filter must be completely emptied.
• Disconnect all connections from the filter.
• The filter must be thoroughly cleaned.
• The filter must be sealed by applying an appropriate anticorrosive, if
necessary.
• The connection flange openings must be sealed with plastic (or similar)
dummy plugs.
7.6 Disposal
DISPOSAL
When the filter or individual components and consumables are finally disposed
of, make sure that they are disposed of in an environmentally friendly manner.
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8 Maintenance and servicing
8.1 Special safety instructions
DANGER!
Risk of accidents from improper maintenance and servicing
Incorrect maintenance and servicing and failure to observe the listed safety
instructions can lead to accidents or damage to property. Make sure of the
following:
• Maintenance and servicing work must only be carried out by qualified
specialist staff or persons who have received appropriate instruction.
• When performing any work on the filter, always wear the appropriate safety
clothing.
• Only perform maintenance and servicing work when the filter is cooled,
depressurised and drained. Depending on the operating temperature, there
may be a risk of burns.
• Ensure the highest levels of cleanliness when opening the filter. No foreign
substances, e.g. tools, cleaning cloths, impurification etc., must be allowed
to remain in the filter.
• Visually inspect all seals during maintenance and replace them as
necessary.
• Clean all sealing surfaces thoroughly before assembly.
• On completion of the maintenance work, re-fit all available safety equipment
properly.
• Filling the filter against the indicated direction of flow of the filter elements is
not permitted.
• Remove the filter from service if the inspection periods (if indicated) have
elapsed.
• Filter elements are sensitive to pressure and impact. Always exercise
extreme caution when installing and removing the filter elements. Before
installation, check all filter elements/seals and replace any damaged filter
elements/seals as necessary.
337/658
8.2 Cleaning agents
CAUTION!
Risk of damage to the filter from incorrect use of cleaning agents
The components of the filter may become damaged if cleaning agents are used
incorrectly. The correct cleaning agent is selected in accordance with the type of
medium being filtered and the associated contaminations.
• BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning
agent. For more detailed information, see the appendix of these operating
instructions.
8.3 Special tools

The manufacturer provides no special tools for the filter.
8.4 Maintenance intervals

In order to make sure the filter continues to operate properly, observe the
following points for maintenance:
• Regularly check:
– the differential pressure (if monitored),
– the leak tightness of the filter, especially all connections and seals and
– the filter for corrosion and other damage,
– the condition of the filter elements and
– the condition of all screw connections and whether they are firmly
tightened.
• If the differential pressure (if monitored) reaches the preset maximum value
the filter will have to be cleaned.
• The filter must be inspected annually for leaks.
• Replace all seals when overhauling the filter.
NOTE
When filtering media which can leave deposits on the filter switch-over
mechanism circuit, it is recommendable to activate the filter switch-over
mechanism as often as possible and at regular intervals in order to prevent it from
seizing up.
DISPOSAL
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8.5 Cleaning/replacing filter elements
8.5.1 Preparatory work
 Shift the reversing lever all the way to the other side and put the stand-by
chamber, which is not contaminated, into operation.
 Close the pressure compensation valve.
DANGER!
DISPOSAL
 Slowly open the vent or the vent on the housing cover safety device (if
included in the scope of your delivery) on the soiled filter chamber which is
switched off. This depressurises the filter chamber and allows you to check
whether the filter chamber is properly shut off by the segmented plug valve.
NOTE
Unlike valve and ball valve circuits, the segmented plug valve circuit cannot be
fully sealed off. Leaking liquid may run out of the drain hole during the cleaning
process.
DANGER!
Hot medium may be expelled when opening the drain hole.
• Collect the expelled medium in a suitable container.
DISPOSAL
 Carefully open the drain hole on the filter which is switched off.
 Remove the housing cover safety device (if available).
 Unfasten the screw connection on the cover.
 Lift the cover off the housing.
339/658
8.5.2 Removing the multimantle element
 Unscrew the nut or the magnetic secondary filter (if available) from the filter
element anchor.
 Carefully pull the inner sieve element upwards by the lifting ring to remove it.
 Remove the other sieve elements by taking hold of the inside of the sieve ring
and pulling upwards.
 Remove the magnetic primary filter (if fitted) from the filter element anchor.
 Allow the sieve elements to drip dry in a suitable container.
8.5.3 Cleaning the multimantle element
CAUTION!
Risk of damage to the filter element from improper cleaning
If the filter element is cleaned or handled improperly, the filter element wire mesh
may become damaged. Observe the following safety instructions:
• Proceed with extreme caution when performing all cleaning work.
• The soaking time in the cleaning agent is 1 - 4 hours, depending on the level
of soiling. Check the progress of cleaning whilst the element is soaking.
• The cleaning temperature, when using "BOLL CLEAN 2000" must not
exceed 60 °C.
• When cleaning using a high-pressure cleaner and flat nozzle, the pressure
must not exceed a maximum of 60 bar. When cleaning using a high-pressure
cleaner, keep a sufficient distance (at least 20 cm) from the surface of the
filter material to prevent damage.
• When cleaning the filter element using a cleaning gun and compressed air,
the pressure must not exceed a maximum of 4 bar.
• Particles of dirt must not be allowed to enter the clean side of the filter
element.
NOTE
BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning
instructions.
 Place the sieve element in a container of suitable cleaning agent with the
opening pointing upwards. The upper sieve ring must protrude from the
cleaning agent. This prevents dirt from penetrating into the clean side.
 Remove loose particles which float on the top of the cleaning agent during
the soaking stage.
 Brush off the individual sieve elements with a brush which is not too hard
(e. g. Person brush).
 Blow out the cleaned sieve elements from the clean side using a cleaning
gun and compressed air. To do so, insert the cleaning gun into the openings
in the sieve ring. Move the cleaning gun up and down and blow out the filter
material from the inside to the outside, along the entire length.
 For final cleaning, rinse the sieve elements in a container with fresh cleaning
agent.
 Place the sieve element on its head so that the cleaning agent or water can
run off.
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 Blow out the sieve elements with compressed air from the inside to the
outside.
 Afterwards, check the filter material for damage and to establish whether it is
clean. The cleaning effect can be assessed by holding the sieve elements up
to the light. Use a torch for finer filter materials. The filter material is properly
clean if the light shines through evenly. Replace any damaged sieve
 Repeat the cleaning process as necessary.
8.5.3.1 Cleaning the multimantle element in case of stubborn soiling
NOTE
BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning
instructions.
 If the filter element is heavily soiled (lacquer contamination, incrustation, tar

residue, fibres, chippings), the filter element will have to be soaked in a
container with cleaning fluid. The upper sieve ring must protrude from the
cleaning agent. This prevents dirt from penetrating into the clean side.
 Remove loose particles which float on the top of the cleaning agent during
the soaking stage.
NOTE
BOLL & KIRCH Filterbau GmbH recommend the use of the BOLL & KIRCH
cleaning unit with nozzle to clean the inside of the multimantle element.
 In case of heavier soiling the sieve element can also be cleaned using a high-
pressure cleaner with a special nozzle for cleaning the inside of the
multimantle element. Use water or water with cleaning agent.
 Blow out the cleaned sieve elements from the clean side using a cleaning
gun and compressed air. To do so, insert the cleaning gun into the openings
in the sieve ring. Move the cleaning gun up and down and blow out the filter
material from the inside to the outside, along the entire length.
 For final cleaning, rinse the sieve elements in a container with fresh cleaning
agent.
 Place the sieve element on its head so that the cleaning agent can run off.
 Blow out the sieve elements with compressed air from the inside to the
outside.
 Afterwards, check the filter material for damage and to establish whether it is
clean. The cleaning effect can be assessed by holding the sieve elements up
to the light. Use a torch for finer filter materials. The filter material is properly
clean if the light shines through evenly. Replace any damaged sieve
 Repeat the cleaning process as necessary.
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8.5.4 Installing the multimantle element
 Clean any soiling which has collected on the inside of the filter.
 Attach the magnetic primary filter (if available) to the filter element anchor.
 Check all the seals for damage. Replace any damaged seals as necessary.
 Re-insert the individual sieve elements into the filter housing. When doing so,
it is important that the sieve ring on the outermost sieve element rests
properly in the specially hollowed-out filter support in the housing.
 Screw the nut or the magnetic secondary filter (if available) firmly in place
with the suitable tightening torque.
Filter element anchor Tightening torque

M12 15 Nm
M16 30 Nm
M24 120 Nm
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8.5.5 Concluding work
8.5.5.1 Filter in pressure lines
 Check the seals for damage. Replace any damaged seals as necessary.
 Place the cover on the housing. Make sure that the seal is properly in place.
 Screw the cover to the housing. Tighten the screw connection evenly,
 Fit the housing cover safety device (if included in the scope of your delivery).
Whilst you do so, the vent remains open.
 Close the drain hole.
DANGER!
When filling the filter chamber, hot medium may be expelled from the vent.
• Collect the expelled medium in a suitable container.
DISPOSAL
 Slowly open the pressure compensation valve and fill the filter chamber
through the pressure compensation valve until medium is expelled from the
vent or the vent on the housing cover safety device (if available).
 Close the vent as soon as medium is expelled from the vent without any
bubbles.
 Open the pressure compensation valve. The pressure compensation valve
remains open during operation.
 The cleaned filter chamber is on stand-by and can be put into operation as
required.
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8.5.5.2 Filters in suction lines
 Close the drain hole.

 Fill and bleed the filter chamber.
 Check the seal for damage. Replace any damaged seals as necessary.
 Place the cover on the housing. Make sure that the seal is properly in place.
 Screw the cover to the housing. Tighten the screw connection evenly,
 Fit the housing cover safety device (if included in the scope of your delivery).
 Close the vent.
 Open the pressure compensation valve. The pressure compensation valve
remains open during operation.
 The cleaned filter chamber is on stand-by and can be put into operation as
required.
344/658
9 Appendix
9.1 Filter
9.1.1 Technical data
Filter
Filter type 2.06.5.4
Nominal connection diameter DN 80
Fine filter units 34 µm
Mesh number 294/31
Permitted operating pressure 16.00 bar
permitted min. operating temperature 1.00 °C
permitted max. operating temperature 150.00 °C
Differential pressure when filter is clean Cleaning 0,6bar/Alarm 0,8bar
Filter element
Element type of filter Multimantle sieve element
Heating
Heated filter housing Steam
Permitted operating pressure 14.00 bar
permitted max. operating temperature 200.00 °C
345/658
9.1.2 Technical data sheet
346/658
9.1.3 Spare parts
9.1.3.1 Spare parts drawing
347/658
9.1.3.2 Spare parts list
Document Description Date

267155 duplex filter 02.04.14
Dimension drawing: Z132467
Assembly: Z106159
Item ID no. Description Qty Unit

00012 7203893 threaded rod 1 m
00013 2100035 hexagon nut 2 pcs.
00023 8650481 key 1 pcs.
00034 9811765 type plate 1 pcs.
00035 9850003 working instructions plate 1 pcs.
00037 2801059 square blind flange 2 pcs.
00038 2000046 hexagon screw 8 pcs.
00040 9403312 label: "cock position" 1 pcs.
00040 2000268 slotted cheese head screw 2 pcs.
00041 9800300 label: "inlet" 1 pcs.
00042 9800301 label: "outlet" 1 pcs.
00047 3380041 flat gasket 2 pcs.
011.0 1001006 Multi Mantle Element 2 pcs.
011.2 9402265 label: "multi-mantle element cleaning" 1 pcs.
011.4 9404388 label: "mesh-type candle cleaning" 1 pcs.
348/658
9.2 Differential pressure indicator
9.2.1 Technical data sheet
349/658
9.2.2 Spare parts list
350/658
9.3 Supplier's documentation
NOTE
Documentation for any components or assembly groups purchased externally by
BOLL & KIRCH Filterbau GmbH is enclosed with these operating instructions.
Adhere to the information contained, in particular information on the subject of
safety.
9.4 Cleaning devices

For particularly good cleaning results, BOLL & KIRCH Filterbau GmbH
recommends the filter element cleaning unit type 5.04 with rotating nozzle and
flat jet nozzle or optionally, the type 5.05 ultrasonic cleaning unit.
351/658
9.5 BOLL CLEAN 2000 cleaning agent product information
Product description:
BOLL CLEAN 2000 is a liquid cleaning and degreasing agent with a broad range
of applications. It can be used practically for all cleaning and degreasing needs.
BOLL CLEAN 2000 cleans quickly and thoroughly and is extremely economical.
The use of BOLL CLEAN 2000 renders all safety precautions unnecessary.
BOLL CLEAN 2000 has all these excellent characteristics without the
disadvantages of solvent-based cleaners.
BOLL CLEAN 2000 is:
• not inflammable
• not subject to compulsory identification markings
• not strong smelling
• not corrosive
• physiologically harmless
• biodegradable
• Umweltbundesamt (Federal German Ministry of Environment) reg. no.
04860019
BOLL CLEAN 2000 can be overcooled or overheated during storage but is then
fully useable when at normal temperature again.
Sieve mesh contaminated with heavy oil:
Sieve meshes which are contaminated with heavy oil must be soaked in normal,
commercially available solvent. After soaking, the sieves are cleaned in the
BOLL & KIRCH cleaning device type 5.04 with BOLL CLEAN 2000 and high-
pressure pump.
Instructions for use:
BOLL CLEAN 2000 is not processed for any specific cleaning method. BOLL
CLEAN 2000 can be used in a soaking bath, in a spray unit, in a steam jet cleaner
or be applied by hand, using a cloth, brush or sponge, depending on the
operational conditions.
It can be used cold or warm.
BOLL CLEAN 2000 can be mixed with water - even with sea water.
• Concentration for mesh cleaning: 1 : 2,5
• Maximum temperature up to 60 °C
The concentration depends on the type and extent of the collected dirt particles
which have to be removed. When using a concentration of 1 : 30 and above,
rinsing is usually not necessary. No visible film is left on the surface.
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9.6 Worldwide sales and service network, subsidiaries and
representatives
If you require service or spare parts, please contact the main site or our
subsidiaries, representatives or service points.
Deutschland Croatia Poland

1 2 3 BOLL & KIRCH Filterbau GmbH 1 Marine Trade d.o.o. 1 TRIMOR sp. z o. o.
Postfach 1420, D-50143 Kerpen Vladimira Nazora 6 ul. Andersa 17
Siemensstr. 10-14, D-50170 Kerpen HR - 47000 Karlovac PL-81-831 Sopot
Tel.: +49/(0)2273/562-0 Tel.: +385/(0)47/ 61 19 07 Tel.: +48/(0)58 551 66 40
Fax: +49/(0)2273/562-223 Fax: +385/(0)47/ 43 12 61 Fax: +48/(0)58 555 19 29
E-Mail: info@bollfilter.com E-Mail: marine-trade@ka.t-com.hr E-Mail: trimor@trimor.com.pl
www.bollfilter.com www.trimor.com.pl
Cyprus
1 3 BOLL & KIRCH Filterbau GmbH 1 M.I.E. Services Ltd. Russia / Ukraine / Belarus
Geschäftsstelle Nord The Hawk Building 1 2 3 000 BOLLFILTER Russland
An der Strusbek 34 124 Gladstonos Street Datschnyi prospekt, 2
D - 22926 Ahrensburg CY - 3032 Limassol Geb. 1, Lit. A, Raum 23N
Tel.: +49/(0)4102/4740-0 Tel.: +357/(0)25 889 999 RUS - 198207 St. Petersburg
Fax: +49/(0)4102/4740-22 Fax: +357/(0)25 763 902 Tel.: + 7/(0)812-364-61-80
E-Mail: info@bollfilter.de E-Mail: info@mieserv.cy.net Fax: + 7/(0)812-364-61-80
www.bollfilter.de www.miegroup.com.cy E-Mail: info@bollfilter.ru
1 IVG Pumpen- und Filtrationstechnik Gera Denmark / Sweden / Norway / 1 2 3 Switzerland / Liechtenstein
Prehlis 13 A Iceland / Finland / Lithuania / EIG CRUSTAG
D - 07552 Gera Latvia / Estonia 120 Route de Frontenex
Tel.:+49/(0)365/42 00 07 4 1 2 3 BOLLFILTER Nordic ApS CH - 1208 Genève
Fax: +49/(0)365/42 00 07 5 Hammerbakken 21 Tel.: +41/(0)22/73 59 50 0
E-Mail: ivg-neubert@superkabel.de DK - 3460 Birkerød Fax: +41/(0)22/78 66 17 1
www.ivg-neubert.de Tel.: +45/(0)45/42 12 00 E-Mail: info@eig-crustag.ch
Fax: +45/(0)45/42 12 99 www.eig-crustag.ch
1 BOLL & KIRCH Filterbau GmbH E-Mail: info@bollfilter.dk
Geschäftsstelle Süd www.bollfilter.dk 1 2 3 Spain / Portugal / Argentina /
Rangaustraße 7a Chile / Peru / Uruguay
D - 91639 Wolframs-Eschenbach BOLLFILTER España S.L.
Tel.: +49/(0)9875/97899-0 Greece / Bulgaria Zona Cami Ral
a
Fax: +49/(0)9875/97899-29 1 2 3 FILTERKON Paseo del Ferrocarril, 339 3ª – 2
E-Mail: norbert.henkelmann@bollfilter.de Vas. Amalias 2 E - 08860 Castelldefels
www.bollfilter.de GR - 14561 Kifissia Tel.: +34/(0)93/634 26 80
Tel.: +30/(0)210/92 17 671 Fax: +34/(0)93/665 22 79
Europe Fax: +30/(0)210/92 42 242 E-Mail: info@bollfilter.es
Austria / E-Mail: filterkon@filterkon.com www.bollfilter.com
Czech Republic / www.filterkon.com
Slovakia / Slovenia 1 2 3 The Netherlands
1 2 3 Schmachtl GmbH Great Britain / Ireland Lubrafil B.V.
Pummererstrasse 36 1 2 3 BOLLFILTER UK Limited Aalborg 2
A - 4020 Linz Unit 9 Station Road NL - 2993 LP Barendrecht
Tel.: +43/(0)732/76 46 0 UK - Tolleshunt D'arcy, Essex CM9 8TY Tel.: +31/(0)180/55 62 55
Fax: +43/(0)732/78 50 36 Tel.: +44/(0)1621/86 21 80 Fax: +31/(0)180/55 62 65
E-Mail: g.oehler@schmachtl.at Fax: +44/(0)1621/86 92 57 E-Mail: lubrafil@lubrafil.nl
www.schmachtl.at E-Mail: sales@bollfilter.co.uk www.lubrafil.nl
www.bollfilteruk.co.uk
Belgium / Luxembourg 1 Turkey
1 2 3 AUXIMECA N.V. Italy ARES PLAKALI ESANJOR SAN.
Wijtschotbaan 3/3 1 2 DE.CO.STA Spa Ve TIC. LTD. STI
B - 2900 Schoten Via Bicetti de Buttinoni, 12 HSOSB ORDU CAD. NO:4
Tel.: +32/(0)3 646 61 80 I - 20156 Mailand 01350 ADANA, Türkei
Fax: +32/(0)3 646 93 98 Tel.: +39/(0)0238/00 52 83 Tel.: +90/(0)322 / 394 3200
E-Mail: info@auximeca.be Fax: +39/(0)0238/00 36 31 Fax: +90/(0)322 / 394 3228
www.auximeca.com E-Mail: sales@decosta.it E-Mail: bollfilter@aresphe.com
www.decosta.it www.aresphe.com
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America Africa
Middle East
USA / Canada 1 2 Safe Technical Supply Co. L.L.C. South Africa
1 2 3 BOLLFILTER Corporation P.O. Box 4832 1 2 Afrifil Manufacturing (PTY) LTD
22635 Venture Drive UAE - Dubai 8 Pressberg Road Modderfontein
Novi, MI 48375 - USA Tel.: +971/(0)4/32 43 24 0 ZA - Isando, 1600
Tel.: +1/(0)248/773-8200 Fax: +971/(0)/4/32 43 78 6 Tel.: +27 11 452 5444
Fax: +1/(0)248/773-8201 E-Mail: info@safetechnical.com Fax: +27 11 609 9535
E-Mail: latorre@bollfilterusa.com www.safetechnical.com E-Mail: sales@afrifil.co.za
www.bollfilterusa.com www.afrifil.co.za
People's Republic of China
2 3 Motor-Services Hugo Stamp, Inc. incl. Hong Kong
USA - Ft. Lauderdale, Florida 33315 1 BOLLFILTER CHINA Ltd.
Tel.: +1/(0)954/763 3660 2/F No. 178 South Riying Road
Fax: +1/(0)954/763 2872 Waigaoquiao Free Trade Zone
Shanghai 200131 China
Asia Tel.: +86 21 5043 3328
Fax: +86 21 5043 3329
India E-Mail: grace.yip@bollfilterchina.com
1 2 3 BOLLFILTER India Pvt. Ltd. www.bollfilterchina.com
"Monarch Plaza", Office No. 106
Sector-11, CBD Belapur, Singapore / Malaysia / Indonesia
IN - Navi Mumbai 400614 1 2 3 IMI Corporation Pte. Ltd.
Tel.: +91/(0)22/27 56 01 47 13 Joo Koon Crescent
Fax: +91/(0)22/27 56 01 46 SGP - Singapur 629021
E-Mail: info@bollfilterindia.com Tel.: +65-68 61 42 22
www.bollfilter.com Fax: +65-68 62 42 22
E-Mail: imicorp@imicorp.com.sg
Japan www.imicorp.com.sg
1 2 3 BOLLFILTER Japan Ltd.
Imon Kobe Bldg. 13F South Korea
95 Edo-machi, Chuo-ku 1 2 3 Blohm + Voss (Korea) Ltd.
JP - Kobe 650-0033 Room 1812, Ocean Tower
Tel.: +81/(0)78/331 8031 760-3, U-Dong, Haeundae-gu
Fax: +81/(0)78/331 8032 612-020 Pusan, Korea
E-Mail: info@bollfilter.jp Tel.: +82-51-740 5700
www.bollfilter.jp Fax: +82-51-740 57 04/5/6
E-Mail: bvkorea@bvkorea.com
1 Verkaufsbüro Agency
2 Lager Stockist
3 Service Service
Januar 2014
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10
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Plate Type Heat Exchangers
Operation and Maintenance Manual
365/658
Project: B14-0500 – 131M082-01_09 (MAN “Kodda”)
Customer: mas maritime assembly GmbH

Zum Dock 3-4
23966 Wismar
Germany
Exchanger type: S19A-IG16
Serial number: SD 18163 till SD 18171
Year: 2014
PED category: [X] Art. 3, par.3 [] Cat. 1 [] Cat. 2 [] Cat. 3 [] Cat. 4
Approved by: SONDEX NB number:
Remarks: SDO 28049
The contents of this publication are based on the latest information available and the
materials that are used at the time of printing. However, because of rapid developments
in this field we cannot be held liable for changes in specifications affecting the contents
of this publication.
COPYRIGHT
Copyright © SONDEX HOLDING A/S. All rights reserved. No part of this publication
may be reproduced or distributed without prior written permission of SONDEX
HOLDING A/S.
366/658
CONTENTS
1 FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 SAFETY ALERT NOTICES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Identification of the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Correct operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4 Thermal design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 CONSTRUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.3 Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.4 Special executions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.5 Right/left plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.1. Requirements to the installation area . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2 Transport, lifting, storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6.3 Installing the pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 COMMISSIONING / OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.1 Commissioning and pre-checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7.3 Shut-down for a short period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
7.4 Shut-down for a long period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
8 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8.1 Clean in place (CIP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8.2 Some cleaning detergents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8.3 Opening the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.4 Cleaning the plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.5 Plate replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.6 Gasket replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
8.7 Tightening of the plate pack and pressure testing . . . . . . . . . . . . . . . . . . 20
8.8 Maintenance of the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
9 PROBLEM SOLVING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
10 AFTER SALES SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

10.1 Ordering parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10.2 Modifications to the heat exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
10.3 Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
367/658
1 FOREWORD
This manual is a guide for installation, commissioning and maintenance of plate type
heat exchangers supplied by SONDEX.
It is meant for those who are responsible for the installation, the use and maintenan-
ce of the heat exchangers. We recommend that you read this manual carefully before
commencing any work.
2 INTRODUCTION
This manual is applicable for all heat exchangers produced and supplied by
SONDEX.
SONDEX can not be held responsible or liable for damage as a result of in-
correct installation, use and / or maintenance of SONDEX plate type heat
exchanger as well as not complying with the instructions in this manual.
Please note that our plate type heat exchangers are specially designed and
built for the operating conditions (pressures, temperatures, capacities and
type of fluids) provided by the customer. Sudden pressure peaks beyond the
normal operating pressure (or pressure surges) which can occur during start-
ing up or stopping of the system can severely damage the heat exchanger and
should be prevented. SONDEX can not be held responsible for any damage as
a result of any operation deviating from the original design conditions.
If you wish to alter the design conditions, please contact us refer page 24. You may
only commission the heat exchanger under the modified conditions after inspection
and written approval by SONDEX. Also the name plate on the heat exchanger will be
adapted.
3 SAFETY ALERT NOTICES

3 Safety Alert Notice
Following must be respected by installing/running/servicing plate heat exchangers:
Keeping current local safety regulations.
Before any work begins ensure that the exchangers are pressureless and cooled till
under 40ºC.
Use gloves for preventing any injury from sharp edges when handling plates.
In all cases ensure that all laws and regulations are strictly kept concerning
human/environment protection.
YELLOW TRIANGLE
Refer to applicable SAFETY ALERT notices within the manual!
All SAFETY ALERT notices are applicable to personal injury and identified by the fol-
lowing symbol.
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4 GENERAL
4.1 Identification of the heat exchanger
All plate type heat exchangers supplied by SONDEX are provided with a name plate.
On this plate the following details are specified:
• type of heat exchanger

• year of manufacture
• manufacturing number
• nominal capacity in kW
• transmission area in m2
• max. working pressure in bar
• test pressure in bar
• max. working temperature in °C
• min. assembling measure in mm
L E
X A MP
E
FIG 1
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4.2 Correct operation
This user manual provides information and instructions for correct and safe operation
of the unit. Many accidents are caused by incorrect use!
It is essential that you study the instructions carefully, and above all, ensure the
availability to those who install, maintain and operate the heat exchanger on a daily
basis. This manual is of no value if it is not available at the time when your staff
needs it.
If a problem occurs with your SONDEX Heat Exchanger which is beyond the scope of
this manual, do not hesitate to contact us. The installation should not be put into ope-
ration before all indistinctnesses have been solved!
To avoid injuries and damages, follow the instructions and local applicable safety
regulations. Also take the necessary protective measures, depending on the nature of
your process or circumstances related to it, at your plant.
Please note that our plate type heat exchangers are especially designed and built for
the operating conditions (pressures, temperatures, capacities and type of fluids) pro-
vided by the customer. Sudden pressure peaks beyond the normal operating pressu-
re (or pressure surges) which can occur during starting up or stopping of the system
can severely damage the heat exchanger and should be prevented.
SONDEX can not be held responsible for any damage as a result of any operation
deviating from the original design conditions.
If you wish to alter the design conditions, please contact us. You may only commissi-
on the heat exchanger under the modified conditions after inspection and written
approval by SONDEX. Also the name plate on the heat exchanger will be adapted.
4.3 Precautions
All potential personal injury hazards are identified by safety alert symbol.
Bodily harm can be caused by:

• burning as a result of touching the heat exchanger or other parts of the
installation;
• the uncontrolled release of pressurized media with which the danger of burning
and other injuries is present;
• contact with chemicals;
• touching sharp edges of the installation.
Damage to equipment can be caused by:

• external forces;
• corrosion;
• chemical action;
• erosion;
• material exhaustion;
• water hammer;
• thermal and / or mechanical shock
• freezing;
• wrong transport / lifting.
370/658
Even after stopping the installation some parts of it can still be hot!
The heat exchanger may only be used with the fluids specified on the datasheet.
The hot medium may not flow through the exchanger without the cold medium flowing
through. This is to prevent damage to the exchanger.
In case the cold medium is present but does not flow while the hot medium is flowing
through, the cold medium will start boiling and the exchanger will be damaged.
Sudden pressure and temperature changes should be prevented.
When a heat exchanger (filled with water or a water mixture) which is not in operation
is exposed to temperatures below zero, the plates can become deformed.
If a danger of frost occurs, the heat exchanger should be drained completely.
Demountable plate heat exchangers can always leak. We advise you to take this into
account while installing. Preferably you should install a drip tray underneath the heat
exchanger to prevent leakages onto the floor and/or harm to electrical equipment.
(Short circuit/moisture damage).
If the heat exchanger is being used with temperatures above 60º C or with aggressive
fluids, we advise you cover the heat exchanger with a screen plate to prevent the risk
of touching.
If welding activities have to be carried out near the heat exchanger, never use the
heat exchanger for earthing the construction work.
Electrical currents can cause severe damage to both plate and gasket.
If you have to weld, dismantle the connecting flanges and isolate the heat exchanger
from the system.
4.4 Thermal Design
Sondex plate type heat exchangers are designed and calculated according to the
newest technology.
If performance test has to be carried out, the exchanger must be totally clean.
In the Sondex data sheet the nominal capacity and pressure losses are mentioned.
The pressure loss can deviate up to 15 % from the data in the data sheet depending
on plate thickness, the plate material and the difference in the two working pressures.
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5 CONSTRUCTION
Upper bar Column
Follower
Head Plate package
Lower bar
Tie bolts
5.1 Frame
The heat exchanger consists of a frame plate (head), a pressure plate (follower), a
carrying bar, a lower bar and a column. Tie (clamping) bolts are used to press the
plate package together. The size and number is depending on the type of heat
exchanger.
5.2 Plates
The plate package consists of plates with a groove along the rim of the
plate and around the ports. The number of plates is, as well as size and
dimension, dependant on the thermal output required. Depending on the
application stainless steel or titanium plates might be used
5.3 Gaskets
The groove provided in the plates holds the special gasket. The purpose
of this gasket is to prevent intermixing of the media and leakage to the
outside.
The gaskets are selected to suit the actual combination of temperature,
chemical resistance and possible other conditions to be considered.
They can be supplied in Viton, Nitrile or EPDM.
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The following types of packings are being used in our plate type heat exchangers:
• Glue gaskets
• "Sonder Snap"
• "Sonder Lock" gaskets (new generation of gaskets)
• "Hang-on" gaskets
"Sonder Snap" gasket "Sonder Lock" gasket "Hang-on" gasket
5.4 Special applications

If the plate heat exchanger works with several fluids at the same time, it can be
necessary to insert intermediate frames.
The intermediate frames are equipped with corner blocks, forming connections be-
tween the different sections. Two connections can be placed in the same corner block,
having connection to two different sections in the plate heat exchanger.
For the exact application of your plate type

heat exchanger please check the docu-
mentation which was supplied with the heat
exchanger.
5.5 Right/left plates

The SONDEX plates are designed in such a way that they can be
used both as right and as left plates. The plates just have to be
turned 180º. ( Excepted are types S1, S53 and SF52, which are “dia-
gonal” plates. Here right and left plates are different ).
Right and left plates:

On a right plate the flow runs from hole 2 to hole 3 or reverse from
hole 3 to hole 2.
On a left plate the flow runs from hole 1 to hole 4 or reverse from
hole 4 to hole 1.
The opening of the corner holes are described in a “plate code
index”. For instance 1234 means that all corner holes are open.
Every plate can be identified by the gasket configuration, the plate
code index and thermal short or thermal long execution.
373/658
Plate types:
Start plate with gasket
Left hand flow plate with gasket
Right hand flow plate with gasket
End plate with gasket
Thermal long plate
Thermal short plate
10
374/658
6 INSTALLATION
6.1 Requirements to the installation area
It is very important that enough space around the plate type

heat exchanger is kept free for servicing of the unit (renewal
of plates, tightening of the plate package).
As a rule the free space around the unit should be

1, 5 to 2 x the width of the unit.
6.2 Transport, lifting and storage
WARNING: To prevent personal injury always use appropriate hoisting equipment. If

you are to lift the heat exchanger itself, straps should be used. They should be placed
as shown on the picture.
11
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Lifting:
Usually the heat exchanger will be supplied horizontally on a pallet.
The back side of the head will then be tightened to the pallet. This allows
you to transport the unit by means of a fork lift truck.
Rising of the unit:

• Remove all tightening elements from the pallet;
• Place straps around one bolt on each side as shown on the picture.
Never use steel cables or chains!
• Lift the heat exchanger from the pallet;
• Lower the heat exchanger slowly to vertical and on it’s feet and place
it in it’s end position on the floor.
• Remove the straps and tighten the heat exchanger to the floor.
Never lift the heat exchanger by using the connections or studs

around them!
Attention:
ALWAYS: Use the lifting eyes (if fitted)

Lift the top side of the head
Attach the straps to the bolts close to the head
NEVER: Lift using the connections

Lift the follower
Lift using an intermediate plate
Lift with a strap attached close to the follower
Storage:
Should it be necessary to store the heat exchanger for a longer period (1 month or
more), certain precautions should be taken in order to prevent unnecessary damage
to the equipment.
Preferably the heat exchanger should be stored inside in a room with a temperature
around 15 to 20 ºC and a humidity of max. 70%.
If this is not possible, place the heat exchanger in a wooden box which is provided
with a lining on the inside against penetration of moisture.
There should absolutely not be any ozone producing equipment in the room, like
electric motors or arc-welding equipment, since ozone destroys many rubber
materials. Also do not store organic solvents or acids in the room and avoid heat or
ultraviolet radiation.
12
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6.3 Installing the pipe connections
Depending on the type the SONDEX plate type heat exchanger will be provided with
flanges, couplings, threaded pipes, etc.
When connecting the pipe system to the heat exchanger make sure that no
stress or strain is imposed, by the pipe system, on to the heat exchanger!
We advise you of the following:

• Heavy pipe work needs to be supported. This will prevent heavy forces on the heat
exchanger.
• Always install flexible connections on the follower to prevent vibrations on the heat
exchanger. These flexible connections also prevent expansion of the pipe work,
caused by temperature influence, onto the heat exchanger.
• These flexible connections need to be fitted in a longitudinal direction to the plate
package.
• The pipe work needs to be thoroughly cleaned and flushed before connecting up to
the heat exchanger.
• Always install vents on both sides of the heat exchanger.
Note: For proper venting the vents should be fitted on the highest point in the direc-
tion of the flow of the medium (preferably on an air vessel).
To enable the heat exchanger to be opened when necessary shut off valves should
be provided in all connections!
Make sure that the pipe work, connected to the heat exchanger, is secured
against pressure peaks / surges and temperature shocks!
Threaded pipe connections:

If a plate type heat exchanger is provided with threaded pipe connections, make sure
that these connections do not rotate when fitting to the pipe work. It could damage
the gasket on the start plate. You need to make “counterhold” on the connection!
Flange connections:
If the connection is rubber lined, the liner will act as the flange gasket.
Bolt the connecting flange directly to the endplate using the drilled and tapped holes
provided. Tighten the bolts evenly – do not over-tighten as this could strip the threads
cut into the frame plate.
If loose backing flanges are fitted to the heat exchanger a suitable gasket is required
to seal the flange.
Unless otherwise stated, the liquid circuits should be connected to flow in reverse
directions through the exchanger (counter-current). Refer to the contract drawing or
quotation details if the connections are not marked.
13
377/658
7 COMMISSIONING
7.1 Commissioning and pre-checks
Commissioning may only be done by staff specially trained for the job or by SONDEX
commissioning engineers.
Control, maintenance and repair of the installation may only be done by authorized,
trained and properly instructed staff.
Maintenance and cleaning may only be done with a heat exchanger cooled to under
40O C and shut down!
Check if all connections are fitted correctly (see also 6.3).
Filtration:
The media flowing through the heat exchanger should not contain particles larger
than 0,5 mm diameter/length. If necessary ”inline” filters should be fitted.
Check the pressures and temperatures of the media and make sure that these are
not more than the values specified on the name plate.
It is essential that the heat exchanger is not subjected to thermal or mechani-

cal shock as this could lead to premature gasket failure
7.2 Operation
Start cold circuit first, then the hot circuit.
• Fully vent the system;

• Close shut off valve fitted between pump and exchanger;
• Fully open valve fitted into return line from the exchanger;
• Start the circulation pump normally placed by the inlet;
• Gradually open closed shut off valve between pump and exchanger;
• Vent system again if necessary.
Repeat the above for the secondary circuit.
14
378/658
When using steam as one of the media:
Use slow acting steam control valves and open slowly shut off valves!
Before start up:
• Ensure that the steam control valve is fully closed
• Ensure that the heat exchanger is fully drained of condensate
• Start cold circuit first, then the steam side
• Open steam control valve slowly – this prevents water hammer of any condensate
in the steam line and reduces the pressure / thermal shock to the exchanger
• Ensure that the steam trap is correctly sized to allow full condensate discharge –
this prevents water clogging inside the exchanger
Check for proper operation:

• Check for pressure pulses in the system caused by the pumps or control valves. If
found, stop operation and rectify. Continuous pressure pulses will result in fatigue
failure of the plates.
Visually check the unit for leakages.
Check that all vents are closed to prevent air being sucked into the system.
When in operation, the conditions should not be changed. The max. condi-
tions specified on the name plate should not be exceeded.
7.3 Shut-down for a short period

If the plate type heat exchanger has to be shut down for a short period, please
follow the following procedure:
• Slowly close the control valve in the hot circuit whilst maintaining the full flow in the
cold circuit;
• Switch off the hot circuit pump;
• Cool down the heat exchanger to under 40O C;
• Slowly close the control valve in the cold circuit;
• Switch off the cold circuit pump;
• Close all remaining shut off valves.
7.4 Shut-down for a long period

If the unit is to be taken off line for an extended period of time then the following pro-
cedure should be followed:
Point 7.3 must be followed, then:
• Allow unit to cool down;
• Drain all circuits;
• Lubricate threads on the tie (clamping) bolts;
• Loosen tie clamping bolts until the plate pack is “loosened” (max. "A" size + 10%).
• The tie bolts should not be removed or loosened to such an extent that dirt is
allowed to enter in-between the plates. We recommend that a warning notice is
attached to the exchanger to remind personnel that the tie clamping bolts need
adjustment before the unit can be put back into service.
• Cover the plate pack with black plastic to exclude any sunlight.
Please also see chapter 6.2 - Storage
15
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8 MAINTENANCE
8.1 Clean in place (CIP)
CIP cleaning (clean in place by circulating cleaning detergents)
To use CIP cleaning, it is a condition that the scaling on the plates is soluble. All
materials in the whole circulation system of course have to be resistant to the clea-
ning detergent.
We advise you to ask for a confirmation from the supplier of the cleaning
detergent that it will not damage the materials in the heat exchanger.
If the solution requires recirculation, select a flow that is as high as possible, and
certainly no less than the service or product flows.
Follow the instructions as given by the detergent supplier / cleaning specialist.

We suggest that for recirculated cleaning detergent methods, the fluid should be
pumped through the exchanger for no less than 30 minutes.
Rinsing
After using any type of cleaning agent, always rinse thoroughly with fresh
water. If cleaning in place then circulate fresh water for at least 10 minutes.
8.2 Some Cleaning Detergents
Oil and grease can be removed with a water emulsifying oil solvent i.e. BP system.
Organic and grease cover can be removed with sodium hydroxide (NaOH) maximum
concentration 1,5% - max. temp. 85 ºC.
Mixture for 1,5% concentration = 5 ltr. 30% NaOH per 100 ltr. water.
Stone and limestone can be removed with nitric acid (HNO3) - max. concentration
1,5 % - max. temp. 65 ºC.
Mixture for 1,5% concentration = 2.4 ltr. HNO3 62% per 100 ltr. water.
Nitric acid also has an affective build up effect on the passivation film of stainless
steel!
CAUTION: Nitric acid and Sodium Hydroxide may cause injury to exposed
skin, eyes, and mucous membranes. Use of protective eyewear and gloves is
strongly recommended.
16
380/658
8.3 Opening the plate heat exchanger
When opening and assembling the heat exchanger observe the following:
• Measure and note the actual "A" size;
• Use the correct tools and lubricant;
• Shut down the heat exchanger as described under 7.3;
• Make sure the heat exchanger cools down (<40 ºC);
• Ensure there is no pressure on any part of the unit;
• Clean the tie (clamping) bolts and grease the threads;
• Loosen the tie clamping bolts equally in the correct order (fig. 10) i.e. that
the follower shall have a parallel opening motion;
• Pull the follower back towards the column;
• Remove the plates without damaging the gaskets.
CAUTION: Ensure unit is depressurized and drained of hot and/or aggressive

product before unit is opened to prevent personal injury.
CAUTION: Sharp edges. When handling plates, gloves should be worn.
Recommendation:
Mark the plate package before opening.
You could mark the plate package with a diagonal line on the outside fig 10a, or num-
ber the plates in sequence.
2 2
3 3
2 2
Fig. 10 Fig. 10a
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8.4 Cleaning the plates
CAUTION:
Always wear gloves and eye goggles when using cleaning detergents.
Use nylon or other types of “soft” scrubbing brushes with detergent.
Never use a metal brush, steel wool or sand/glass paper.

This will damage the passivation film of the plates.
Use Acetone or other types of solvents which do not contain chlorine to remove old
gasket glue. Alternatively use a ”lowtemp.” gas flame softly heating the reverse side
of the plate. Do not use any other type of gas which may produce a “harder” flame.
Remember ventilation. Boiling water can be used with some success.
Consult a cleaning specialist for a suitable choice of detergent. Ensure that all deter-
gents used are compatible with the plate and gasket material before use.
In case plates are removed for manual cleaning, make sure they are re-fitted in the
same order.
Always remove plates one by one and number them!
A high pressure cleaner can be used but with absolute care and never add abrasives.
If the scaling or organic layer is thick the plates can be put in a barrel with qualified
cleaning material.
Before fitting chemical cleaned plates they need to be thoroughly rinsed with
fresh water!
Important:
Cleaning is an important part, influencing the effectiveness of the plate heat exchan-
ger. Insufficient cleaning can have the following results:
• too low circulation flow;

• insufficient thermal output;
• life time of the heat exchanger will be shortened.
If a plate has to be renewed because of serious damage, the plates next to

this plate normally need to be replaced.
18
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8.5 Plate replacement
The plates must be clean, dry and free from oil or grease. If there are any oil remains
on the gaskets, or on the gasket seating area, then there is a high risk that the plates
or gaskets shall slip out of place when the unit is being tightened. If the gaskets are
contaminated with dirt or grit, then these could cause leakage.
• make sure that all seating areas are flat, clean and undamaged.
• always use new gaskets.
Correct
Fit the plates according to the Plate Sequence Sheet – ensure all
gaskets face towards the fixed frame plate (head).
Alternate between left and right handed plates – if the plate edges form a
regular honeycomb pattern, the left / right hand sequence is correct, see
fig.11.
Wrong
8.6. Gasket replacement
Glue free gaskets

This type of gasket (“Hang-on”) and “Sonder Lock” (new generation of
glue free gasket) require no adhesive. They are located by pushing the
gasket fully down into the gasket groove or fastened by special devices.
Fig 11 Make sure groove and gasket are clean!
Glue type gaskets

The surfaces need to be clean and free of oil.
Only use chloride free glues like Pliobond 20 or 30, Bostic 1782,
3M EC 1099 and Bond Spray 77.
Follow the instructions of the manufacturer; these will be printed on the
cover of the glue.
CAUTION: When using commercial solvents and adhesives, follow

the manufacturers recommendations carefully, as many of these
materials are hazardous.
19
383/658
Ring Gaskets
The ring gaskets are used in connection with intermediate frames, by connections in
the follower and by ”SW” (Semi Welded) types.
It can be necessary to use a little glue for positioning the ring gasket during assembly
of the heat exchanger.
Rubber Liners
There is one type of rubber liners for connections in the head an another type of rub-
ber liners for connections in the follower.
8.7 Assembling of the plate package and pressure testing
• Lightly oil the tie (clamping) bolt threads. Do not allow oil or grease onto the gaskets
or the gasket seating faces on the back of the plates. Wet or contaminated plates can
be-come misaligned during tightening. In this case, dismantle, clean, and dry all
areas in contact with the gaskets. Evenly tighten all bolts in the correct order (refer
page 17 fig. 10). We advise the use of ratchet spanners.
• Ensure clamping is as uniform as possible, thus keeping the frames and plates paral-
lel throughout the operation. Avoid skewing the frame plates by more than 5 mm.
• Tightening is complete when the distance between the inside faces of both frame
plates equals the “A” distance as shown on the contract drawing, see fig. 12.
This tightening distance can also be calculated using the following formula:
Assembly distance = No. of plates x (plate thickness + coefficient)
The coefficients can vary depending on the model type, but is often 0,1 mm.
• Finally check that all tie (clamping) bolts are in tension and clean any spilt oil off the
head, follower and plates.
• On completion the unit can be pressure tested (test pressure is stated on the name
plate).
”A-measure”
Fig 12
20
384/658
If dimension "A" is not reached with application of maximum tightening torque:
• check the number of plates and dimension A on the data sheet;

• check that all the nuts and bearing boxes are running freely. If not, clean and lubri-
cate or replace.
If the unit does not fully seal, it may be tightened step by step to give dimension “A”
min. This dimension is mentioned on the name plate, see fig. 1.
However, the minimum measure must not be exceeded.
Under no circumstances distance “A” may be smaller than “A” min.
Tightening of the plate package can only be done with a fully depressurized
unit.
8.8 Maintenance of the heat exchanger
Time interval – once a year as a minimum

Check temperatures and flows against commissioning data.
Check general condition and look for any signs of leakage.
Wipe clean all painted parts and check surfaces for signs of damage – “touch up” if
necessary.
Check bolts and bars for rust and clean. Lightly coat threaded parts with molybdenum
grease or a corrosion inhibitor (ensure that no grease, etc. falls onto the plate
gaskets.
If rollers are fitted to the follower, lubricate the bearings with light machine oil.
21
385/658
9 PROBLEM SOLVING
If you have problems with your plate type heat exchanger, in most cases these can
be solved by your own personnel. Please find below a summary of possible problems
as well as possible causes and solutions.
A condition for the continuous proper functioning of your plate type heat
exchanger is in strict compliance with the permissible values for pressure and
temperature mentioned on the name plate.
Exceeding these values, even as short-lasting pressure peaks will cause
damage to the unit and be the cause of problems.
To avoid costly repairs, we advise you to have the installation work and maintenance
carried out by properly trained personnel. You can also contact relevant SONDEX
Sales Office.
Problem Possible cause Possible solution
Leakage At the connections - Check the rubber liners (if fitted)

- Check the flange gasket (if fitted)
- Check the O-ring
- Fit the pipes tension-free
Mixing of primary and - Check the plates for holes and/or

secondary circuit cracks
In plate package - Check the assembly distance

- Check the condition of the gaskets
- Check the proper position of the gaskets
The operating conditions - Adjust the operating conditions

deviate from the specification
Insuffi- Air in the system - De-aerate the pipe system

cient - Check the pipe work for possible air traps
capacity
The operating conditions - Adjust the operating conditions
deviate from the specification
The heat exchanger is dirty - Clean the heat exchanger
The connections have been - Redo the pipe work

interchanged
Too high Flow larger than the design flow - Adjust the flow
pressure
drop Channels in plate(s) blocked - Flush / clean
Incorrect measurement - Check the pressure indicator
Medium deviating from the - Addition of for instance anti-freeze will

design increase the pressure drop
Air in the system - De-aerate the pipe system

- Check the pipe work for possible air traps
22
386/658
For nearly all leakage problems it will be necessary to dismantle the unit before any
attempts to rectify the fault can be made. Mark the area(s) where the leakage seems
to be with a felt tip marker or similar before taking apart the exchanger.
“Cold leakage” is caused by a sudden change in temperature. The sealing properti-

es of certain elastomers are temporarily reduced when the temperature changes sud-
denly. No action is required as the gaskets should re-seal after the temperature has
stabilised.
Gasket failures are generally a result of:
• old age
• excessive exposure to ozone
• high operating temperature – above the temp. limit of the material
• exposure to pressure surges
• chemical attack
• physical damage, resulting from incorrect assembly work, or damage
• resulting from a misaligned plate (check the hanging system at the top of the plate
for distortion).
Decrease in performance is generally a result of:
• plate surfaces require cleaning or de-scaling

• pumps or associated controls have failed
• plate channels blocked
• liquid flows not as per design specification
• associated chiller / cooling tower / boiler under sized or dirty
• cooling water temperature to the exchanger is higher than the design
• heating media temperature to the exchanger is lower than the design
• steam flow not sufficient – control valve malfunction
• steam trap broken or jammed – unit becomes filled with condensate
• plate package has been assembled incorrectly
• unit is running in co-current flow, instead of counter current – check with contract
drawing and alter pipe work if necessary. Check direction of pump flows.
• air lock has developed in the plate package or pipe work
23
387/658
10 AFTER SALES SERVICE
10.1 Ordering parts
When ordering parts it is important that the correct details are given.
At least the following should be quoted:
• Project and order number
• Exchanger type and manufacturing number (see name plate)
• Required parts
When ordering separate plates it is important that the correct plate code index and
type of plate is given. See chapter 5.2
When ordering separate gaskets it is important to indicate the correct gasket material.
When ordering tie (clamping) bolts, the existing ones should be measured in order to
get new ones of the same size and length.
10.2 Modifications to the heat exchanger
The plate heat exchanger is built up in modules and therefore flexible with respect
to enlargements or reductions. It is easy to change the capacity by respectively en-
larging or reducing the number of plates.
We would be pleased to advise you.
10.3 Contacts
AUSTRALIA GERMANY HOLLAND

SONDEX, Australia PTY LTD SONDEX, Deutschland GmbH SONDEX, BV
Phone +61 3 9707 5511 Phone +49 4171 788330 Phone +31 299 674 934
Fax +61 3 9707 5501 Fax +49 4171 788350 Fax +31 299 674 936
E-mail: info@sondexaustralia.com.au E-mail: info@sondex.de E-mail: info@sondex.nl
Internet: www.sondexaustralia.com Internet: www.sondex.de Internet: www.sondex.nl
ITALY POLAND USA

SONDEX, Italy S.r.l. SONDEX, Poland SONDEX, Inc USA
Phone +39 0363 905086 Phone +48 58 676 0012 Phone : +1 502 933 9991
Fax +39 0363 905422 Fax +48 58 676 0497 Fax : +1 502 933 9914
E-mail: info@sondex.it E-mail : ksw@sondex.pl E-mail: sales@sondex-usa.com
Internet: www.sondex.it Internet : www.sondex.pl Internet: www.sondex.dk
FRANCE UNITED ARABIAN EMIRATES DENMARK

Sondex France SARL Gulf Sondex FZCO SONDEX
12 Avenue de Saules Warehouse No. FZS 1 - BJ 01 Jernet 9
69600 Oullins Jebel Ali Free Zone DK-6000 Kolding
France Dubai Tel. +45 76 30 61 00
Phone: 0033478 463640 Phone: +9714 886 1027 Fax. +45 75 53 89 68 /
Fax: 0033478 461942 Fax: +9714 886 1028 +45 75 50 50 19
E-mail: sondex@wanadoo.fr E-mail: sondexgulf@yahoo.co.in E-mail: info@sondex.dk
Internet: www.sondex.fr Internet: pramod@gulfsondex.ae Internet: www.sondex.dk
SONDEX ROMANIA HONG KONG

S.C. Sondex Romania SRL SONDEX Distribution Centre Hong Kong
50, Fagului Street Unit 42A, 2/F., Cambridge Plaza
400483 Cluj-Napoca Sheun Shui, New Territories
Romania Hong Kong
Phone: +40 364 402 270 China
Fax: +40 364 402 272 Phone: +85 2 3124 0228
Fax: +85 2 3124 0221
24
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SONDEX Deutschland GmbH - Design & Datalist
mas GmbH Att : Frau Engel Item : 1 V10A33

QuotationNo : SDA 48392160 Ref : 5301770 Kodda / 131M083 Montag, 27. Mai 2013
PHE-Type S19A-IG16-46-TL-LIQUID Hot side Cold side
Flowrate (m3/h) 10,60 8,00

Inlet temperature (°C) 67,76 51,00
Outlet temperature (°C) 54,00 58,97
Pressure drop (bar) 0,18 0,09
Heat exchanged (kW) 73
Thermodynamic properties: MDO/MGO LT-Water
Specific gravity (kg/m³) 823,00 985,86
Specific heat (kJ/kg*K) 2,19 4,18
Thermal conductivity (W/m*K) 0,22 0,65
Mean viscosity (mPa*s) 9,89 0,53
Wall viscosity (mPa*s) 13,08 0,49
Fouling factors (m²*K/kW) 0,0158 0,0158
Dimensioning factor (%) 4.6
Inlet branch F1 F3
Outlet branch F4 F2
Design of Frame / Plates:
0,4 mm
Plate arrangement (passes*channel) 1 × 23 + 0 × 0
Plate arrangement (passes*channel) 1 × 22 + 0 × 0
Number of plates 46
Effective heat surface (m²) 9,80
Overall K-value Duty/Clean (W/m²*K) 1384 / 1447
Plate material 0.4 mm AISI 316
Gasket material / Max. temp. (°C) NITRIL HT HANG ON (H) / 140
Max. design temperature (°C) 100,00
Max. Working/test pressure (bar) 10,00 / 15,00 ACC. to PED 97/23/EC Art 3.3
Max. Differential pressure (bar) 10,00
Frame type Paint Specification IG No 1 Category C3 RAL 9002
Connections HOT side (F1->F4) DN 65 Flange rubberlind HT PN10/PN16
Connections COLD side (F3->F2) DN 65 Flange rubberlind HT PN10/PN16
Liquid volume (liter) 27
Frame length (L) (mm) 443 Max. No. of Plates 59
Net weight (net) (kg) 252
PRICE EACH EURO Approval
TERMS OF DELIVERY
TERMS OF PAYMENT
DELIVERY TIME
VALIDITY OF QUOTATION
DESIGNED BY Albus
low load operation!
Accesories: EURO
SONDEX Deutschland GmbH Robert-Koch-Str. 3 D-21423 Winsen (Luhe)
Tlf : +49 (0)4171 788330 Fax : +49 (0)4171 788340
391/658
192 L1
114
114
B2 B1
F1 F2
F1-F4 AND B1-B4

DN65 DIN2632/2633
2,5" ANSI CLASS150
CLADDED OR RUBBERLINED
700
700
946
946
F4 F3 B3 B4
132
132
8
7
F1-F4 42 L 60 192
395
DN65 DIN2632/2633
2,5" ANSI CLASS150 395
UNCLADDED L+102
20 L+57 25
275
395
40
18
18
Dimensions Designed by Date Approved by Date Rev. no. Revision Text

without tolerance:
LGK 21-07-2009 JRD 09-05-2012 03 ADDED CONNECTIONS
Description:
ISO 2768-m
ISO projektion
SONDEX S19a IG PN16 DN65 DIM DRAW
LENGTH 400-1000 MM
Jernet 9 Rev. date Rev. by Drawing no. Sheet
DK-6000 Kolding 07-05-2012 LGK S19aIGPN16DN65L400-1000 1 /1

392/658
Material Declaration
Date of Declaration
I Date 121.07.2010
Supplier Information
Company name SONDEX Deutschland GmbH
Division name
Address Robert-Koch-Str. 3
Telephone no. 0417117883-30
Fax no. 0417117883-40
E-mail address info@sondex.de
Product Information
Part or drawing number Product total mass
Product name Product information
MAN Diesel Mass Unit
Plate Heat Exchanger I
Material I Substance information per engine
Intentiona
lIyadded
above Ifyes, If yes,detailed
Threshold
Table Materials name threshold material mass material
level
level information
yeslno Mass Unit
Asbestos Asbestos no threshold no
level
Polychloinated POlychloinated no
Biphenyls Biphenyls 50 mglkg
• (PCBs) (PCBs)
CFCs no
Halons no
• Other fullyl no
halogenated
CFCs
TableA Carbon Tetra- no
(Materials chloride
listed in Ozone 1,1,1
Trichloroethane no threshold no
appendix 1 Depleting
(Methyl chloroform) level I
ofthe Substance
Convention) Hydrochloro- no
fluorocarbons I
Hydrobromo- I no
fluorocarbons
Methyl bromide I no
Bromochlorom no
ethane
Tributyl Tins no
Organotin Triphenyl Tins no
2500 mg/kg
compounds Tributyl Tin no
I Oxide (TBTO)
_ ... _ .... _- - - - - - - - - - - - - - - - - - - -
393/658
Intentionally
added If yes,
above substance If yes, detailed
Threshold
Table Material threshold mass substance
level
level information
yeslno mass unit
Cadmium and Cadmium no
100 mg/kg
Compounds
Hexavalent Chromium no
1000 mg/kg
Compounds
Lead and Lead no
1000 mg/kg
Compounds
no
Table B • Mercury and Mercury 1000 mg/kg
(Materials
Compounds
listed in Polybrominated Biphenyl no
appendix 2 (PBBs) 1000 mg/kg
ofthe
Convention) Polybrominated Dephenyl no
1000 mglkg
ethers (PBDEs)
Polychloronaphthalanes no threshold no
(CI=>3) level
no threshold no
Radioactive Substances level
Certain Shortchain no
1%
ChloJl'i1)ted Paraffins
We hereby
best knOWle~
t7lrm that the products we dellver to MAN Diesel are declared to our
SONDEX 11
RoIIet1
TtIefcIo .....{O}
'f lnd GmbH
"- 4Z3 Wlnstn/L
:z ...T.w- mllUII
E-MIII: ,...,",·WWW.lOl1dex.de
\J
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406/658
Armaturen und Automatisierungs GmbH
Fritz Wehlan
Am Alten Bahnhof 17, 19273 Neuhaus/Elbe
Operatinge, Montage and Maintenance Recommendation

for Ball Valves
Index: Page
1. General 2
2. Safety instructions 2
3. Transport 2
4. Storage 3
5. Functioning 3
6. Installation 3
7. Initial operation 4
8. Maintenance 4
9. Troubleshooting 4
-1-
407/658
Fritz Wehlan
1. General:
- When making inquiries or spare part orders please always quote our order no. and, if
possible, the ball valve type and year of manufacture.
- We assume no liability in cases of disregard of operating or safety instructions or of faulty
installation or maintenance.
- Please refer to all data on further automation equipment such as drives, actuators,
electrovalves, limit switches etc.
- Unfortunately, we are unable to take back customer-specific valves.
2. Safety instructions:
- Maintenance, assembly and repair work may only be carried out by duly authorised and
qualified personnel.
- The manufacturer assumes no liability for damages or any other occurrences resulting from
changes made without consulting the manufacturer or use of parts other than original parts.
- These operating instructions do not replace any national accident prevention regulations or
local safety regulations; they are invariably subordinate to these.
- Observe the following before carrying out any repair or maintenance work:
® Always turn off the power supply of the drives before carrying out repair or
maintenance work (danger of bruising!).
® Make sure that no-one puts the plant into operation.
® Evacuate the pipe, prevent pressure build-up or retention.
® Inform yourself on possible dangers emanating from residues of operating material;
wear safety gloves and goggles etc. as necessary.
® Let valves cool off if necessary.
® Ensure that limit values relating to pressure, temperature and the operating material are
not exceeded.
3. Transport:
- Valves should be transported to the building site in a firm packing.

- Do not attach cranes or elevators to the handle or to any mounted drive to prevent damage.
- Check valves for any transport damage immediately upon delivery and report as necessary.
We assume no liability for transport damages that have not been duly reported.
-2-
408/658
Fritz Wehlan
4. Storage:
- Ball valves must always be stored either completely opened or completely closed. We
advise storing them completely opened to prevent damage to the ball surface.
- Valves that are not needed immediately should be fitted with a protective cap and stored in a
well-aired, dry room.
5. Functioning:
- Ball valves serve as shut-off devices in plants, where they are screwed or welded into the
pipe system.
- Ball valves are OPEN/CLOSE devices which are generally opened and closed by rotation
through 90°. The closing direction according to DIN standards is achieved by rotating the
handele clockwise. They are not intended for throttling or regulating the flow of medium,
and intermediate positions are therefore not permissible.
- Granulate ball valves of the 400 and 190TR series are characterised by bearings located on
either side of the ball and valve sealing on one side only. Granulate ball valves have proven
themselves idelly suited to use with critical media which contain solids or are highly
viscous. The packing on the incoming side is not directly exposed to the flow. This prevents
product material from getting jammed between the ball and housing wall as the ball valve
closes. It is essential that the material always flows in the right direction through the ball
valve.
6. Installation:
- The piplines must be cleaned or flushed before installation, so that any residues and foreign
bodies do not get into the ball valves.
- Should the valves be dirty or contaminated, then set the ball previously to 45° and blow the
interior clean with oil-free comressed air. Then clean the housing.
- Lead the piplines free of stress up to valve to be installed.
- Ensure that the ball valves are in their open position.
- Place the fitting between the pipes using a crane or elevator if necessary. Tighten the flange
screws in opposite directions with the appropriate torque.
- Caution: There is only one permissible direction of flow through type 400 and 190TR
granulate ball valves. The valve should close clockwise and should be mounted facing
horizontally or vertically downward. The piping upstream and downstream of the valve
should be straight over a length of approx. 3x its nominal width, and the valve should be
easily accessible.
- Protect the interior parts of the valve before carrying out any welding (observe maximum
tolerable temperature of gasket!).
-3-
409/658
Fritz Wehlan
7. Initial operation
- Read and ensure compliance with all operating instructions and check that operating
conditions are as required and the valves has been installed correctly.
- Flush the piping with valves fully opened before testing their function.
- After completing the installation and before putting the valve into operation, check that it
works properly by opening and closing it several times.
- Make sure that the valve works perfectly and that it turns in the right direction.
8. Maintenance:
- The ball valves are designed so that when used as intended no maintenance work at all is
required over a period of 3 years.
- To test the function, the valves should be moved open and closed according to loading every
6 or 12 months thus to confirm safe and leak-free operation.
- It is advisable to check the flange and selector shaft packing for leakage after prolonged
operation.
- In the event of rough operating conditions flush the ball valve via the provided borings if
necessary.
9. Troubleshooting:
® Leakage at the selector shaft

This work can be done in the built-in condition and with the line under pressure.
However, it is prossible to do this work only under increased safety precautions. It should
also be observed that this work may be done under no circumstances at very high or very
low temperatures, with combustible media or with aggressive substances.
® Leakage at the ball
For this work the ball valve must be dismantled from the pipeline and only trained skilled
personnel should be entrusted with this work.
Please turn to us if you have any questions or before attempting repair in the event of
operating trouble.
-4-
410/658
Switches
Plastic-bodied
compact limit switches
Tiny Ti2
Compact design
Mounting measurements according to
DIN EN 50047
Hinged snap lid
q
The switching system for C2 and Ti2 l Compact switches for safety or control
l Small hysteresis on the snap-action applications in protection class IP 65
system l 3 different contact configurations
l Large variety of contact functions available as slow-action or snap-action
l Optimized size utilising proven terminal devices
technology l Positive break p
l Snap-action type prevents undefined l Two channel safety monitoring possible
status even with very slow actuation l Galvanically isolated terminals, type Zb
l Approvals UL, CSA, BG
l Cable entries M 16 x 1.5
l 4 screw terminals M3.5 with self-lifting
clamps
l PBT enclosure, fiberglass reinforced, self-
extinguishing UL 94-V0
l Lid, PA 6.6 UL 94-V0
l 2 mm contact opening of slow-action
system according to EN 81-1 for lift con-
struction Mounting
l Actuator mounting in 4 x 90° a) adjustable mounting with two M4
screws (22 mm centres)
b) fixed positioning with two M5 screws

(23 mm centres) for safety applications
(0.22")
M4 5.5
Slow-action device
M5
(0.16")
(0.08")
4
22
(0.87")
23
(0.91")
Contact configuration
Switching element Switch function Switch contact Designation Voltage Continuous current
Slow-action changeover 1NC/1NO U1Z 250 V 10 A

Snap-action changeover 1NC/1NO SU1Z 250 V 10 A
Slow-action normally-closed 2NC A2Z 250 V 10 A
Snap-action device Snap-action normally-closed 2NC SA2Z 250 V 10 A
Slow-action normally-open 2NO E2 250 V 10 A
Snap-action normally-open 2NO SE2 250 V 10 A
13
411/658
Plastic-bodied
compact limit switches
Tiny Ti2
Compact design
Mounting measurements according to
DIN EN 50047
Hinged snap lid
Designation Ti2-U1Z w Ti2-SU1Z w Ti2-A2Z w Ti2-U1Z Riw Ti2-SU1Z Riw Ti2-A2Z Riw
Part number 608.8103.001 608.8153.002 608.8803.003 608.8117.007 608.8167.008 608.8817.009
Switching diagram
p positive break according to 11 12 13 14 11 12 11 12 13 14 11 12
IEC 947-5-1 Chap. 3
Za: changeover contact is not galvanically isolated 23 24 21 22 21 22 23 24 21 22 21 22
Zb: changeover contact is galvanically isolated p Zb p Zb p Zb p Zb p Zb p Zb
Slow-action contact/snap-action contact l/– –/l l/– l/– –/l l/–
Gasket inside (iw)/outside (w) w w w iw iw iw
Contact travel mm Actuating force N

Tol. ± 0.25 mm Tol. ± 10%
Switching angle Actuating torque Ncm

degree Tol. ± 10%
Tol. ± 3.5°
In Out
Voltage max. 250 V AC 250 V AC 250 V AC 250 V AC 250 V AC 250 V AC

Continuous current max. 10 A 10 A 10 A 10 A 10 A 10 A
Making current, acc. to IEC 947-5-1 AC 15/DC 13 l l l l l l
Switching frequency max. 100/min. 100/min. 100/min. 100/min. 100/min. 100/min.

Mech. operational life – number of switching cycles 3 x 106 3 x 106 3 x 106 3 x 106 3 x 106 3 x 106
Ambient temperature min./max. –30 °C/+80 °C –30 °C/+80 °C –30 °C/+80 °C –30 °C/+80 °C –30 °C/+80 °C –30 °C/+80 °C
–22 °F/+176 °F –22 °F/+176 °F –22 °F/+176 °F –22 °F/+176 °F –22 °F/+176 °F –22 °F/+176 °F
Approvals UL, CSA UL, CSA UL, CSA UL, CSA UL, CSA UL, CSA
BG BG BG BG BG BG
Weight 0.04 kg 0.04 kg 0.04 kg 0.05 kg 0.05 kg 0.05 kg
Delivery: ex-stock/built to order l/– l/– l/– l/– l/– l/–
Further switching functions
SA2 E2 SE2
11 12 13 14 13 14
21 22 23 24 23 24
Dimensions
All dimensions in mm
14
412/658
Switches
Ti2-U1Z Hw Ti2-SU1Z Hw Ti2-A2Z Hw Ti2-U1Z AH Ti2-SU1Z AH Ti2-A2Z AH Ti2-U1 AD Ti2-SU1 AD Ti2-A2 AD
608.8121.015 608.8171.016 608.8821.017 608.8135.021 608.8185.022 608.8835.023 608.8137.027 608.8187.028 608.8837.029
11 12 13 14 11 12 11 12 13 14 11 12 11 12 13 14 11 12
23 24 21 22 21 22 23 24 21 22 21 22 23 24 21 22 21 22
p Zb p Zb p Zb p Zb p Zb p Zb Zb Zb Zb
l/– –/l l/– l/– –/l l/– l/– –/l l/–
w w w iw iw iw iw iw iw
250 V AC 250 V AC 250 V AC 250 V AC 250 V AC 250 V AC 250 V AC 250 V AC 250 V AC

10 A 10 A 10 A 10 A 10 A 10 A 10 A 10 A 10 A
l l l l l l l l l
100/min. 100/min. 100/min. 100/min. 100/min. 100/min. 100/min. 100/min. 100/min.

3 x 106 3 x 106 3 x 106 3 x 106 3 x 106 3 x 106 3 x 106 3 x 106 3 x 106
–30 °C/+80 °C –30 °C/+80 °C –30 °C/+80 °C –30 °C/+80 °C –30 °C/+80 °C –30 °C/+80 °C –30 °C/+80 °C –30 °C/+80 °C –30 °C/+80 °C
–22 °F/+176 °F –22 °F/+176 °F –22 °F/+176 °F –22 °F/+176 °F –22 °F/+176 °F –22 °F/+176 °F –22 °F/+176 °F –22 °F/+176 °F –22 °F/+176 °F
UL, CSA UL, CSA UL, CSA UL, CSA UL, CSA UL, CSA UL, CSA UL, CSA UL, CSA
BG BG BG BG BG BG
0.05 kg 0.05 kg 0.05 kg 0.07 kg 0.07 kg 0.07 kg 0.07 kg 0.07 kg 0.07 kg
l/– l/– l/– l/– l/– l/– l/– l/– l/–
15
413/658

414/658
415/658
416/658
Operating Instructions
Vibrating level switch for liquids
VEGASWING 61
- NAMUR
Document ID: 29226
417/658
Contents
Contents
1 About this document
1.1 Function............................................................................................................................ 4
1.2 Target group...................................................................................................................... 4
1.3 Symbolism used................................................................................................................ 4
2 For your safety
2.1 Authorised personnel........................................................................................................ 5
2.2 Appropriate use................................................................................................................. 5
2.3 Warning about incorrect use.............................................................................................. 5
2.4 General safety instructions................................................................................................ 5
2.5 Safety label on the instrument........................................................................................... 5
2.6 CE conformity.................................................................................................................... 5
2.7 SIL conformity................................................................................................................... 6
2.8 Safety instructions for Ex areas......................................................................................... 6
2.9 Environmental instructions................................................................................................ 6
3 Product description
3.1 Configuration..................................................................................................................... 7
3.2 Principle of operation........................................................................................................ 8
3.3 Operation.......................................................................................................................... 8
3.4 Storage and transport....................................................................................................... 9
4 Mounting
4.1 General instructions........................................................................................................ 10
4.2 Instructions for installation............................................................................................... 12
5 Connecting to power supply
5.1 Preparing the connection................................................................................................ 14
5.2 Connection procedure..................................................................................................... 14
5.3 Wiring plan, single chamber housing.............................................................................. 15
5.4 Wiring plan - version IP 66/IP 68, 1 bar............................................................................ 16
6 Setup
6.1 General information......................................................................................................... 17
6.2 Adjustment elements....................................................................................................... 17
6.3 Function chart................................................................................................................. 18
7 Maintenance and fault rectification
7.1 Maintenance................................................................................................................... 20
7.2 Rectify faults.................................................................................................................... 20
7.3 Exchanging the electronics............................................................................................. 21
7.4 Instrument repair............................................................................................................. 22
8 Dismounting
8.1 Dismounting steps.......................................................................................................... 23
8.2 Disposal.......................................................................................................................... 23
9 Supplement
29226-EN-130409
9.1 Technical data................................................................................................................. 24

9.2 Dimensions..................................................................................................................... 31
2 VEGASWING 61 • - NAMUR
418/658
Contents
Supplementary documentation
Information:
Supplementary documents appropriate to the ordered version come
with the delivery. You can find them listed in chapter "Product descrip-
tion".
Instructions manuals for accessories and replacement parts

Tip:
To ensure reliable setup and operation of your VEGASWING 61, we
29226-EN-130409
offer accessories and replacement parts. The corresponding docu-

mentations are:
• Operating instructions manual "Remote housing - VEGASWING"
• Operating instructions manual "Oscillator VEGASWING series 60"
Editing status: 2012-12-06
VEGASWING 61 • - NAMUR 3
419/658

1.1 Function
This operating instructions manual provides all the information you
need for mounting, connection and setup as well as important instruc-
tions for maintenance and fault rectification. Please read this informa-
tion before putting the instrument into operation and keep this manual
accessible in the immediate vicinity of the device.
1.2 Target group

This operating instructions manual is directed to trained qualified
personnel. The contents of this manual should be made available to
these personnel and put into practice by them.
1.3 Symbolism used

Information, tip, note
This symbol indicates helpful additional information.
Caution: If this warning is ignored, faults or malfunctions can result.
Warning: If this warning is ignored, injury to persons and/or serious
damage to the instrument can result.
Danger: If this warning is ignored, serious injury to persons and/or
destruction of the instrument can result.
Ex applications
This symbol indicates special instructions for Ex applications.
• List
The dot set in front indicates a list with no implied sequence.
→ Action
This arrow indicates a single action.
1 Sequence
Numbers set in front indicate successive steps in a procedure.
Battery disposal
This symbol indicates special information about the disposal of bat-
teries and accumulators.
29226-EN-130409
420/658
2 For your safety
2 For your safety

2.1 Authorised personnel
All operations described in this operating instructions manual must
be carried out only by trained specialist personnel authorised by the
plant operator.
During work on and with the device the required personal protective
equipment must always be worn.
2.2 Appropriate use

The VEGASWING 61 is a sensor for level detection.
You can find detailed information on the application range in chapter
"Product description".
Operational reliability is ensured only if the instrument is properly
used according to the specifications in the operating instructions
manual as well as possible supplementary instructions.
For safety and warranty reasons, any invasive work on the device
beyond that described in the operating instructions manual may be
carried out only by personnel authorised by the manufacturer. Arbi-
trary conversions or modifications are explicitly forbidden.
2.3 Warning about incorrect use

Inappropriate or incorrect use of the instrument can give rise to
application-specific hazards, e.g. vessel overfill or damage to system
components through incorrect mounting or adjustment.

This is a high-tech instrument requiring the strict observance of stand-
ard regulations and guidelines. The user must take note of the safety
instructions in this operating instructions manual, the country-specific
installation standards as well as all prevailing safety regulations and
accident prevention rules.
The instrument must only be operated in a technically flawless and
reliable condition. The operator is responsible for trouble-free opera-
tion of the instrument.
During the entire duration of use, the user is obliged to determine the
compliance of the necessary occupational safety measures with the
current valid rules and regulations and also take note of new regula-
tions.
2.5 Safety label on the instrument

The safety approval markings and safety tips on the device must be
observed.
29226-EN-130409
2.6 CE conformity
This device fulfills the legal requirements of the applicable EC guide-
lines. By attaching the CE mark, VEGA provides a confirmation of
421/658
2 For your safety
successful testing. You can find the CE conformity declaration in the

download area of "www.vega.com".
2.7 SIL conformity

VEGASWING 61 fulfills the requirements of functional safety accord-
ing to IEC 61508 resp. IEC 61511. You can find further information in
the Safety Manual "VEGASWING series 60".
2.8 Safety instructions for Ex areas

Please note the Ex-specific safety information for installation and op-
eration in Ex areas. These safety instructions are part of the operating
instructions manual and come with the Ex-approved instruments.
2.9 Environmental instructions

Protection of the environment is one of our most important duties.
That is why we have introduced an environment management system
with the goal of continuously improving company environmental pro-
tection. The environment management system is certified according
to DIN EN ISO 14001.
Please help us fulfil this obligation by observing the environmental
instructions in this manual:
• Chapter "Packaging, transport and storage"
• Chapter "Disposal"
29226-EN-130409
422/658
3.1 Configuration
Scope of delivery The scope of delivery encompasses:
• VEGASWING 61 point level switch
• Documentation
–– this operating instructions manual
–– Safety Manual "Functional safety (SIL)" (optional)
–– Supplementary instructions manual "Plug connector for level
sensors" (optional)
–– Ex-specific "Safety instructions" (with Ex versions)
–– if necessary, further certificates
Constituent parts The VEGASWING 61 consists of the components:

• Housing cover
• Housing with electronics
• Process fitting with tuning fork
Fig. 1: VEGASWING 61 with plastic housing

1 Housing cover
2 Housing with electronics
3 Process fitting
Type plate The type plate contains the most important data for identification and
use of the instrument:
• Article number
• Serial number
• Technical data
• Article numbers, documentation
• SIL identification (with SIL rating ex works)
With the serial number, you can access the delivery data of the instru-
ment via www.vega.com, "VEGA Tools" and "serial number search".
In addition to the type label outside, you can also find the serial num-
29226-EN-130409
ber on the inside of the instrument.
423/658
3.2 Principle of operation

Application area VEGASWING 61 is a point level sensor with tuning fork for level
detection.
It is designed for industrial use in all areas of process technology and
can be used in liquids.
Typical applications are overfill and dry run protection. With its tuning
fork of only 40 mm length, VEGASWING 61 can also be mounted e.g.
in pipelines from DN 32. The small tuning fork allows use in vessels,
tanks and pipes. Thanks to its simple and robust measuring system,
VEGASWING 61 is virtually unaffected by the chemical and physical
properties of the liquid.
It functions even under difficult conditions such as turbulence, air bub-
bles, foam generation, buildup, strong external vibration or changing
products.
Fault monitoring
The electronics module of VEGASWING 61 continuously monitors via
frequency evaluation the following criteria:
• Strong corrosion or damage on the tuning fork
• Loss of vibration
• Line break to the piezo drive
If one of these faults is detected or if the power supply fails, the elec-
tronics takes on a defined output status (safe condition).
Functional principle The tuning fork is piezoelectrically energised and vibrates at its
mechanical resonance frequency of approx. 1200 Hz. The piezos are
fixed mechanically and are hence not subject to temperature shock
limitations. The frequency changes when the tuning fork is covered
by the medium. This change is detected by the integrated electronics
module and converted into a switching command.
Voltage supply VEGASWING 61 is a compact instrument, i.e. it can be operated with-

out external evaluation system. The integrated electronics evaluates
the level signal and outputs a switching signal. With this switching
signal, a connected device can be operated directly (e.g. a warning
system, a pump etc.).
The data for power supply are specified in chapter "Technical data".
3.3 Operation
The switching condition of VEGASWING 61 with plastic housing can
be checked when the housing is closed (signal lamp). With the basic
setting, products with a density > 0.7 g/cm³ (0.025 lbs/in³) can be de-
tected. The instrument can be adapted if products with lower density
are to be measured.
On the electronics module you will find the following indicating and
29226-EN-130409
adjustment elements:
• Control lamp for indication of the switching status
• DIL switch for sensitivity adjustment
424/658
• Mode switch to select the switching condition (reverse character-

istics)
• Simulation key
3.4 Storage and transport

Packaging Your instrument was protected by packaging during transport. Its
capacity to handle normal loads during transport is assured by a test
according to DIN EN 24180.
The packaging of standard instruments consists of environment-
friendly, recyclable cardboard. The sensor is also equipped with a
protective cap of ABS. For special versions, PE foam or PE foil is also
used. Dispose of the packaging material via specialised recycling
companies.
Transport Transport must be carried out under consideration of the notes on the
transport packaging. Nonobservance of these instructions can cause
damage to the device.
Transport inspection The delivery must be checked for completeness and possible transit
damage immediately at receipt. Ascertained transit damage or con-
cealed defects must be appropriately dealt with.
Storage Up to the time of installation, the packages must be left closed and
stored according to the orientation and storage markings on the
outside.
Unless otherwise indicated, the packages must be stored only under
the following conditions:
• Not in the open
• Dry and dust free
• Not exposed to corrosive media
• Protected against solar radiation
• Avoiding mechanical shock and vibration
Storage and transport • Storage and transport temperature see chapter "Supplement -
temperature Technical data - Ambient conditions"
• Relative humidity 20 … 85 %
29226-EN-130409
425/658
4 Mounting
4 Mounting
4.1 General instructions
Suitability for the process Make sure that all parts of the instrument coming in direct contact with
conditions the process, especially the sensor element, process seal and process
fitting and suspension cable, are suitable for the existing process
conditions, such as process pressure, process temperature as well as
the chemical properties of the medium.
You can find the specifications in chapter "Technical data" and on the
type plate.
Switching point In general, VEGASWING 61 can be installed in any position. The

instrument only has to be mounted in such a way that the tuning fork
is at the height of the desired switching point.
The tuning fork has lateral markings (notches) that indicate the
switching point with vertical mounting. The switching point refers
to water with the basic setting of the sensitivity switch ≥ 0.7 g/cm³
(0.025 lbs/in³). When mounting VEGASWING 61, make sure that
this marking is at the height of the requested switching point. Keep in
mind that the switching point of the instrument is shifted if the medium
has a density other than water - water 1 g/cm³ (0.036 lbs/in³). For
products < 0.7 g/cm³ (0.025 lbs/in³) and > 0.5 g/cm³ (0.018 lbs/in³)
the density switch must be set to ≥ 0.5 g/cm³.
Keep in mind that foams with a density > 0.45 g/cm³ (0.016 lbs/in³)
are detected by the sensor. This can cause faulty switchings particu-
lary when used as dry run protection system.
1
4
3
Fig. 2: Mounting vertical

29226-EN-130409
1 Switching point approx. 13 mm (0.51 in)

2 Switching point with lower density
3 Switching point with higher density
4 Switching point approx. 27 mm (1.06 in)
426/658
4 Mounting
Fig. 3: Mounting horizontal

1 Switching point
2
1
Fig. 4: Horizontal installation (recommended mounting position, particularly for

adhesive products)
1 Switching point
2 Marking with screwed version on top, with flange versions directed to the
flange holes
With flange versions, the fork is directed as follows to the flange holes.
Fig. 5: Fork position with flange versions
Moisture Use the recommended cables (see chapter "Connecting to power

supply") and tighten the cable gland.
You can give your instrument additional protection against moisture
penetration by leading the connection cable downward in front of the
cable entry. Rain and condensation water can thus drain off. This ap-
plies mainly to outdoor mounting as well as installation in areas where
high humidity is expected (e.g. through cleaning processes) or on
cooled or heated vessels.
29226-EN-130409
427/658
4 Mounting
Fig. 6: Measures against moisture penetration
Transport Caution:
Do not hold VEGASWING 61 on the tuning fork. Particularly with
flange or tube versions, the tuning fork can be damaged just by the
weight of the instrument. Transport coated instruments very carefully
and avoid touching the tuning fork.
Remove the packaging or the protective cover just before installation.
Pressure/Vacuum The process fitting must be sealed if there is gauge or low pressure in
the vessel. Before use, check if the seal material is resistant against
the measured product and the process temperature.
The max. permissible pressure is specified in chapter "Technical
data" or on the type label of the sensor.
Handling The vibrating level switch is a measuring instrument and must be

treated accordingly. Bending the vibrating element will destroy the
instrument.
Warning:
The housing must not be used to screw the instrument in! Applying
tightening force can damage internal parts of the housing.
Use the hexagon above the thread for screwing in.
4.2 Instructions for installation

Welded socket VEGASWING 61 has a defined thread starting point. This means
that every VEGASWING 61 is in the same fork position after being
screwed in. Remove therefore the supplied seal from the thread of
VEGASWING 61. This seal is not required when using a welded
socket with O-ring in front.
Keep in mind that this welded socket is not suitable for coated instru-
ment versions.
Screw VEGASWING 61 completely into the welded socket. The
later position can be determined already before welding. Mark the
appropriate position of the welded socket. Before welding, unscrew
29226-EN-130409
VEGASWING 61 and remove the rubber ring from the welded socket.
The welded socket has a marking (notch). Weld the socket with the
notch facing upward, or in case of pipelines (DN 32 up to DN 50),
aligned with the direction of flow.
428/658
4 Mounting
Fig. 7: Marking on the welded socket

1 Marking
Adhesive products In case of horizontal mounting in adhesive and viscous products,

the surfaces of the tuning fork should be vertical in order to reduce
buildup on the tuning fork. On the screwed version you will find a
marking on the hexagon. With this, you can check the position of the
tuning fork when screwing it in. When the hexagon touches the seal,
the thread can still be turned by approx. half a turn. This is sufficient to
reach the recommended installation position.
With flange versions, the fork is directed to the flange holes.
When used in adhesive and viscous products, the tuning fork should
protrude into the vessel to avoid buildup. For that reason, sockets
for flanges and mounting bosses should be avoided when mounting
horizontally.
Inflowing medium If VEGASWING 61 is mounted in the filling stream, unwanted false

measurement signals can be generated. For this reason, mount VE-
GASWING 61 at a position in the vessel where no disturbances, e.g.
from filling openings, agitators, etc., can occur.
Flows To minimise flow resistance caused by the tuning fork, VEGASWING

61 should be mounted in such a way that the surfaces of the blades
are parallel to the product movement.
Enamel coating Instruments with enamel coating should be treated very carefully and
shocks should be avoided. Unpack VEGASWING 61 directly before
installation. Insert VEGASWING 61 carefully into the vessel opening
and avoid touching any sharp vessel parts.
Gas-tight leadthrough The gas-tight leadthrough avoids due to a second sealing the
uncontrolled penetration of the medium. The lifetime of the gastight
leadthrough depends ont he chemical resistance of the materials.
See "Technical data".
Caution:
If it is determined (e.g. by an error message of VEGASWING 61) that
29226-EN-130409
medium has already penetrated into the vibrating element, the instru-
ment must be exchanged immediately.
429/658

5.1 Preparing the connection
Note safety instructions Always keep in mind the following safety instructions:
• Connect only in the complete absence of line voltage
Take note of safety In hazardous areas you must take note of the respective regulations,
instructions for Ex conformity and type approval certificates of the sensors and power
applications supply units.
Voltage supply Connect the operating voltage according to the following diagrams.
Take note of the general installation regulations. As a rule, connect
VEGASWING 61 to vessel ground (PA), or in case of plastic vessels,
to the next ground potential. On the side of the instrument housing
there is a ground terminal between the cable entries. This connection
serves to drain off electrostatic charges. In Ex applications, the instal-
lation regulations for hazardous areas must be given priority.
The data for power supply are specified in chapter "Technical data".
Connection cable The instrument is connected with standard two-wire cable without
screen. If electromagnetic interference is expected which is above the
test values of EN 61326 for industrial areas, screened cable should
be used.
Use cable with round cross-section. A cable outer diameter of
5 … 9 mm (0.2 … 0.35 in) ensures the seal effect of the cable gland.
If you are using cable with a different diameter or cross-section,
exchange the seal or use a suitable cable gland.
In hazardous areas, only use approved cable connections for VEGAS-
WING 61.
Connection cable Take note of the corresponding installation regulations for Ex applica-
for Ex applications tions.
Cover all housing openings conforming to standard according to
EN 60079-1.
5.2 Connection procedure

With Ex instruments, the housing cover may only be opened if there is
no explosive atmosphere present.
Proceed as follows:
1. Unscrew the housing cover
2. Loosen compression nut of the cable entry
3. Remove approx. 10 cm (4 in) of the cable mantle, strip approx.
1 cm (0.4 in) of insulation from the ends of the individual wires
4. Insert the cable into the sensor through the cable entry
29226-EN-130409
5. Open the terminals with a screwdriver

6. Insert the wire ends into the open terminals according to the wir-
ing plan
7. Tighten the terminals with a screwdriver
430/658
8. Check the hold of the wires in the terminals by lightly pulling on

them
9. Tighten the compression nut of the cable entry. The seal ring must
completely encircle the cable
10. Screw the housing cover back on
The electrical connection is hence finished.
5.3 Wiring plan, single chamber housing

The following illustrations apply to the non-Ex as well as to the Ex-d
version.
Housing overview
4 4 4
1 2 3
Fig. 8: Material versions, single chamber housing
1 Plastic (not with EEx d)
2 Aluminium
3 Stainless steel (not with EEx d)
4 Filter element for pressure compensation or blind plug with version IP 66/
IP 68, 1 bar (not with EEx d)
Electronics and connec-

tion compartment
NAMUR
1
(IEC 60947-5-6)
+ -
max. 0,5 g / cm3
2
Simul.
7
min. 0,7 g / cm3 3
6
4
Fig. 9: Electronics and connection compartment, single chamber housing

1 Control lamp
2 DIL switch for characteristics reversal
3 DIL switch for sensitivity adjustment
29226-EN-130409
4 Ground terminal
5 EMC filter element
6 Simulation key
7 Connection terminals
431/658
Wiring plan For connection of the amplifier according to NAMUR (IEC 60947-5-6,

EN 50227). You can find further information in the "Technical data".
- +
1 2
+ -
Fig. 10: Wiring plan, single chamber housing
5.4 Wiring plan - version IP 66/IP 68, 1 bar

Wire assignment, con-
nection cable
1
2
Fig. 11: Wire assignment, connection cable
1 brown (+) and blue (-) to power supply or to the processing system
2 Shielding
29226-EN-130409
432/658
6 Setup
6 Setup
6.1 General information
The figures in brackets refer to the following illustrations.
Function/Configuration With plastic housings, the switching condition of the electronics can
be checked when the housing cover is closed (control lamp). With the
basic setting, products with a density > 0.7 g/cm³ (0.025 lbs/in³) can
be detected. For products with lower density, the switch must be set
to > 0.5 g/cm³ (0.018 lbs/in³).
On the electronics module you will find the following indicating and
adjustment elements:
• Signal lamp (1)
• DIL switch for characteristics reversal - min./max. (2)
• DIL switch for sensitivity adjustment (3)
• Simulation key (4)
Note:
For test purposes, immerse the tuning fork of VEGASWING 61 always
in liquids. Do not test the function of VEGASWING 61 with your hand.
This can damage the sensor.
6.2 Adjustment elements

1
2
3
4
Fig. 12: Oscillator SWE60N - NAMUR output

1 Signal lamp (LED)
4 Simulation key
5 EMC filter element
29226-EN-130409
Signal lamp (1) Single-coloured control lamp for indication of the switching condition.
• red = High current ≥ 2.6 mA
• dark = Low current ≤ 0.6 mA
• red (flashing) = Failure ≤ 0.6 mA
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6 Setup
Characteristics reversal The characteristics reversal can be carried out with the DIL switch.
(2) You can choose between falling characteristic curve (switch position
max.) and rising characteristic curve (switch position min.). This al-
lows you to output the desired current.
Modes
• min. - rising characteristic curve (High current when immersed)
• max. - falling characteristics (Low current when immersed)
The NAMUR output can be switched over to falling or rising charac-
teristics (see also "Function chart").
For applications according to WHG, the DIL switch must be set to
position max.
Sensitivity adjustment (3) With this DIL switch (3) you can set the switching point to liquids
having a density between 0.5 and 0.7 g/cm³ (0.018 and 0.025 lbs/
in³). With the basic setting, liquids with a density of > 0.7 g/cm³ (0.025
lbs/in³) can be detected. In liquids with lower density, you must set
the switch to > 0.5 g/cm³ (0.018 lbs/in³). The specifications for the
position of the switching point relate to water - density value 1 g/cm³
(0.036 lbs/in³). In products with a different density, the switching point
will shift in the direction of the housing or tuning fork end depending
on the density and type of installation.
Note:
Keep in mind that foams with a density > 0.45 g/cm³ (0.016 lbs/in³)
are detected by the sensor. This can cause faulty switchings particu-
lary when used as dry run protection system.
Simulation key (4) The simulation key is located in a recess on the upper side of the
electronics module. Push the simulation key with a suitable object
(screwdriver, pen, etc.).
When the key is pushed, a line break between sensor and process-
ing unit is simulated. The signal lamp on the sensor extinguishes. The
measuring system must signal a fault and take on a safe condition
when the key is pushed.
Keep in mind that downstream connected instruments will be acti-
vated during operation. This allows you to check the correct function
of the measuring system.
6.3 Function chart

The following chart provides an overview of the switching conditions
depending on the set mode and the level.
Note:
The mode setting on the NAMUR amplifier must be selected in such a
way that the switching output takes on safe condition in case of failure
(I ≤ 0.6 mA).
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6 Setup
Level Signal current - Control lamp

Sensor
Falling characteris- ≥ 2.6 mA
tics max.
Red
Falling characteris- ≤ 0.6 mA
tics max.
off
Rising characteris- ≥ 2.6 mA
tics min.
Red
Rising characteris- ≤ 0.6 mA
tics min.
off
Failure any ≤ 0.6 mA
flashes red
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7.1 Maintenance
If the instrument is used properly, no special maintenance is required
in normal operation.
7.2 Rectify faults

Reaction when malfunc- The operator of the system is responsible for taking suitable meas-
tions occur ures to rectify faults.
Failure reasons VEGASWING 61 offers maximum reliability. Nevertheless, faults can

occur during operation. These may be caused by the following, e.g.:
• Sensor
• Process
• Voltage supply
• Signal processing
Fault rectification The first measure to be taken is to check the output signal. In many
cases, the causes can be determined this way and the faults rectified.
24 hour service hotline Should these measures not be successful, please call in urgent cases
the VEGA service hotline under the phone no. +49 1805 858550.
The hotline is available to you 7 days a week round-the-clock. Since
we offer this service world-wide, the support is only available in the
English language. The service is free of charge, only the standard
telephone costs will be charged.
29226-EN-130409
436/658
Checking the switching

signal
Error Cause Rectification
VEGASWING 61 Operating voltage Check operating voltage
signals "covered" too low
without being sub-
Electronics de- Press the characteristic reversal
merged (overfill
fective switch. If the instrument then changes
protection)
the mode, the vibrating element may
VEGASWING 61 be covered with buildup or mechani-
signals "uncov- cally damaged. Should the switching
ered" when being function in the correct mode still be
submerged (dry faulty, return the instrument for repair.
run protection)
Push the characteristic reversal
switch. If the instrument then does
not change the mode, the electronics
module may be defective. Exchange
the electronics module.
Unfavourable in- Mount the instrument at a location in
stallation location the vessel where no dead zones or air
bubbles can form.
Buildup on the vi- Check the vibrating element and
brating element the sensor if there is buildup and re-
move it.
Wrong character- Set the correct characteristics on the
istic selected characteristics reversal switch (over-
flow protection, dry run protection).
Wiring should be carried out accord-
ing to the quiescent current principle.
Signal lamp flash- Error on the vi- Check if the vibrating element is dam-
es red brating element aged or extremely corroded.
Interference on Exchanging the electronics module
the electronics
module
instrument de- Exchange the instrument or send it in
fective for repair
Reaction after fault recti- Depending on the reason for the fault and the measures taken, the
fication steps described in chapter "Set up" may have to be carried out again.
7.3 Exchanging the electronics

If the electronics module is defective, it can be replaced by the user.
In Ex applications only an electronics module with respective Ex ap-
proval may be used.
You find all information to the electronics exchange in the operating
instructions of the new electronics module.
In general, all electronics modules of series SW60 can be inter-
changed. If you want to use an electronics module with a different
29226-EN-130409
signal output, you carry out the complete setup. You find the neces-
sary, suitable operating instruction on our homepage.
437/658
Note:
Keep in mind that enamelled instrument versions need special
electronics modules. These electronics modules are called SW60E or
SW60E1.
7.4 Instrument repair

If a repair is necessary, please proceed as follows:
You can download a return form (23 KB) from our Internet homepage
www.vega.com under: "Downloads - Forms and certificates - Repair
form".
By doing this you help us carry out the repair quickly and without hav-
ing to call back for needed information.
• Print and fill out one form per instrument
• Clean the instrument and pack it damage-proof
• Attach the completed form and, if need be, also a safety data
sheet outside on the packaging
• Please ask the agency serving you for the address of your return
shipment. You can find the respective contact data on our website
www.vega.com under: "Company - VEGA worldwide"
29226-EN-130409
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8 Dismounting
8 Dismounting
8.1 Dismounting steps
Warning:
Before dismounting, be aware of dangerous process conditions such
as e.g. pressure in the vessel, high temperatures, corrosive or toxic
products etc.
Take note of chapters "Mounting" and "Connecting to power supply"
and carry out the listed steps in reverse order.
With Ex instruments, the housing cover may only be opened if there is
no explosive atmosphere present.
8.2 Disposal
The instrument consists of materials which can be recycled by spe-
cialised recycling companies. We use recyclable materials and have
designed the parts to be easily separable.
WEEE directive 2002/96/EG

This instrument is not subject to the WEEE directive 2002/96/EG and
the respective national laws. Pass the instrument directly on to a spe-
cialised recycling company and do not use the municipal collecting
points. These may be used only for privately used products according
to the WEEE directive.
Correct disposal avoids negative effects on humans and the environ-
ment and ensures recycling of useful raw materials.
Materials: see chapter "Technical data"
If you have no way to dispose of the old instrument properly, please
contact us concerning return and disposal.
29226-EN-130409
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9 Supplement
9 Supplement
9.1 Technical data
General data
Material 316L corresponds to 1.4404 or 1.4435
Materials, wetted parts
ƲƲ Process fitting - thread 316L, Hastelloy C22 (2.4602)
ƲƲ Process fitting - flange 316L, 316L with Hastelloy C22 coating, steel enamelled,
316L with ECTFE coating, 316L with PFA coating
ƲƲ Process seal Klingersil C-4400
ƲƲ Tuning fork 316L, Hastelloy C22 (2.4602), Hastelloy C4 (2.4610)
enamelled
ƲƲ Extension tube: ø 21.3 mm (0.839 in) 316L, Hastelloy C22 (2.4602), Hastelloy C22 (2.4602)
enamelled, 316L with ECTFE coating, 316L with PFA
coating
Materials, non-wetted parts
ƲƲ Plastic housing plastic PBT (Polyester)
ƲƲ Aluminium die-casting housing Aluminium die-casting AlSi10Mg, powder-coated - basis:
Polyester
ƲƲ Stainless steel housing - precision 316L
casting
ƲƲ Stainless steel housing, electropol- 316L
ished
ƲƲ Seal between housing and housing NBR (stainless steel housing, precision casting), silicone
cover (aluminium/plastic housing; stainless steel housng,
electropolished)
ƲƲ Light guide in housing cover (plastic) PMMA (Makrolon)
ƲƲ Ground terminal 316L
ƲƲ Temperature adapter (optional) 316L
Gas-tight leadthrough (optional)
ƲƲ Supporting material 316L
ƲƲ Glass potting Borosilicate glass - Schott no. 8421
ƲƲ Contacts 1.4101
ƲƲ Helium leak rate < 10-6 mbar l/s
ƲƲ Pressure resistance PN 64
Sensor length
ƲƲ Length VEGASWING 61 See chapter "Dimensions"
ƲƲ switching point as VEGASWING 81 +51 mm (+2 in)
or 81A
29226-EN-130409
Instrument weight (depending on pro- 0.8 … 4 kg (0.18 … 8.82 lbs)

cess fitting)
Layer thickness
ƲƲ Enamel 0.8 mm (0.031 in)
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9 Supplement
ƲƲ ECTFE 0.5 mm (0.02 in)

ƲƲ PFA 0.5 mm (0.02 in)
Surface quality
ƲƲ Standard Ra 3 µm (1.18-4 in)
ƲƲ Hygienic version (3A) Ra < 0.8 µm (3.15-5 in)
ƲƲ Hygienic version (3A) Ra < 0.3 µm (1.18-5 in)
Process fittings
ƲƲ Pipe thread, cylindrical (DIN 3852-A) G¾ A, G1 A
ƲƲ American pipe thread, conical ¾ NPT, 1 NPT
(ASME B1.20.1)
ƲƲ Flanges DIN from DN 25, ANSI from 1"
ƲƲ hygienic fittings Bolting DN 40 PN 40, Clamp 1" DIN 32676
ISO 2852/316L, Clamp 1½" PN 10 DIN 32676
ISO 2852/316L, conus DN 25 PN 40, Tuchenhagen
Varivent DN 50 PN 10
Max. torque - process fitting
ƲƲ Thread G¾ A, ¾ NPT 75 Nm (55 lbf ft)
ƲƲ Thread G1 A, 1 NPT 100 Nm (73 lbf ft)
High voltage test (enamel) < 5 KV
Output variable
Output Two-wire NAMUR output
Current consumption
ƲƲ Falling characteristics ≥ 2.6 mA uncovered/≤ 0.6 mA covered
ƲƲ rising characteristics ≤ 0.6 mA uncovered/≥ 2.6 mA covered
ƲƲ Fault message ≤ 0.6 mA
Necessary processing system NAMUR processing system according to IEC 60947-5-6
(EN 50227/DIN 19234)
Modes (NAMUR output adjustable to falling or rising characteristics)
ƲƲ Min. rising characteristic curve (High current when immersed)
ƲƲ Max. falling characteristics (Low current when immersed)
Accuracy (according to DIN EN 60770-1)

Reference conditions and actuating variables according to DIN EN 61298-1
ƲƲ Ambient temperature +18 … +30 °C (+64 … +86 °F)
ƲƲ Relative humidity 45 … 75 %
ƲƲ Air pressure 860 … 1060 mbar/86 … 106 kPa (12.5 … 15.4 psig)
ƲƲ Product temperature +18 … +30 °C (+64 … +86 °F)
ƲƲ Product density 1 g/cm³ (0.036 lbs/in³) (water)
29226-EN-130409
ƲƲ Product viscosity 1 mPa s

ƲƲ Superimposed pressure 0 kPa
ƲƲ Sensor installation Vertically from top
ƲƲ Density selection switch > 0.7 g/cm³
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9 Supplement
Measuring accuracy
Deviation ± 1 mm (0.04 in)
Influence of the process temperature on the switching point

1
4 10 ( 25/64")
8 ( 5/16")
6 ( 15/64")
4 ( 5/32")
3 2 ( 5/64")
0
-2 (-5/64")
2
-4 (-5/32")
-6 (-15/64")
-8 (-5/16")
-10 (-25/64")
0°C 50°C 100°C 150°C 200°C 250°C
(32 °F) (122 °F) (212 °F) (302 °F) (392 °F) (482 °F)
Fig. 22: Influence of the process temperature on the switching point

1 Shifting of the switching point in mm (in)
2 Process temperature in °C (°F)
3 Switching point at reference conditions (notch)
4 Tuning fork
Influence of the product density on the switching point

1
6 10 ( 25/64")
8 ( 5/16")
6 ( 15/64")
4 ( 5/32")
5 2 ( 5/64")
0
-2 (-5/64")
2
4
-4 (-5/32")
-6 (-15/64")
3
-8 (-5/16")
-10 (-25/64")
0,6 0,8 1 1,2 1,4 1,6 1,8 2 2,2 2,4
(0,022) (0,029) (0,036) (0,043) (0,051) (0,058) (0,065) (0,072) (0,079) (0,087)
Fig. 23: Influence of the product density on the switching point

2 Product density in g/cm³ (lb/in³)
3 Switch position 0.5 g/cm³ (0.018 lb/in³)
4 Switch position 0.7 g/cm³ (0.025 lb/in³)
29226-EN-130409

6 Tuning fork
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9 Supplement
Influence of the process pressure to the switching point

1
4 10 ( 25/64")
8 ( 5/16")
6 ( 15/64")
4 ( 5/32")
3 2 ( 5/64")
0
-2 (-5/64") 2
-4 (-5/32")
-6 (-15/64")
-8 (-5/16")
-10 (-25/64")
12 25 38 51 64
(174,1) (362,6) (551,1) (739,7) (928,2)
Fig. 24: Influence of the process pressure to the switching point

2 Process pressure in bar (psig)
4 Tuning fork
Repeatability 0.1 mm (0.004 in)

Hysteresis approx. 2 mm (0.08 in) with vertical installation
Switching delay approx. 500 ms (on/off)
Measuring frequency approx. 1200 Hz
Ambient conditions
Ambient temperature on the housing -40 … +70 °C (-40 … +158 °F)
Storage and transport temperature -40 … +80 °C (-40 … +176 °F)
Process conditions
Measured variable Limit level of liquids
Process pressure -1 … 64 bar/-100 … 6400 kPa (-14.5 … 928 psig)
The process pressure is dependent on the process
fitting, for example Clam p or flange (see the following
diagrams)
Process pressure - Clamp fittings
ƲƲ Clamp connection up to 2" -1 … 16 bar/-100 … 1600 kPa (-14.5 … 232 psig)
max. 150 °C (302 °F)
ƲƲ Clamp connection > 2" -1 … 0.5 bar/-100 … 50 kPa (-14.5 … 7.25 psig)
> 150 °C (> 302 °F)
Maximum allowable operating pressure 100 bar/10000 kPa (1450 psig) or 1.5 times process
pressure
29226-EN-130409
The function of the instrument is ensured up to an

operating pressure of 100 bar/10000 kPa (1450 psig)
at a maximum process temperature of +50 °C (+122 °F)
(only with threaded versions).
443/658
9 Supplement
Process temperature (thread or flange

temperature)
ƲƲ VEGASWING 61 of 316L/Hastelloy -50 … +150 °C (-58 … +302 °F)
C22 (2.4602)
Process temperature (thread or flange
temperature) with temperature adapter
(option)
ƲƲ VEGASWING 61 of 316L/Hastelloy -50 … +250 °C (-58 … +482 °F)
C22 (2.4602)
ƲƲ VEGASWING 61 enamelled -50 … +200 °C (-58 … +392 °F)
ƲƲ VEGASWING 61 with ECTFE coating -50 … +150 °C (-58 … +302 °F)
ƲƲ VEGASWING 61 with PFA coating -50 … +150 °C (-58 … +302 °F)
2
3
70 °C
(158 °F)
40 °C
(104 °F)
0 °C
1
(32 °F)
-50 °C 50 °C 100 °C 150 °C 200 °C 250 °C
(-58 °F) (122 °F) (212 °F) (302 °F) (392 °F) (482 °F)
-40 °C
(-40 °F)
Fig. 25: Ambient temperature - Process temperature

2 Ambient temperature in °C (°F)
3 Temperature range with temperature adapter
1
64
(928)
40
(580)
20
(290)
-1 (-14,5)
-50 °C 0°C 50°C 100°C 150°C 200°C 250°C

2
(-58 °F) (32 °F) (122 °F) (212 °F) (302 °F) (392 °F) (482 °F)
Fig. 26: Process temperature - Process pressure with switch position 0.7 g/cm³ (sensitivity switch)
29226-EN-130409
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9 Supplement
1
64
(928)
40
(580)
20
(290)
-1 (-14,5)
-50 °C 0°C 50°C 100°C 150°C 200°C 250°C

2
(-58 °F) (32 °F) (122 °F) (212 °F) (302 °F) (392 °F) (482 °F)
Fig. 27: Process temperature - Process pressure with switch position 0.5 g/cm³ (sensitivity switch)
Viscosity - dynamic 0.1 … 10000 mPa s (requirement: with density 1)

Flow velocity max. 6 m/s (with a viscosity of 10000 mPa s)
Density 0.7 … 2.5 g/cm³ (0.025 … 0.09 lbs/in³); 0.5 … 2.5 g/cm³
(0.018 … 0.09 lbs/in³) by switching over
Electromechanical data - version IP 66/IP 67 and IP 66/IP 68; 0.2 bar

Cable entry/plug1)
ƲƲ Single chamber housing –– 1 x cable gland M20 x 1.5 (cable: ø 5 … 9 mm), 1 x
blind plug M20 x 1.5
or:
–– 1 x closing cap ½ NPT, 1 x blind plug ½ NPT
or:
–– 1␣x plug (depending on the version), 1␣x blind stopper
M20␣x␣1.5
Screw terminals for wire cross-section up to 1.5 mm² (AWG 16)
Electromechanical data - version IP 66/IP 68 (1 bar)

Cable entry
ƲƲ Single chamber housing –– 1 x IP 68 cable gland M20 x 1.5; 1 x blind plug
M20 x 1.5
or:
–– 1 x closing cap ½ NPT, 1 x blind plug ½ NPT
Connection cable
ƲƲ Wire cross-section 0.5 mm² (AWG 20)
ƲƲ Wire resistance < 0.036 Ω/m (0.011 Ω/ft)
ƲƲ Tensile strength < 1200 N (270 lbf)
ƲƲ Standard length 5 m (16.4 ft)
29226-EN-130409
ƲƲ Max. length 1000 m (3280 ft)

ƲƲ Min. bending radius 25 mm (0.984 in) with 25 °C (77 °F)
ƲƲ Diameter approx. 8 mm (0.315 in)
1)
Depending on the version M12 x 1, according to ISO 4400, Harting, 7/8" FF.
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9 Supplement
ƲƲ Colour - standard PE Black

ƲƲ Colour - standard PUR Blue
ƲƲ Colour - Ex-version Blue
Adjustment elements
Mode switch
ƲƲ Min. rising characteristic curve (High current when immersed)
ƲƲ Max. falling characteristics (Low current when immersed)
Sensitivity switch
ƲƲ 0.5 0.5 … 2.5 g/cm³ (0.018 … 0.9 oz/in³)
ƲƲ 0.7 0.7 … 2.5 g/cm³ (0.025 … 0.9 oz/in³)
Test key simulation of a line break between sensor and process-
ing unit
Voltage supply
Operating voltage (characteristics ac- for connection to an amplifier according to NAMUR
cording to standard) IEC 60947-5-6, approx. 8.2 V
Off-load voltage U0 approx. 8.2 V
Shortcircuit current IU approx. 8.2 mA
Electrical protective measures

Protection rating
ƲƲ Plastic housing IP 66/IP 67
ƲƲ Aluminium and stainless steel stand- IP 66/IP 68 (0.2 bar)2)
ard
ƲƲ Aluminium and stainless housing IP 66/IP 68 (1 bar)
(optionally available)
Overvoltage category III
Protection class II
Approvals
Instruments with approvals can have different technical data depending on the version.
For that reason the associated approval documents of these instruments have to be carefully
noted. They are part of the delivery or can be downloaded under www.vega.com via "VEGA Tools"
and "serial number search" as well as via "Downloads" and "Approvals".
29226-EN-130409
2)
A suitable cable is the prerequisite for maintaining the protection rating.
446/658
9 Supplement
9.2 Dimensions
Housing in protection IP 66/IP 67 and IP 66/IP 68; 0.2 bar

~ 69 mm ~ 59 mm ~ 69 mm
(2.32") (2.72") ~ 116 mm (4.57")
(2.72")
ø 79 mm ø 80 mm ø 79 mm ø 86 mm (3.39")
(3.03") (3.15") (3.11")
116 mm (4.57")
117 mm (4.61")
112 mm (4.41")
112 mm (4.41")
M20x1,5/ M20x1,5/ M20x1,5/ M20x1,5
½ NPT ½ NPT ½ NPT
M20x1,5/
1 ½ NPT 2 3 4
Fig. 28: Housing versions in protection IP 66/IP 67 and IP 66/IP 68; 0.2 bar
1 Plastic housing
2 Stainless steel housing, electropolished
3 Stainless steel housing - precision casting
4 Aluminium housing
Housing in protection IP 66/IP 68 (1 bar)

~ 103 mm
(4.06") ~ 150 mm (5.91")
ø 77 mm
(3.03") ø 84 mm (3.31")
116 mm (4.57")
117 mm (4.61")
M20x1,5 M20x1,5 M20x1,5
1 2
Fig. 29: Housing versions with protection rating IP 66/IP 68 (1 bar)
1 Stainless steel housing - precision casting
2 Aluminium housing
29226-EN-130409
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9 Supplement
VEGASWING 61
18,5 mm
(0.73")
36 mm
(1.42")
32 (G¾A, ¾"NPT)
41 (G1A, 1"NPT)
57 mm
(2.24")
G¾A, ¾"NPT
G1=69 mm (2.72")
G¾=66 mm (2.6")
G1A, 1"NPT
53 mm
(2.09")
55 mm
(2.17")
1 2 6
3
19 mm
(0.75")
ø 33,7 mm
50 mm
(1.97")
50 mm
(1.97")
(1.33")
53 mm
(2.09")
49 mm
4 5 (1.93") 6
53 mm
(2.09")
Fig. 30: VEGASWING 61

1 Thread
2 Clamp
3 Cone DN 25
4 Bolting DN 40
5 Flange
6 Tuchenhagen Varivent
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9 Supplement
VEGASWING 61, options
178 mm (7.01")
34 mm
(1.34")
1 2
Fig. 31: Options

1 Gas-tight leadthrough
2 Temperature adapter
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9 Supplement
9.3 Industrial property rights

VEGA product lines are global protected by industrial property rights. Further information see
www.vega.com.
Only in U.S.A.: Further information see patent label at the sensor housing.
VEGA Produktfamilien sind weltweit geschützt durch gewerbliche Schutzrechte.
Nähere Informationen unter www.vega.com.
Les lignes de produits VEGA sont globalement protégées par des droits de propriété intellec-
tuelle. Pour plus d'informations, on pourra se référer au site www.vega.com.
VEGA lineas de productos están protegidas por los derechos en el campo de la propiedad indus-
trial. Para mayor información revise la pagina web www.vega.com.
Линии продукции фирмы ВЕГА защищаются по всему миру правами на интеллектуальную
собственность. Дальнейшую информацию смотрите на сайте www.vega.com.
VEGA系列产品在全球享有知识产权保护。
进一步信息请参见网站<www.vega.com>。
9.4 Trademark
All the brands as well as trade and company names used are property of their lawful proprietor/
originator.
29226-EN-130409
450/658
Notes
29226-EN-130409
451/658
Printing date:
29226-EN-130409
All statements concerning scope of delivery, application, practical use and operat-
ing conditions of the sensors and processing systems correspond to the information
available at the time of printing.
Subject to change without prior notice
© VEGA Grieshaber KG, Schiltach/Germany 2013
VEGA Grieshaber KG Phone +49 7836 50-0

Am Hohenstein 113 Fax +49 7836 50-201
77761 Schiltach E-mail: info.de@vega.com
Germany www.vega.com
452/658
Specification sheet
VEGASWING 61
NAMUR
Vibrating level switch for liquids
Technical data
Process pressure -1 … +64 bar/-100 … +6400 kPa

(-14.5 … +928 psig)
Process temperature -50 … +250 °C (-58 … +482 °F)
Viscosity - dynamic 0.1 … 10000 mPa s
Density 0.5 … 2.5 g/cm³ (0.018 … 0.09 lbs/in³)
Ambient temperature on the -40 … +70 °C (-40 … +158 °F)
housing
Storage and transport temper- -40 … +80 °C (-40 … +176 °F)
ature
Hysteresis approx. 2 mm (0.08 in) with vertical instal-
lation
Process fitting Thread from G¾ A, ¾ NPT flanges from
DN 25, Clamp from 1", cone from DN 25,
bolting from DN 25, hygienic fittings
Operating voltage for connection to an amplifier according to
NAMUR IEC 60947-5-6, approx. 8.2 V
Application area Off-load voltage U0 approx. 8.2 V
The VEGASWING 61 is used as a universal vibrating level switch for all Shortcircuit current IU approx. 8.2 mA
liquids. Independent of the mounting position, it detects reliably with Current consumption
millimetre accuracy the limit level. The instrument can be used as empty
or full detector, as approved overfill protection, dry run protection or pump – Falling characteristics ≥ 2.2 mA uncovered/≤ 1 mA covered
protection in vessels and pipelines. The VEGASWING 61 offers maximum – rising characteristics ≤ 1 mA uncovered/≥ 2.2 mA covered
reliability and safety in a wide application range.
– Fault message ≤ 1 mA
SIL qualification up to SIL2
Advantages
• Minimum time and cost expenditure thanks to simple setup without Materials
medium
The wetted parts of the instrument are made of stainless steel 316L. The
• Precise and reliable function due to product-independent switching
supplied process seal is made of Klingersil C-4400.
point
You can find a complete overview of the available materials and seals in
• Low maintenance costs the "configurator" on our homepage under www.vega.com/configurator.
Function Housing versions
The heart of the sensor is the piezo drive by which the tuning fork is The housings are available in plastic, stainless steel or Aluminium.
energized to vibrate at its resonance frequency. When covered with They are available with protection ratings up to IP 67.
medium, the frequency of the fork decreases. This frequency change is
processed by the integrated electronics and converted into a switching
command. With the tuning fork with only 40 mm length, the VEGASWING Electronics versions
work reliably independent of the installation position in any liquid. Pres- The instruments are available in different electronics versions. Apart from
sure, temperature, foam, viscosity and the composition of the liquid do not the versions with transistor output, contactless electronic switch and relay
influence the switching accuracy. output, a two-wire version for connection to a signal conditioning instru-
ment and a NAMUR version are also available.
Approvals
The instruments are suitable for use in hazardous areas and are
approved, e.g. according to ATEX, FM, CSA and IEC. The instruments
also have different ship approvals such as e.g. GL, LRS or ABS and are
approved as overfill protection according to WHG.
You can find detailed information on the existing approvals in the
"configurator" on our homepage under www.vega.com/configurator.
VEGA Grieshaber KG, Am Hohenstein 113, 77761 Schiltach/Germany, www.vega.com VEGASWING 61 – 34665-EN-120223
453/658
Specification sheet
Operation Instrument selection
The mode and sensitivity of the level switch can be adjusted on the With the "finder" you can select the most suitable measuring principle for
electronics module. A signal lamp shows the switching status of the your application: www.vega.com/finder.
instrument. You can find detailed information on the instrument versions in the
"configurator" on our homepage under www.vega.com/configurator.
N
NAMUR
1 Contact
(IEC 60947-5-6)
+ - 2
Simul.
max. 0,5 g / cm3 You can find the VEGA agency serving your area on our homepage
7
min. 0,7 g / cm3 3 www.vega.com.
6
4
Electronics and connection compartment, single chamber housing
1 Control lamp
4 Ground terminal
5 Simulation key
6 Connection terminals
Electrical connection
1 2
Wiring plan
You can find details on electrical connection in the instrument operating

instructions on our homepage at www.vega.com/downloads.
Dimensions
18,5 mm
(0.73")
19 mm
(0.75")
SW 41 mm
36 mm
(1.42")
(1.61")
G1 A
69 mm
(2.72")
53 mm
(2.09")
53 mm
(2.09")
1 2 3
VEGASWING 61
1 Threaded version
2 Tri-Clamp version
3 Flange version
Information
You can find further information about the VEGA product line on our
homepage www.vega.com.
In the download section under www.vega.com/downloads you'll find free
operating instructions, product information, brochures, approval
documents, instrument drawings and much, much more.
VEGASWING 61 – 34665-EN-120223 VEGA Grieshaber KG, Am Hohenstein 113, 77761 Schiltach/Germany, www.vega.com
454/658
Safety instructions
VEGASWING 61/63.C******N*
PTB 00 ATEX 2217 X
II 1G, II 1/2G, II 2G Ex ia IIC T6 Ga, Ga/Gb, Gb
0044
38001
455/658
Contents
EG-Konformitätserklärung 4
EC declaration of conformity 4
Déclaration CE de conformité 4
1 Area of applicability 5
2 General information 5
2.1 Category 1G instruments 5
2.2 Category 1/2G instruments 5
2.3 Category 2G instruments 5
3 Technical data 5
3.1 Electrical data 5
3.2 Application conditions 6
3.3 Permissible differing application conditions 8
4 Protection against static electricity 8
5 Installation/mounting 9
6 Impact and friction sparks 9
7 Use of an overvoltage arrester 9
8 Material resistance 9
9 Grounding 9
Please note:
These safety instructions are part of the operating instructions:
38001-EN-101012
l 29226 - VEGASWING 61 - NAMUR

l 29231 - VEGASWING 63 - NAMUR
l 38002 - EC type approval PTB 00 ATEX 2217 X
2 VEGASWING 61/63.C******N*
456/658
Sicherheitshinweise für den Einsatz in explosionsgefährdeten Bereichen, verfügbar in den
DE Sprachen deutsch, englisch, französisch und spanisch.
Safety instructions for the use in hazardous areas are available in German, English, French
EN and Spanish language.
Consignes de sécurité pour l'utilisation en atmosphère explosible, disponibles dans les
FR langues allemande, anglaise, française et espagnole.
Instrucciones de seguridad para el empleo en áreas con riesgo de explosión, disponible en
ES los siguientes idiomas alemán, ingles, francés y español.
Pokud nastanou potíže při čtení bezpečnostních upozornění v otištěných jazycích,
CZ poskytneme. Vám na základě žádosti k dispozici kopii v jazyce Vaší země.
Hvis De har svært ved at forstå sikkerhedsforskrifterne på de trykte sprog, kan. De få en kopi
DA på Deres sprog, hvis De ønsker det.
Εάν δυσκολεύεστε να διαβάσετε τις υποδείξεις ασφαλείας στις γλώσσες που ήδη έχουν
EL τυπωθεί, τότε σε περίπτωση ζήτησης μπορούμε να θέσουμε στη διάθεσή σας ένα
αντίγραφο αυτών στη γλώσσα της χώρας σας.
Kui teil on raskusi trükitud keeltes ohutusnõuete lugemisega, siis saadame me teie
ET järelepärimise peale nende koopia teie riigi keeles.
Laitteen mukana on erikielisiä turvallisuusohjeita. Voit tilata meiltä äidinkieliset turvallisuu-
FI sohjeet, jos et selviä mukana olevilla kielillä.
Ha a biztonági előírásokat a kinyomtatott nyelveken nem tudja megfelelően elolvasni, akkor
HU lépjen velünk kapcsolatba: azonnal a rendelkezésére bocsátunk egy példányt az Ön
országában használt nyelven.
Se le Normative di sicurezza sono stampate in una lingua di difficile comprensione, potete
IT richiederne una copia nella lingua del vostro paese.
Jei Jums sunku suprasti saugos nuorodų tekstą pateiktomis kalbomis, kreipkitės į mus ir mes
LT Jums duosime kopiją Jūsų šalies kalba.
Ja Jums ir problēmas drošības noteikumus lasīt nodrukātajās valodās, tad mēs Jums
LV sniegsim pēc pieprasījuma kopiju Jūsu valsts valodā.
F’kaz li jkollok xi diffikulta` biex tifhem listruzzjonijiet ta’ sigurta`kif ipprovduti, infurmana u ahna
MT nibghatulek kopja billingwa tieghek.
Als u moeilijkheden mocht hebben met het lezen van de veiligheidsinstructies in de
NL afgedrukte talen, sturen wij u op aanvraag graag een kopie toe in uw eigen taal.
W przypadku trudności odczytania przepisów bezpieczeństwa pracy w wydrukowanych
PL językach, chętnie udostępnimy Państwu kopię w języku obowiązującym w danym kraju.
Caso tenha dificuldade de ler as instruções de segurança no idioma, no elas foram
PT impressas, poderá solicitar junto a nós uma cópia em seu idioma.
Pokiaľ nastanú problémy pri čítaní bezpečnostných pokynov vo vydaných jazykoch,
SK poskytneme Vám na základe žiadosti k dispozícii kópiu v jazyku Vašej krajiny.
Kadar se pojavijo težave pri branju varnostnih navodil v izdanih jezikih, vam bomo na osnovi
SL zahtevka dali na razpolago kopijo v jeziku vaše države.
Om du har problem att läsa säkerhetsanvisningarna på de här tryckta språken, ställer vi gärna
SV på begäran en kopia på ditt språk till förfogande.
38001-EN-101012
VEGASWING 61/63.C******N* 3
457/658
EC declaration of conformity
Déclaration CE de conformité
VEGA Grieshaber KG
Am Hohenstein 113
77761 Schiltach
Deutschland
erklärt in alleiniger Verantwortung, dass das Produkt
declare under our sole responsibility that our product
déclare sous sa seule responsabilité que le produit
VEGASWING 61/63.C******N*
auf das sich diese Erklärung bezieht, mit den folgenden Normen übereinstimmt
to which this declaration relates is in conformity with the following standards
auquel se réfère cette déclaration est conforme aux normes
EN 60079-0: 2009
EN 60079-11: 2007
EN 60079-26: 2007
EN 61326-1: 2006 Emission: class B, Imission: industrial area
EN 61010-1: 2001
gemäß denBestimmungen der Richtlinien

following the provision of Directives
conformément aux dispositions des Directives
94/9/EG
2006/95/EG
2004/108/EG
EG Baumusterprüfbescheinigung Nummer PTB 00 ATEX 2217 X

EC-Type Examiniation Certificate Number 5. Supplement
Numéro du certificat d'examen CE de type
Benannte Stelle/Kennnummer TÜV Nord Cert./0044
Notified Body/Itdentification number
Organisme notifié/Numéro d'identification
Schiltach, 19.08.2010
ppa. J. Fehrenbach i.V. Frühauf

Entwicklungsleitung Leiter Zertifizierung
Development Management Certification Manager
Directeur du service recherche et développement Directeur du service de certification
38001-EN-101012
458/658
1 Area of applicability
These safety instructions apply to the vibrating level switches VEGASWING61/63.C******N*
according to EG type approval certificate PTB 00 ATEX 2217 X with the 5. supplement (certificate
number on the type label) and for all instruments with the number of the safety instruction (38001) on
the type label.
2 General information
The VEGASWING61/63.C******N* are used for monitoring or control of levels in hazardous areas,
also when combustible liquids, gases, mist or vapours are present.
The VEGASWING61/63.C******N* are suitable for applications in hazardous atmospheres of all
combustible materials of explosion group IIA, IIB and IIC, for applications requiring instruments of
category 1G, 1/2G or 2G.
If the VEGASWING61/63.C******N* are installed and operated in hazardous areas, the general Ex
installation regulations EN 60079-14 as well as these safety instructions must be observed.
The installation of explosion-endangered systems must always be carried out by qualified personnel.
2.1 Category 1G instruments

The VEGASWING61/63.C******N* are installed in areas requiring instruments of category 1G.
2.2 Category 1/2G instruments

The electronics housing is installed in hazardous areas requiring instruments of category 2G. The
process connection elements are installed in the separating wall, which separates areas requiring
instruments of category 2G or 1G. The sensor with the mechanical fixing element is installed in
hazardous areas requiring instruments of category 1G.
2.3 Category 2G instruments

The VEGASWING61/63.C******N* are installed in hazardous areas requiring an instrument of
category 2G.
3 Technical data
3.1 Electrical data

The VEGASWING61/63.C******N* have intrinsically safe circuits. These intrinsically safe circuits are
connected to terminals which are located in an "Ex i" connection compartment.
38001-EN-101012
459/658
Supply and signal circuit
Terminals 1[+], 2[-] In ignition protection type intrinsic safety Ex ia IIC/IIB
Only for connection to a certified, intrinsically safe
circuit.
Maximum values:
Ui = 20 V
Ii = 103 mA
Pi = 516 mW
Li = negligibly small
In the version with fix mounted connection cable Li =

55 µH/m.
Ci = 2.2 nF
In the version with fix mounted connection cable Ci
wire/wire = 58 pF/m and Ci wire/screen = 270 pF/m must
be also taken into account.
The intrinsically safe circuits are electrically separated from parts which can be grounded.
For applications requiring instruments of category 2G or 1/2G, the intrinsically safe power supply and
signal circuit can correspond to protection class ia or ib. For connection to a circuit of category ib, the
ignition protection type identification is Ex ib IIC T6 Gb.
For applications requiring instruments of category 1G, the intrinsically safe power supply and signal
circuit must be in conformity with category ia.
For applications requiring instruments of category 1G the VEGASWING61/63.C******N* is preferably
connected to appropriate instruments with electrically isolated intrinsically safe circuits.
3.2 Application conditions
Permissible ambient temperatures

On the sensor - category 1G
Temperature class
- T6 -20 … +51 °C
- T5, T4, T3, T2, T1 -20 … +60 °C
On the sensor - category 1/2G

Temperature class
- T6 -20 … +85 °C
- T5 -20 … +100 °C
T4 -20 … +135 °C
38001-EN-101012
-
- T3 without temperature adapter -20 … +150 °C
- T3 with temperature adapter -20 … +200 °C
460/658
- T2, T1 with temperature adapter -20 … +250 °C
If the sensors of VEGASWING61/63.C******N* are operated at temperatures higher than those

specified in the above table, please make sure by means of appropriate measures that there is no
danger of ignition from hot surfaces. The temperature on the electronics/housing must not exceed
the values specified in the above table.
Please make sure that the sensor (also in case of failure) does not generate heat itself.
Responsibility for safe operation of the equipment, with respect to pressures/temperatures of the
materials used, rests with the operator.
On the sensor - category 2G

Temperature class
- T6 -40 … +85 °C
- T5 -40 … +100 °C
- T4 -40 … +135 °C
- T3 without temperature adapter -40 … +150 °C
- T3 with temperature adapter -50 … +200 °C
- T2, T1 with temperature adapter -50 … +250 °C
If the sensors of VEGASWING61/63.C******N* are operated at temperatures higher than those

specified in the above table, please make sure by means of appropriate measures that there is no
danger of ignition from hot surfaces. The temperature on the electronics/housing must not exceed
the values specified in the above table.
On the electronics - category 1G

Temperature class
- T6 -20 … +51 °C
- T5, T4, T3, T2, T1 -20 … +60 °C
On the electronics - category 1/2G or 2G

Temperature class
- T6 -40 … +67 °C
- T5 -40 … +82 °C
- T4, T3, T2, T1 -40 … +90 °C
Permissible operating pressure in the area of the measuring probe

Category 1G or 1/2G
38001-EN-101012
Under explosive atmosphere requiring instruments of category 1G: 0.8 … 1.1 bar
461/658
Category 2G
Operating pressure Vacuum … 64 bar (when applicable, take nominal
pressure of the process connection element into
account)
Information:
The application conditions mentioned before also apply to SWING63.C******N* with lock
fitting AVR60.3*** or ARV-SG63.2** (Pmax. 16 bar, Tmax. 150 °C) and lock fitting
AVR60.4*** or ARV-SG63.3** (Pmax. 64 bar, Tmax. 250 °C).
3.3 Permissible differing application conditions

The VEGASWING61/63.C******N* (also with lock fitting AVR60.3/4*** and ARV-SG63.2/3**.) can
also be operated as category 1/2G instrument according to the conditions mentioned below.
Temperature class Temperature on the Ambient temperature on Process pressure

sensor the electronics
T4, T3, T2, T1 -20 … +60 °C -40 … +90 °C 0 … 6 bar
Note:
If the abovementioned application conditions in the area of the sensor are different when
using VEGASWING61/63.C******N* as category 1/2G instrument, please make sure that
the sensor does not heat up (even in case of malfunctions). It is the responsibility of the
plant operator to make sure the pressure/temperature of the processed materials
presents no danger.
The permissible pressures and temperatures for operation are mentioned in the
operating instructions manuals.
4 Protection against static electricity
The VEGASWING61/63.C******N* in the versions with electrostatically chargeable parts, as e.g.

plastic housing, plastic-coated or enamelled parts, are provided with a caution label on the housing
referring to the safety measures that should be taken in case of electrostatic charge during mounting
and operation and especially during repair work.
Caution: Plastic parts! Danger of static charge!
l Avoid friction
38001-EN-101012
l No dry cleaning
l Do not mount in areas with flowing, non-conductive products
462/658
5 Installation/mounting
The SWING63.C*******N* must be mounted in a way that adequately ensures that the sensor tube
will not oscillate, vibrate or bend due to the movements of other installations or the medium in the
vessel.
6 Impact and friction sparks

The VEGASWING61/63.C******N* must be mounted in such a way that sparks from impact and
friction between aluminium and steel (except stainless steel, if the presence of rust particles can be
excluded) cannot occur.
7 Use of an overvoltage arrester

The VEGASWING61/63.C******N* do not require overvoltage measures according to EN 60079-14
when used as category 1/2G.
When used as category 1G instrument, the VEGASWING61/63.C******N* have to be connected to a
suitable overvoltage arrester according to EN 60079-14, e.g. the certified type B62-36G from VEGA
(TÜV 07 ATEX 553276) to protect against overvoltage surges.
8 Material resistance
The VEGASWING61/63.C******N* must only be used in media against which the materials of the
wetted parts are sufficiently resistant.
9 Grounding
The VEGASWING61/63.C******N* must be grounded electrostatically (transfer resistance ≤ 1 MΩ),
e.g. via the internal or external ground terminal on the housing. The metallic parts of the
VEGASWING61/63.C******N* are electrically connected with the internal or external ground terminal
on the housing.
38001-EN-101012
463/658
VEGA Grieshaber KG
Am Hohenstein 113
77761 Schiltach
Germany
Phone +49 7836 50-0
Fax +49 7836 50-201
E-mail: info@de.vega.com
www.vega.com
ISO 9001
© VEGA Grieshaber KG, Schiltach/Germany 2010
Subject to change without prior notice 38001-EN-101012
464/658
465/658
466/658
467/658
468/658
MAKING MODERN LIVING POSSIBLE
Data sheet
Temperature sensor with integrated transmitter

for industrial applications, Type MBT 3560
With MBT 3560 we have combined

the technology of our standard temperature
sensors and the electrical connections
from our MBS pressure transmitters with
a new developed electronics which has
resulted in a compact temperature sensor
with a built-in transmitter.
The MBT 3560 is designed for use in harsh
industrial enviroments where reliable, robust
and accurate equipment is required.
Available with a wide selection of process
and electrical connections. Can be delivered
with a 33 mm extension length which makes
it possible to measure temperatures
up to 200 °C without damaging
the built-in electronics.
Features yy Designed for use in harsh industrial yy Ultra compact design

environments where reliable, robust yy Temperature range -50 – 200 °C
and accurate equipment is required
yy Sensor pockets available for applications
yy All metal enclosure parts made where emptying the system is not an option
of stainless steel (AISI 316)
yy Based on Pt 1000 technology
yy Output signals: 4 – 20 mA
or Ratiometric 10 – 90%
yy A wide selection of process and electrical
connections
© Danfoss A/S (IA-MS / IM) 2013-july IC.PD.P30.B6.02 / 520B5687 1
469/658
Data sheet Temperature sensor with integrated transmitter for industrial applications, type MBT 3560
Technical data Main specifications

Process connections See page 3
Measuring ranges Any combinations between -50 – 200 °C
Minimum span 25 °C
Output signals 4 – 20 mA or Ratiometric 10 – 90%
Electrical connections See page 4
Performance
Indicative response times
Water 0.2 m/s Air 1 m/s
t0.5 t0.9 t0.5 t0.9
ø8 mm
10 s 35 s 95 s 310 s
Accuracy < ± 0.5% FS (typ.)
< ± 1.0% FS (max.)
Max. load protection tube 100 bar
Electrical specifications
Nom. Output signal (short-circuit protected)

ratiometric 10 – 90%
4 – 20 mA
of supply voltage
Supply voltage [US] polarity 4.75 – 8 V d.c.
10 – 30 V d.c.
protected 5 V d.c. (Nom.)
Supply – current consumption – < 4 mA at 5 V d.c.
> 100 MΩ at > 100 MΩ at
Insulation resistance
100 V d.c. 100 V d.c.
Supply voltage dependency < ± 0.05% FS / 10 V –
Current limitation 30 mA –
Output impedance – < 25 Ω
Load [RL] RL<(US-10) / (0.02 A) ohm RL> 5 kohm at 5 V d.c.
Environmental conditions
Media temperature (max. 120 °C without extension length) -50 – 200 °C
Temperature on electronics )
-40 – 85 °C
1
Transport temperature range -50 – 85 °C

EMC – Emmision EN 61000-6-3
EMC – Immunity EN 61000-6-2
Sinusoidal 15.9 mm-pp, 5 Hz – 25 Hz –
Vibration stability 4 g, 25 Hz – 2 kHz IEC 60068-2-6
Random 7.5 g ms, 5 Hz – 1 kHz IEC 600868-2-34, IEC 60068-2-36
Shock 500 g / 1 ms IEC 60068-2-27
Shock resistance
Free fall IEC 60068-2-32
Enclosure (depending on electrical connections) See page 4
1
) Temperature of the electronics depends on the media temperature, extension length, ambient temperature and air velocity.
Mechanical characteristics
Wetted parts W.no. 1.4571 (AISI 316 Ti)
Materials:
Enclosure W.no. 1.4404 (AISI 316 L)
Measuring insert fixed
Net weight
0.1 – 0.15 kg
(Depending on design)
470/658
Ordering standard
Sensor
Type MBT 3560
Measuring range Transmitter setting

-50 – 200 °C 0 1 1 0 0 – 100 °C
1 1 5 0 – 150 °C
Output signal 1 2 0 0 – 200 °C
4 – 20 mA 0 4 1 5 -50 – 150 °C
Ratiometric...10 – 90% 1 4 2 0 -50 – 200 °C
9 9 9 Other
Protection tube, W.no. 1.4571 (AISI 316 TI)

Acid-proof steel, ø8 mm (-50 – 200 °C) 0 Process connection
0 G 1/4 A
Extension length 1 G 3/8 A
None 0 2 G½A
33 mm 1 7 ½ – 14 NPT
9 Other
Insertion length
0050 mm 0050 Electrical connection
0080 mm 0080 1 Plug, EN 175301-803, Pg 9
0100 mm 0100 4 Plug, AMP Econoseal, J series, Male, excl. female plug
0120 mm 0120 5 Screened cable, 2 m
0150 mm 0150 6 Plug, IEC 947-5-2, M12 × 1, male, excl. female plug
0200 mm 0200 A Flying leads
0250 mm 0250 9 Other
Preferred versions
Non-standard build up combinations

may be selected. However, minimum
order quantities may apply,
please contact your local Danfoss
office for more information
471/658
Electrical connections AMP Econoseal IEC 947-5-2

EN 175301-803 Flying leads 2 m screened cable
J series (male) M12 × 1
Enclosure
IP65 IP67 IP67 IP67 IP67
Materials
Glass filled Glass filled Glass filled Glass filled
PUR
polyamid, PA 6.6 polyamid, PA 6.6 polyamid, PA 6.6 polyamid, PA 6.6
Electrical connection, 4 – 20 mA output (2 wire)

Pin 1: +supply Red wire: +supply
Pin 1: +supply
Pin 2: ÷supply Pin 1: +supply Red wire: +supply White wire: ÷supply
Pin 2: Not used
Pin 3: Not used Pin 2: ÷supply Black wire: ÷supply Red/black wire: Not used
Pin 3: Not used
Earth: Not connec- Pin 3: Not used Screen: Not connected to
Pin 4: ÷supply
ted to MBT housing MBT housing
Electrical connection, Ratio metric (3-wire) 10 – 90%

Pin 1: +supply
Red wire: +supply
Pin 2: ÷supply Pin 1: +supply
Pin 1: +supply Red wire: +supply White wire: ÷supply
Pin 3: Output Pin 2: not used
Pin 2: ÷supply Black wire: ÷supply Red/ Black wire: Output
Earth: Not Pin 3: Output
Pin 3: Output Blue wire: Output Screen: Not connected
connected Pin 4: ÷supply
to MBT housing
to MBT housing
Dimensions AMP Econoseal IEC 947-5-2 EN 175301-803,

Flying leads 2 m Screened cable
J series (male) M12 × 1, 4-pin Pg 9
Ø30.5
L = Insertion length
H = 9 mm
Ø8
Ø8
472/658
Betriebsanleitung Druckschalter
Mode d‘emploi
Instructions
Pressostat
Pressure Switch
Elektrischer Anschluss / Connexion électrique / Electrical connection
Mikroschalter als Ein-, Aus- oder Umschalter Le micro switch est utilisable comme enclencheur, It is possible to connect the micro switch as a
anschliessbar déclencheur ou commutateur cut-in, cut-out or change-over switch.
Klemmen 2 - 1: Bornes 2 - 1: Terminals 2 - 1:
Bei Druckanstieg Kontakt öffnend Déclenchant avec pression montante Opening at rise of pressure
Klemmen 1 - 4: Bornes 1 - 4: Terminals 1 - 4:
Bei Druckanstieg Kontakt schliessend Enclenchant avec pression montante Closing at rise of pressure
IP-Schutzart / IP-Protection / IP-Protection
IP65
Anziehdrehmoment Druckanschluss / Couple de serrage raccord de pression / Torque moment pressure connection
max. 25Nm
Betriebstemperatur / Température de service / Operating temperature
-25°C ... +70°C (-13°F ... +158°F)
Medientemperatur / Température du fluide / Media temperature
-40°C ... +150°C (-40°F ... +300°F)
for Types: 94X.XXXX.701/703/705/707/709/711/713/715/723/725: -15°C ... + 150°C ( +5°F ... + 300°F)

94X.XXXX.700/702/704/706/708/710/712/714/722/724: -30°C ... + 100°C (-22°F ... + 212°F)
Lagertemperatur / Température de stockage / Storage temperature
-25°C ... +85°C (-13°F ... +185°F)

Betriebsdruck / Pression de fonctionnement / Operating pressure
Type: 900.../901.../902.../904.../905.../906.../912.../915
bar 903.../907.../940.../941.../942... bar Type: 944.../947...
Bereich 1 ... 10 Überdruck max. 100

Bereich 0.02 ... 0.25 Überdruck max. 2
Plage 4 ... 40 Surpression 200
Plage 0.03 ... 0.40 Surpression 2
Range 6 ... 60 Over pressure 200
Range 0.03 ... 0.60 Over pressure 4
10 ... 100 200
0.05 ... 1.0 4
16 ... 160 400
[bar] -0.9 ... 1.5 [bar] 10
[bar] 25 ... 250 [bar] 400
0.2 ... 1.6 10
40 ... 400 800
0.2 ... 2.5 10
60 ... 600 800
0 ... 4.0 12
psi
0 ... 6.0 12
1 ... 10 24 Type: 900.../904.../912...
1 ... 16 24
2 ... 25 40
Range 5 ... 50 Over pressure max. 175
4 ... 40 40
Bereich 10 ... 100 Überdruck 350
6 ... 60 100
Plage 25 ... 200 Surpression 350
10 ... 100 100
50 ... 500 500
[psi] 125 ... 1500 [psi] 1500
Trafag AG Tel +41 44 922 32 32

Industriestrasse 11 Fax +41 44 922 32 33
CH-8608 Bubikon www.trafag.com
473/658
Massbilder / Cotes d‘encombrement / Dimensions
2x
Ø
7
SW24
M20x1.5
27.5
103
G1/2“
Cable-Ø: aussen/mâle/male
5...10
XXX.XX.XX.XXX.XX.07
M20x1.5
G1/4“
innen/femelle/female
1/4“ NPT
XXX.XX.XX.XXX.XX.27 XXX.XX.XX.XXX.XX.40 1/4“ NPT

M24x1.5 M18x1.5 innen/femelle/female
Einstellen des Schaltpunktes / Ajustage de seuil / Setpoint adjustment
Fig. 1
H71261i Trafag AG 03/2013

Die Skalengenauigkeit beträgt ±2% des Bereiches. La précision de l’échelle est garantie avec ±2% The dial accuracy is ±2% of the range. Every
Das Gerät ist individuell geeicht, so dass sich eine de la plage. Chaque pressostat est étalloné indi- unit is individually calibrated, so a manometer
Manometer-Kontrolle erübrigt. viduellement. L’emploi d’un manomètre n’est pas verification is not necessary.
nécessaire.
Ausführung mit fester Schaltdifferenz Exécution avec différentiel fixe Type with invariable differential
1. Lösen der Arretierschraube (A) 1. Desserrer le dispositif d’arrêt (A) 1. Loosen lock screw (A)
2. Einstellen des oberen Schaltpunktes mit der 2. Régler la valeur de pression supérieure (point de 2. Adjust upper switching point with range
Bereichsspindel (B) déclenchement) avec la tige filetée (B). spindle (B)
Der untere Schaltpunkt ergibt sich aus der La valeur inférieure de pression (point d’enclen- The lower switching point results from the fixed
festliegenden Schaltdifferenz chement) se donne par le différentiel fixe. switching differential
3. Festziehen der Arretierschraube (A) 3. Serrer le dispositif d’arrêt (A) 3. Tighten lock screw (A) We reserve the right to make alterations as technical progress may warrant.
Ausführung mit verstellbarer Schaltdifferenz Exécution avec différentiel réglable Type with variable differential
1. Lösen der Arretierschraube (C) 1. Desserrer le dispositif d’arrêt (C) 1. Loosen lock screw (C)
2. Einstellen des unteren Schaltpunktes mit der 2. Régler la valeur de pression inférieure (point 2. Adjust lower switching point with range
Bereichsspindel (D) d’enclenchement) avec la tige filetée (D) spindle (D)
3. Festziehen der Arretierschraube (C) 3. Serrer le dispositif d’arrêt (C) 3. Tighten lock screw (C)
4. Einstellen des oberen Schaltpunktes mittels 4. Réglage de la valeur supérieure de pression 4. Adjust upper switching point with a screw
Schraubenzieher an der Differenzverstell- (point de déclenchement) avec tournevis à la driver at differential adjusting screw (E)
schraube (E) vis du différentiel (E)
Durch Drehen im Uhrzeigersinn wird die Schalt- En tournant dans le sens horaire le différentiel aug- By turning clockwise the differential gets enlarged,
differenz vergrössert, bzw. der obere Schaltpunkt mente et par conséquence le point d’éclenchement resp. the upper switching point is displaced
nach oben verschoben. Mittels der Merkskala se déplace vers le haut. À l’aide d’échelle de repère upwards. The desired differential is adjusted by
(F) und dem auf der Gehäusedeckelinnenseite (F) et du diagramm (G) à l’intérieur du couvercle way of the dial (F) and of the diagram (G) glued
aufgeklebten Diagramm (G) wird die gewünschte on règle le différentiel. to the inside of the housing cover.
Schaltdifferenz eingestellt.
Montage / Montage / Installation
Beim Anschliessen des Druckfühlers ist ein Verdre- Pour éviter un déréglage du capteur, ne pas tenir To avoid altering the sensing element adjustments,
hen durch Gegenhalten unbedingt zu vermeiden. le boîtier du pressostat pendant le raccordement do not hold the housing of the pressure switch
(Fig. 1). de la connexion de pression. (Fig. 1). while tightening the pressure connection.
(Fig. 1).
Trafag AG Tel +41 44 922 32 32

Industriestrasse 11 Fax +41 44 922 32 33
CH-8608 Bubikon www.trafag.com
474/658
900/904/912
pressostat p/ps
anwendungen Applications Applications
Schiffbau Construction navale Shipbuilding

ABS, BV, CCS, DNV, ABS, BV, CCS, DNV, ABS, BV, CCS, DNV,
GL, KRS, LRS, RINA GL, KRS, LRS, RINA GL, KRS, LRS, RINA
Motorenbau Constr. de moteurs Engine manufacturing
Schienenfahrzeuge Véhicules sur rail Railways
Maschinenbau Machines-outils Machine tools
Hydraulik Hydraulique Hydraulics
HLK CVC HVAC
Kältetechnik Réfrigération Refrigeration
Prozess Techn. Techn. de procédés Process technology
Wasseraufbereitung Traitement de l‘eaux Water treatment
Autoindustrie Industrie automobile Automotive industry
Prüfstände Banc d‘essai à frein Test benches
Ex Ex Ex
Lebensmittelindustrie Industrie alimentaire Food Industry
Autoklaven Autoclavage Autoclaves
Hauptmerkmale Caractères distinctifs Main characteristics
 Fühler: Balg  Capteur: soufflet  Sensor: bellows

 Messbereich: -0.9...1.5 bis 10...100 bar  Plage de mesure: -0.9...1.5 à 10...100 bar  Measuring range: -0.9...1.5 to 10...100 bar
 Ausgang: potentialfreier Umschaltkontakt  Sortie: inverseur libre de potentiel  Output: floating change-over contact
 Schaltdifferenz: nicht einstellbar  Différentiel de l'interrupteur: non ajustable  Switching differential: not adjustable
 Reproduzierbarbeit: ± 1.0 % d.S. typ.  Reproductibilité: ± 1.0 % E.M. typ.  Repeatability: ± 1.0 % FS typ.
 Skalengenauigkeit: ± 2.0 % d.S. typ.  Précision de l'échelle: ± 2.0 % E.M. typ.  Scale accuracy: ± 2.0 % FS typ.
 EN60730-1/ EN60730-2-6: Typ 2.B.H  EN60730-1/ EN60730-2-6: Typ 2.B.H  EN60730-1/ EN60730-2-6: Typ 2.B.H
Vorteile Avantages principaux Main features
 Robustes Alu-Gehäuse  Boîtier robuste en aluminium  Rugged aluminium housing

 Schutzart IP 65  Protection IP 65  Protection IP 65
 Beliebige Einbaulage  Montage toutes positions  Any mounting position possible
änderungen vorbehalten - sous réserve de modifications - Subject to change
File: H72252n Page: 1 (5) Date: 03/2013
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pressostat p/ps
Bestellinformation / Information pour la commande / Ordering information
Lager Code (kurze Lieferzeit)/ Codification stock (delai de livraison bref)/ Code for stock products (short delivery time): P/PS (z.B./ Ex./e.g: P16)

 siehe Katalog/ voir catalogue/ see catalogue: „Standard Products“
Varianten Code/ Codification de variantes/ Custom build code xxx.xxxx.xXx.xx.XX...
Mit Anzeige; mit Verstell-Schraube/ Avec affichage; réglage par vis/ 900
With display; with adjusting screw
Ohne Anzeige; mit Verstell-Schraube/ Sans affichage; réglage par vis/ 904
Without display; with adjusting screw
Mit Anzeige; mit Verstell-Knopf/ Avec affichage; réglage par mollette/ 912
With display; with adjusting knob
Mikroschalter1) Kleine Schaltdifferenz/ Interrupteur à petit différentiel/ Small switching differential 10

Microrupteur Mittlere Schaltdifferenz/ Interrupteur à moyen différentiel/ Average switching differential 11
Microswitch Erhöhte Vibrationsbeständigkeit/ Résistance de vibration élevée/ Improved vibration resistance 23
Hohe Vibrationsfestigkeit/ Résistance de vibration forte/ High vibration resistance 26
Mit vergoldeten Kontakten/ Avec contacts dorés/ With gold plated contacts 21
1)
Schaltdifferenz/ Différentiel de l‘interrupteur/ Switching differential: nicht einstellbar/ non ajustable/ Not adjustable
Bereich -0.9... 1.5 Überdruck 10 Berstdruck 13 72

Plage 0.2... 1.6 Surpression 10 Pression destruction 13 73
Range 0.2... 2.5 Overpressure 10 Burst pressure 13 75
0.0... 4.0 12 26 76
[bar] 0.0... 6.0 [bar] 12 [bar] 26 77
1.0... 10.0 24 36 78
1.0... 16.0 24 36 79
2.0... 25.0 40 75 80
4.0... 40.0 40 75 81
6.0... 60.0 100 160 82
10.0... 100.0 100 160 83 Medienberührende Teile:1.4435
Hous.: brass chem. nickel plated
Fühler Matériel contact. avec médias:

Gehäuse: Messing chem. vern.
Medium contact. parts:1.4435

Housing: brass, nickel plated
Capteur
Boîtier: laiton chim. nickelé
Sensor
Gehäuse: MS vernickelt
Boîtier: laiton nickelé

Gehäuse: Messing
Soufflet: 1.4435
Bellows: 1.4435
Soufflet: bronze
Bellows: bronze
Soufflet: bronze
Bellows: bronze

Housing: brass
Boîtier: laiton
Balg: 1.4435
Balg: Bronze
Balg: Bronze

1.4435
Material/ matière/ material
Gewinde/ filet/ thread G1/4“f 2) G1/2“m3) G1/4“f

2)
G1/2“m3) G1/4“f
2)
G1/2“m3)
Bereich 72 900 909 950 959 800 809
Plage 73, 75 901 902 951 952 801 802
Range 76, 77 903 904 953 954 803 804
78, 79 905 906 955 956 805 806
80, 81 907 908 957 958 807 808
82, 83 9404) 9414) 840 841

2)
innen/ femelle/ female 3)
aussen/ mâle/ male 4)
Balg/ Soufflet/ Bellows: 1.4435
Befestigung Direkt am Fühler oder Gehäuse/ Directement à capteur ou boîtier/ Direct on sensor or housing 00
Fixation Mit Montagebügel/ Avec platine murale/ By mounting bracket 31
Mounting
Zubehör Plombierung (Schutz vor Manipulation)/ Plombage (protection contre manipulations/ 16
Accessoires Lead seal (mani-pulation protection)
Accessories Kabelverschraubung/ Passe-câble à vis/ Screwed cable gland M20x1.5 (EN 50262) 07
Kabelverschraubung/ Passe-câble à vis/ Screwed cable gland M24x1.5 (DIN89280) 27
Kabelverschraubung/ Passe-câble à vis/ Screwed cable gland M18x1.5 (DIN89280) 40
Ohne Kabelverschraubung/ Sans passe-câble à vis/ Without screwed cable gland 33
Bahnsichere Ausführung / Exécution pour ferroviaire/ Railway-safety execution 28
Dämpfungselemente und Snubber/ Eléments d‘amortissement et Snubber/ Damping elements and Snubber:
siehe Datenblatt/ voir spécification /see specification sheet H72258
Trafag entwickelt und produziert auch speziell auf Ihre Bedürfnisse zugeschnittene Produkte. Bitte fragen Sie uns an.
i Trafag développe et fabrique des produits adaptés à vos besoins spécifiques en se basant sur votre cahier des charges.Contactez-nous s.v.p.
Trafag develops and manufactures customized products according to your specifications to meet your requirements. Please contact us.
File: H72252n Page: 2 (5) Date: 03/2013
476/658
900/904/912
pressostat p/ps
Spezifikationen Spécifications Specifications
Hauptmerkmale Caractères distinctifs Main characteristics

Fühler: Balg Capteur: soufflet Sensor: bellow
Messbereich: -0.9...1.5 bis 10...100 bar Plage de mesure: -0.9...1.5 à 10...100 bar Measuring range: -0.9...1.5 to 10...100 bar
Ausgang: potentialfreier Umschaltkontakt Sortie: inverseur libre de potentiel Output: floating change-over contact
Schaltdifferenz: nicht einstellbar Différentiel de l‘interrupteur: non ajustable Switching differential: not adjustable
EN60730-1/ EN60730-2-6: Typ 2.B.H EN60730-1/ EN60730-2-6: Typ 2.B.H EN60730-1/ EN60730-2-6: Typ 2.B.H
Genauigkeit (@ 20°C) Précision (@ 20°C) Accuracy (@ 20°C)

Reproduzierbarkeit Fühler: ± 1.0 % d.S. typ. Reproductibilité capteur: ± 1.0 % E.M. typ. Repeatability sensor: ± 1.0 % FS typ.
Skalengenauigkeit: ± 2.0 % d.S. typ. Précision de l‘échelle: ± 2.0 % E.M. typ. Scale accuracy: ± 2.0 % FS typ.
Schaltdifferenz : siehe Tabelle Différentiel de l‘interrupteur: voir tableau Switiching differential: see table
MiKROSCHALTER microrupteur microswitch

Schaltleistung: siehe Tabelle Pouvoir de coupure: voir tableau Rating: see table
Isolationswiderstand: > 2 MΩ Résistive d‘isolation: > 2 MΩ Resistance of insulation: > 2 MΩ
Spannungsfestigkeit: U ≤ 250V: 1.45 kV / Rigidité diélectrique: U ≤ 250V: 1.45 kV / Dielectric strength: U ≤ 250V: 1.45 kV /
U ≤ 500V: 2 kV U ≤ 500V: 2 kV U ≤ 500V: 2 kV
gegenüber Masse contre la masse terminal ground
Lebensdauer (mechanisch) Durée de vie (mécanique) Life time (mechanical)
Mikroschalter 10/11: 20 Mio. Lastspiele Microrupteur 10/11: 20 Mio. cycles Microswitch 10/11: 20 Mio. cycles
Mikroschalter 21: 0.5 Mio. Lastspiele Microrupteur 21: 0.5 Mio. cycles Microswitch 21: 0.5 Mio. cycles
Mikroschalter 23/26: 0.3 Mio. Lastspiele Microrupteur 23/26: 0.3 Mio. cycles Microswitch 23/26: 0.3 Mio. cycles
Elektrischer anschluss Connection électrique Electrical connection

Kabelverschraubung: M20x1.5 Passe-câble à vis: M20x1.5 Screwed cable gland: M20x1.5
Kabel-Ø 6...13 mm Câble-Ø 6...13 mm Cable-Ø 6...13 mm
Schraubenklemmen: 3 x 1.5...4 mm2 Borne à vis: 3 x 1.5...4 mm2 Terminal screw: 3 x 1.5...4 mm2
Umgebungsbedingungen Conditions d‘environnement Environmental conditions

Betriebstemperatur: -25...+70°C Température de service: -25...+70°C Operating temperature: -25...+70°C
Medientemperatur: -40...+150°C Température de médias: -40...+150°C Media temperature -40...+150°C
Lagertemperatur: -25...+85°C Temp. de stockage: -25...+85°C Storage temperature: -25...+85°C
Schutzart: IP65 Protection: IP65 Protection: IP65
Feuchtigkeit: max. 95 % relativ Humidité: max. 95 % relatif Humidity: max.95 % relative
Vibration (Schalter 23/26): Vibration (interrupteur 23/26): Vibration (switch 23/26):
5...25 Hz: ±1.6 mm 5...25 Hz: ±1.6 mm 5...25 Hz: ±1.6 mm
25...100 Hz: 4g 25...100 Hz: 4g 25...100 Hz: 4g
Bereiche 72, 73, 75 Plages 72, 73, 75 Ranges 72, 73, 75
5...50 Hz: 20 mm/Sek. 5...50 Hz: 20 mm/sec. 5...50 Hz: 20 mm/sec.
Schock: 50g/ 11ms Choc: 50g/ 11 ms Shock: 50g/ 11 ms
Mechanische Daten Spécifications mécaniques Mechanical data

Material Matière Material
Fühler: siehe Bestellinformation Capteur: voir information pour la commande Sensor: see ordering information
Gehäuse: AlSi10Mg/ Epoxy beschichtet Boîtier: AlSi10Mg/ Vernis avec époxy Housing: AlSi10Mg/ Epoxy coated
Dichtung: NBR Joint: NBR Seal: NBR
Kabelverschraubung: Messing vernickelt Passe-câble à vis: laiton nickelé Screwed cable gland: brass nickel plated
Anziehdrehmoment: max. 25 Nm Couple de serrage: max. 25 Nm Mounting torque: max. 25 Nm
Einbaulage: beliebig Montage: toute position Installation: any position
Gewicht: ~ 710 g Poids: ~ 710 g Weight: ~ 710 g
File: H72252n Page: 3 (5) Date: 03/2013
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pressostat p/ps
Schaltdifferenz (typ.) / Différentiel de l’interrupteur (typ.) / Switching differential (typ.)
Balgfühler Bereich/ Plage/ Range [bar]

Capteur soufflet -0.9...1.5 0...4 1...10 2...25 6...60
Bellows sensor 0.2...1.6 0...6 1...16 4...40 10...100
0.2...2.5
Mikroschalter/ Microrupteur/ Microswitch 10 0.03 0.08 0.2 0.5 1.5
11/21/23 0.1 0.2 0.4 1.0 3.0
26 0.1 0.3 0.8 2.0 5.0
P max. 10 12 24 40 100
Schaltdifferenz [bar]: fester Wert, nicht einstellbar

Différentiel de l’interrupteur [bar]: valeur fixe, non ajustable
Switching differential [bar]: fixed value, not adjustable
Elektrische Daten Schalter / Spécifications électriques de l‘interrupteur / Electrical data switch
Typ Merkmale Schaltleistung 5)

Type Caractéristiques Pouvoir de coupure
Type Features Rating
AC DC
10 Kleine Schaltdifferenz (nicht geeignet für Anwendungen unter Vibration) 125 V 10 (1.5) A 250 V 0.2 (0.02) A
Interrupteur à petit différentiel (pas approprié pour applications sous vibrations) 250 V 10 (1.25) A 125 V 0.4 (0.03) A
Small switching differential (not suitable for applications under vibrations) 30 V 2 (1) A
14 V 15 (2.5) A
11 Mittlere Schaltdifferenz 125 V 15 (1.5) A 250 V 0.25(0.03) A
Interrupteur à moyen différentiel 250 V 15 (1.25) A 125 V 0.5(0.05) A
Average switching differential 500 V 10 (0.75) A 30 V 6 (1.5) A
14 V 15 (2.5) A
23 Erhöhte Vibrationsfestigkeit; mittlere Schaltdifferenz
125 V 15 (1.5) A 250 V 0.3(0.05) A
Résistance de vibration élevée; interrupteur à moyen différentiel
250 V 15 (1.25) A 125 V 0.75(0.1) A
Improved vibration resistance; average switching differential
500 V 10 (0.75) A 30 V 15 (1.5) A
14 V 15 (1.5) A

26 Hohe Vibrationsfestigkeit; mittlere Schaltdifferenz
125 V 15 (1.5) A 250 V 0.3(0.2) A
Résistance de vibration forte; interrupteur à moyen différentiel
250 V 15 (1.25) A 125 V 0.75(0.4) A
High vibration resistance; average switching differential
500 V 10 (0.75) A 30 V 15 (1.5) A
14 V 15 (1.5) A

21 Mit Goldkontakten 24 V 0.1(0.1)A 24 V 0.1(0.1)A
Avec contacts dorés 12 V 1 (1.0) A 12 V 1.0 (1.0) A
Gold plated contacts 5 V 2 (2.0) A 5 V 2.0 (2.0) A
Ohmsche Last
5)
(Induktive Last)
Charge ohmique (Charge inductive)
Resistive Load (Inductive Load)
Schalter/ Interrupteur/ Switch 10/11/23 Schalter/ Interrupteur/ Switch 21/26
File: H72252n Page: 4 (5) Date: 03/2013
478/658
900/904/912
pressostat p/ps
Massbilder / Cotes d‘encombrement / Dimensions

X voir spécification H72271
G1/2“ G1/4“
aussen/mâle/male innen/femelle/female
siehe Datenblatt
see data sheet
900.XX.XX.XXX.XX.XX 904.XX.XX.XXX.XX.XX 912.XX.XX.XXX.XX.XX
Befestigung / Fixation / Mounting Zubehör / Accessoires / Accessories
2x
Ø
7
SW24
103
M20x1.5
27.5
Cable-Ø:
5...10
XXX.XX.XX.XXX.XX.07 XXX.XX.XX.XXX.XX.27 XXX.XX.XX.XXX.XX.40

XXX.XX.XX.XXX.31.XX M20x1.5 M24x1.5 M18x1.5
Trafag AG, Industriestrasse 11, CH-8608 Bubikon, Tel +41 44 922 32 32, Fax +41 44 922 32 33, www.trafag.com
File: H72252n Page: 5 (5) Date: 03/2013
479/658

480/658
1440013 /12
IM-S02-13
ST Issue 12
FT14
Ball Float Steam Trap ½" (DN15) to 1" (DN25)
Installation and Maintenance Instructions
1. Safety information
2. General
product information
3. Installation
4. Commissioning
5. Operation
6. Maintenance
7. Spare parts
Printed in theST
IM-S02-13 UKIssue 12 © Copyright 20071
481/658
2 482/658 IM-S02-13 ST Issue 12
1. General safety information
Safe operation of this product can only be guaranteed if it is properly installed,
commissioned, used and maintained by qualified personnel (see Section 1.11)
in compliance with the operating instructions. General installation and safety
instructions for pipeline and plant construction, as well as the proper use of tools
and safety equipment must also be complied with.
1.1 Intended use

Referring to the Installation and Maintenance Instructions, name-plate and Technical
Information Sheet, check that the product is suitable for the intended use/application.
This product complies with the requirements of the European Pressure Equipment
Directive 97 / 23 / EC and falls within Category 'SEP'. It should be noted that products
within this category are required by the Directive not to carry the mark.
i) This product has been specifically designed for use on steam, air or water/
condensate which are in Group 2 of the above mentioned Pressure Equipment
Directive. The products’ use on other fluids may be possible but, if this is
contemplated, Spirax Sarco should be contacted to confirm the suitability of
the product for the application being considered.
ii) Check material suitability, pressure and temperature and their maximum and
minimum values. If the maximum operating limits of the product are lower than
those of the system in which it is being fitted, or if malfunction of the product
could result in a dangerous overpressure or overtemperature occurrence, ensure
a safety device is included in the system to prevent such over-limit situations.
iii) Determine the correct installation situation and direction of fluid flow.
iv) Spirax Sarco products are not intended to withstand external stresses that may
be induced by any system to which they are fitted. It is the responsibility of the
installer to consider these stresses and take adequate precautions to minimise
them.
v) Remove protection covers from all connections and protective film from all
name-plates, where appropriate, before installation on steam or other high
temperature applications.
1.2 Access
Ensure safe access and if necessary a safe working platform (suitably guarded)
before attempting to work on the product. Arrange suitable lifting gear if required.
1.3 Lighting
Ensure adequate lighting, particularly where detailed or intricate work is required.
1.4 Hazardous liquids or gases in the pipeline

Consider what is in the pipeline or what may have been in the pipeline at some
previous time. Consider: flammable materials, substances hazardous to health,
extremes of temperature.
1.5 Hazardous environment around the product

Consider: explosion risk areas, lack of oxygen (e.g. tanks, pits), dangerous gases,
extremes of temperature, hot surfaces, fire hazard (e.g. during welding), excessive
noise, moving machinery.
IM-S02-13 ST Issue 12 483/658 3

1.6 The system
Consider the effect on the complete system of the work proposed. Will any proposed
action (e.g. closing isolation valves, electrical isolation) put any other part of the
system or any personnel at risk?
Dangers might include isolation of vents or protective devices or the rendering
ineffective of controls or alarms. Ensure isolation valves are turned on and off in a
gradual way to avoid system shocks.
1.7 Pressure systems

Ensure that any pressure is isolated and safely vented to atmospheric pressure.
Consider double isolation (double block and bleed) and the locking or labelling of
closed valves. Do not assume that the system has depressurised even when the
pressure gauge indicates zero.
1.8 Temperature
Allow time for temperature to normalise after isolation to avoid danger of burns.
1.9 Tools and consumables

Before starting work ensure that you have suitable tools and/or consumables
available. Use only genuine Spirax Sarco replacement parts.
1.10 Protective clothing

Consider whether you and/or others in the vicinity require any protective clothing
to protect against the hazards of, for example, chemicals, high/low temperature,
radiation, noise, falling objects, and dangers to eyes and face.
1.11 Permits to work

All work must be carried out or be supervised by a suitably competent person.
Installation and operating personnel should be trained in the correct use of the
product according to the Installation and Maintenance Instructions.
Where a formal 'permit to work' system is in force it must be complied with. Where
there is no such system, it is recommended that a responsible person should know
what work is going on and, where necessary, arrange to have an assistant whose
primary responsibility is safety.
Post 'warning notices' if necessary.
1.12 Handling
Manual handling of large and/or heavy products may present a risk of injury. Lifting,
pushing, pulling, carrying or supporting a load by bodily force can cause injury
particularly to the back. You are advised to assess the risks taking into account the
task, the individual, the load and the working environment and use the appropriate
handling method depending on the circumstances of the work being done.
1.13 Residual hazards

In normal use the external surface of the product may be very hot. If used at the
maximum permitted operating conditions the surface temperature of some products
may reach temperatures in excess of 250°C (482°F).
Many products are not self-draining. Take due care when dismantling or removing
the product from an installation (refer to 'Maintenance instructions').
4 484/658 IM-S02-13 ST Issue 12

1.14 Freezing
Provision must be made to protect products which are not self-draining against
frost damage in environments where they may be exposed to temperatures below
freezing point.
1.15 Disposal
Unless otherwise stated in the Installation and Maintenance Instructions, this
product is recyclable and no ecological hazard is anticipated with its disposal
providing due care is taken.
1.16 Returning products

Customers and stockists are reminded that under EC Health, Safety and Environment
Law, when returning products to Spirax Sarco they must provide information on
any hazards and the precautions to be taken due to contamination residues or
mechanical damage which may present a health, safety or environmental risk. This
information must be provided in writing including Health and Safety data sheets
relating to any substances identified as hazardous or potentially hazardous.
IM-S02-13 ST Issue 12 485/658 5

2. General product information
2.1 General description
The FT14 is an SG iron bodied ball float steam trap having stainless steel working
internals and integral automatic air venting facility. It can be maintained without disturbing
the pipework and is supplied with either horizontal screwed or flanged connections with
flow from right to left (R-L) or left to right (L-R). The screwed version is also available with
vertical connections (FT14V) with flow vertically downwards.
Capsule
The BP99/32 capsule which is used in the FT14 ball float steam trap is suitable for use
on 150°C superheat @ 0 bar g and 50°C superheat @ 32 bar g.
Optional extras
A manually adjustable needle valve (designated 'C' on the nomenclature i.e. FT14-C)
can be fitted to the trap. This option provides a steam lock release (SLR) feature in
addition to the standard air vent. For further information please consult Spirax Sarco.
The FT14 has the option of an integral strainer screen (designated 'X' on the nomenclature
i.e. FT14-X).
Standards
This product fully complies with the requirements of the European Pressure Equipment
Directive 97 / 23 / EC.
Certification
This product is available with a manufacturers’ Typical Test Report. Note: All certification /
inspection requirements must be stated at the time of order placement.
Note: For additional product data see the following Technical Information sheets TI-S02-03
and TI-S02-26.
2.2 Sizes and pipe connections

½", ¾" and 1" screwed BSP or NPT.
DN15, DN20 and DN25 standard flange EN 1092 PN16, ANSI 150 and JIS / KS 10.
6 486/658 IM-S02-13 ST Issue 12

Fig. 1
FT14 (R-L) screwed
Main valve assembly size

DN25 (1")
Fig. 2
FT14-C (R-L) screwed
Fig. 3
FT14 (R-L) flanged
Fig. 4
FT14-C (R-L) flanged
IM-S02-13 ST Issue 12 487/658 7

2.3 Pressure /temperature limits (ISO 6552)
Pressure psi g
� ��
Temperature °C ��
Temperature °F
��
��
�� Steam
saturation ��
�� curve
��
�
� � � � � ��
Pressure bar g
The product must not be used in this region.
Body design conditions PN16

PMA Maximum allowable pressure 16 bar g @ 100°C (232 psi g @ 212°F)
TMA Maximum allowable temperature 250°C @ 13 bar g (482°F @ 188 psi g)
Minimum allowable temperature -10°C (14°F)
Maximum operating pressure
PMO 14 bar g (203 psi g)
for saturated steam service
TMO Maximum operating temperature 250°C @ 13 bar g (482°F @ 188 psi g)
Minimum operating temperature 0°C (32°F)
Maximum FT14-4.5 4.5 bar (65.25 psi)
PMX differential FT14-10 10 bar (145 psi)
pressure FT14-14 14 bar (203 psi)
Designed for a maximum
24 bar g (348 psi g)
cold hydraulic test pressure of:
8 488/658 IM-S02-13 ST Issue 12

3. Installation
Note: Before actioning any installation observe the 'Safety information' in Section 1.
Refering to the Installation and Maintenance Instructions, name-plate and Technical
Information Sheet, check that the product is suitable for the intended installation.
3.1 Check materials, pressure and temperature and their maximum values. If the maximum
operating limit of the product is lower than that of the system in which it is being fitted,
ensure that a safety device is included in the system to prevent overpressurisation.
3.2 Determine the correct installation situation and the direction of fluid flow.
3.3 Remove protective covers from all connections and the protective film from all
name-plates, where appropriate, before installation on steam or other high
temperature applications.
Installation note:
- If the trap is to discharge to atmosphere ensure it is to a safe place, the discharging
fluid may be at a temperature of 100°C (212°F).
- The trap must be fitted with the float arm in a horizontal plane so that it rises and
falls vertically, therefore the arrow on the name-plate must point downwards.
- Unless specified, traps will be supplied with horizontal connections and
with right to left flow (R-L). Traps can be supplied with vertical connections with
flow from top to bottom or horizontal connections with flow from right to left (R-L) or
left to right (L-R).
- The connection orientation can be changed on site by undoing the four cover bolts and
moving the cover to the preferred orientation. A new gasket must always be fitted.
- Minimum withdrawal distance to remove cover is 105 mm (4.13").
Installation of the manually adjustable needle valve (SLR - steam lock release feature)
3.4 The manually adjustable needle valve is fitted to all float traps where a suffix 'C' is
hard stamped on the name-plate e.g. FT14-10C. 'C' = Combined steam lock release
feature and thermostatic air vent.
3.5 Check if the application requires the manually adjustable needle valve for correct
operation. The manually adjustable needle valve should only be used to prevent 'steam
locking' and therefore is designed to pass only a small amount of steam.
3.6 The manually adjustable needle valve will be dispatched, pre-set to a partial bleed
condition. The unit should be screwed clockwise to close and anticlockwise to open.
When required the SLR should be used as a controlled continuous bleed, it is not
recommended that the SLR be left in the fully open condition as this may lead to
premature trap failure and more frequent maintenance schedules.
Warning
The cover gasket contains a thin stainless steel support ring which may cause physical
injury if not handled and disposed of carefully.
Please consult Spirax Sarco should further information be required.
IM-S02-13 ST Issue 12 489/658 9

4. Commissioning
After installation or maintenance ensure that the system is fully functioning. Carry out tests
on any alarms or protective devices.
5. Operation
The float trap is a continuous discharge trap, removing condensate the instant it forms.
On start-up, the thermostatic air vent allows air to bypass the main valve preventing the system
air binding. Hot condensate will close the air vent tightly, but as soon as it enters the main
chamber of the trap, the float rises and the lever mechanism attached to it opens the main
valve - keeping the system drained of condensate at all times. When steam arrives, the float
drops and closes the main valve. Float traps are renown for their high start-up load handling
capability, clean tight shut-off and resistance to waterhammer and vibration.
6. Maintenance
Note: Before actioning any maintenance program observe
the 'Safety information' in Section 1.
Warning
The cover gasket contains a thin stainless steel support ring which may
cause physical injury if not handled and disposed of carefully.
6.1 General information:

Before undertaking any maintenance on the trap it must be isolated from both the supply
line and return line and any pressure allowed to safely normalise to atmosphere. The trap
should then be allowed to cool. When reassembling, ensure that all joint faces are clean.
6.2 How to fit the main valve assembly:

- Undo the cover bolts (2) and lift off the body (1).
- Remove the complete float assembly by undoing the two screws (7).
- Remove the main valve seat (5) and replace with a new one supplied with new gasket.
Note: A valve spring (item 28) is fitted to the DN25 (1") traps only.
- Fit a complete new float assembly by tightening the assembly set screws (7) to the
recommended torque (see Table 1).
- Refit the body (1) using a new gasket (3).
6.3 How to fit the air vent assembly:

- Remove the spring clip, element and spacer plate (17).
- Unscrew the seat.
- Fit a new gasket, seat and frame.
- Assemble the spacer plate, fit element and clips.
- Align the complete air vent horizontally so that the frame clears the cover.
10 490/658 IM-S02-13 ST Issue 12

6.4 How to fit the Steam Lock Release (SLR) assembly:
- Unscrew the complete SLR assembly (19) and (21).
- Remove the SLR gasket (20).
- Replace the SLR assembly and gasket with new ones.
- Reset the SLR to the desired bleed rate.
Table 1 Recommended tightening torques
or
Item Nm (lbf ft)
mm
2 17 A /F M10 x 30 47 - 50 (35 - 37)
5 17 A /F 50 - 55 (37 - 40)
7 Pozidrive M4 x 6 2.5 - 3.0 (1.8 - 2.2)
17 17 A /F 50 - 55 (37 - 40)
19 + 21 19 A /F 50 - 55 (37 - 40)
Steam lock release Air vent

assembly assembly
19 + 21 20 1 18 17 3
Frame
Seat
2 6 5 11 10 7 28 8 3
Main valve assembly
Note: Item 28 is required for the DN25 (1") size only
Fig. 6
IM-S02-13 ST Issue 12 491/658 11

7. Spare parts
The spare parts available are shown in solid outline. Parts drawn in broken line are not
supplied as spares.
Available spares
Main valve assembly with float 3, 5, 6, 7 (2 off), 8, 10, 11, 16 (1" only)
Air vent assembly 3, 17, 18
Steam lock release unit and air vent assembly (FT14C only) 3, 17, 18, 19, 20, 21
Cover gasket (packet of 3) 3
Maintenance kit 3, 5, 6, 7 (2 off), 8, 10, 11, 17, 18, 28 (1" only)
How to order spares

Always order spares by using the description given in the column headed 'Available spares'
and state the size and type of trap.
Example: 1 - Air vent assembly for a Spirax Sarco DN20 FT14-10 (R - L) ball float steam trap.
Steam lock release Air vent

assembly assembly
19 + 21 20 1 18 17 3
2 6 5 11 10 7 28 8 3
Main valve assembly
Note: Item 28 is required for the DN25 (1") size only
Fig. 7
12 492/658 IM-S02-13 ST Issue 12

Page 1 of 3
TI-S02-03
ST Issue 9
Cert. No. LRQ 0963008 FT14

ISO 9001
Ball Float Steam Trap
(Screwed)
Description
The FT14 is an SG iron bodied ball float steam trap having stainless
steel working internals and integral automatic air venting facility.
The FT14 can be maintained without disturbing the pipework. FT14-C (R-L) 20
19
Available types
21
FT14 (R-L) Horizontal connections with flow from right to left
FT14 (L-R) Horizontal connections with flow from left to right
FT14V Vertical connections with flow downwards
Capsule 8 4 17 6 3
The BP99/32 capsule which is used in the FT14 is suitable for use
on 150°C superheat @ 0 bar g and 50°C superheat @ 32 bar g.
Optional extras
A manually adjustable needle valve (designated 'C' on the
nomenclature i.e. FT14-C) can be fitted to the trap. This option
provides a steam lock release (SLR) feature in addition to
the standard air vent. For further information please consult 2
Spirax Sarco.
The FT14 has the option of an integral strainer screen
(designated 'X' on the nomenclature i.e. FT14-X). 1
Standards
This product fully complies with the requirements of the
European Pressure Equipment Directive 97 / 23 / EC.
Certification 7
This product is available with a manufacturers’ Typical Test Report.
Note: All certification/inspection requirements must be stated at 5
the time of order placement.
6
Sizes and pipe connections
½", ¾" and 1" screwed BSP or NPT.
Pressure /temperature limits (ISO 6552) 28 12

11 10 FT14 (R-L)
��
Temperature °C
��
�� Main valve assembly 1"
�� Steam
saturation Materials
�� curve No. Part Material
� * 1 Body SG iron DIN 1693 GGG 40
� � � � � ��
Pressure bar g 2 Cover bolts Steel BS 3692 Gr.8.8
3 Cover gasket Reinforced exfoliated graphite
The product must not be used in this region. 4 Cover SG iron DIN 1693 GGG 40
Body design conditions PN16 5 Valve seat Stainless steel BS 970 431 S29
PMA Maximum allowable pressure 16 bar g @ 100°C 6 Valve seat gasket Stainless steel BS 1449 409 S19
TMA Maximum allowable temperature 250°C @ 13 bar g 7 Pivot frame assembly screws Stainless steel BS 6105 Cl A2-70
Minimum allowable temperature -10°C 8 Ball float and lever Stainless steel BS 1449 304 S16
Maximum operating pressure 10 Pivot frame Stainless steel BS 1449 304 S16
PMO 14 bar g
for saturated steam service 11 Pivot pin Stainless steel
TMO Maximum operating temperature 250°C @ 13 bar g 12 Erosion deflector (1" only) Stainless steel BS 970 431 S29
*
Minimum operating temperature 0°C 17 Air vent assembly Stainless steel
Maximum FT14-4.5 4.5 bar 18 Air vent gasket Stainless steel BS 1449 409 S19
PMX differential FT14-10 10 bar 19 SLR assembly Stainless steel BS 970 303 S21
pressure FT14-14 14 bar 20 SLR gasket Stainless steel BS 1449 304 S16
Designed for a maximum cold hydraulic test pressure of 24 bar g 21 SLR seal Graphite
28 Valve spring (1" only) Stainless steel BS 2056 302 S26
* Note: Item 12 is pressed into item 1 (1" only).
Local regulations may restrict the use of this product to below the conditions quoted.
In the interests of development and improvement of the product, we reserve the right to change the specification without notice. © Copyright 2007
493/658
Page 2 of 3
Capacities
� ��
� ��
�
��
� ��
��
��
��
��
��
��
��
�
��
� ��
��
��
Condensate kg /h
��
��
��
��
�
��
� ��
��
��
��
� ��
�
��
� ��
��
��
��
��
��
��
��
Differential pressure bar (x 100 = kPa)
Capacities shown above are based on condensate at saturation temperature. When discharging sub-cooled condensate the air vent provides
extra capacity. Under start-up conditions when the condensate is cold the internal thermostatic air vent will be open and provides additional
capacity to the main valve. On 4.5 bar units this will provide a minimum of 50% increased capacity above the hot condensate figures shown.
On 10 and 14 bar units this will be a minimum increase of 100% on the published capacity. The following table gives the minimum additional
cold water capacities from the air vent.
P (bar) 0.5 1 2 3 4.5 7 10 14

Minimum additional cold water capacity (kg / h)
½" and ¾" 70 140 250 380 560 870 1 130 1 500
1" 120 240 360 500 640 920 1 220 1 500
FT14 Ball Float Steam Trap (Screwed) TI-S02-03 ST Issue 9
494/658
Page 3 of 3
Dimensions /weights (approximate) in mm and kg

E
Size A B B1 C D F Weight
Withdrawal distance
½" 121 107 96 67 147 105 30 2.9
¾" 121 107 96 67 147 105 30 2.9
1" 145 107 117 75 166 110 23 4.0
A D
C
F
FT14-C
B B1
Safety information, installation and maintenance

For full details see the Installation and Maintenance Instructions (IM-S02-13) supplied with the product.
Installation note:
The FT14 must be installed with the direction of flow as indicated on the body, and with the float arm in a horizontal plain so that it rises and
falls vertically. If required the flow orientation can be changed on site.
Disposal
This product is recyclable. No ecological hazard is anticipated with the disposal of this product providing due care is taken.
How to order
Example: 1 off Spirax Sarco ½" FT14-4.5 (R-L) ball float steam trap with screwed BSP connections and integral air vent.
Spare parts
The spare parts available are shown in solid outline. Parts drawn in broken line are not supplied as spares.
Available spares
Main valve assembly with float 3, 5, 6, 7 (2 off), 8, 10, 11, 16 (1" only)
Air vent assembly 3, 17, 18
Steam lock release and air vent assembly 3, 17, 18, 19, 20, 21
Cover gasket (packet of 3) 3
Maintenance kit 3, 5, 6, 7 (2 off), 8, 10, 11, 17, 18, 28 (1" only)
How to order spares
Always order spares by using the description given in the column headed 'Available spares' and state the size, type of trap and
pressure range.
Example: 1 - Main valve assembly for a Spirax Sarco ½" FT14-10 ball float steam trap.
Steam lock
release assembly Air vent assembly Recommended tightening torques
19 + 21 20 18 17 3 or
Item Nm
mm
2 17 A / F M10 x 30 47 - 50
5 17 A / F 50 - 55
7 Pozidrive M4 x 6 2.5 - 3.0
17 17 A / F 50 - 55
19 and 21 19 A / F 50 - 55
2 6 5 11 10 7 28 8 3
Main valve assembly

Note: Item 28 is required for 1" size only
FT14 Ball Float Steam Trap (Screwed) TI-S02-03 ST Issue 9
495/658

496/658
Operating and installation instructions
Strainer
Contents
1.0 General information on operating 6.0 Putting the valve into operation ..................6
instructions ................................................... 2 7.0 Care and maintenance..................................6
2.0 Notes on possible dangers.......................... 2 8.0 Troubleshooting ............................................7
2.1 Significance of symbols ........................................2 9.0 Troubleshooting table ..................................7
2.2 Explanatory notes on safety information ...............2 10.0 Dismantling the valve or the top part .......8
3.0 Storage and transport ................................. 2 11.0 Warranty / Guarantee ..................................8
4.0 Description .................................................... 3 12.0 EC declaration of conformity .....................9
4.1 Scope of applications ............................................3
4.2 Operating principles ..............................................3
4.3 Diagram.................................................................4
4.4 Technical data - remarks .......................................4
4.5 Marking .................................................................5
5.0 Installation..................................................... 5
5.1 General notes on installation.................................5
5.2 Installing valves with butt weld ends .....................6
Rev. 0040101000 0410 englisch

497/658
Strainer
1.0 General information on operating instructions

These operating instructions provide information on mounting and maintaining the fittings.
Please contact the supplier or the manufacturer in case of problems which cannot be
solved by reference to the operating instructions.
They are binding on the transport, storage, installation, start-up, operation, maintenance
and repair.
The notes and warnings must be observed and adhered to.
- Handling and all work must be carried out by expert personnel or all activities must be
supervised and checked.
It is the owner’s responsibility to define areas of responsibility and competence and to
monitor the personnel.
- In addition, current regional safety requirements must be applied and observed when
taking the fittings out of service as well as when maintaining and repairing them.
The manufacturer reserves the right to introduce technical modifications at any time.
These Operating Instructions comply with the requirements of EU Directives.
2.0 Notes on possible dangers
2.1 Significance of symbols
ATTENTION !
... Warning of general danger.
2.2 Explanatory notes on safety information

In these Operating and Installation Instructions dangers, risks and items of safety
information are highlighted to attract special attention.
Information marked with the above symbol and “ATTENTION ! ” describe practices, a
failure to comply with which can result in serious injury or danger of death for users or third
parties or in material damage to the system or the environment. It is vital to comply with
these practices and to monitor compliance.
All other information not specifically emphasised such as transport, installation, operating
and maintenance instructions as well as technical data (in the operating instructions,
product documentation and on the device itself) must also be complied with to the fullest
extent in order to avoid faults which in turn can cause serious injury to persons or damage
to property.

ATTENTION !
- Protect against external force (like impact, vibration, etc.).
- Valve mountings such as actuators, handwheels, hoods must not be used to
take external forces, e.g. they are not designed for use as climbing aids, or as
connecting points for lifting gear.
- Suitable materials handling and lifting equipment should be used.
See catalog sheet for weights.
- At -20°C to +65°C.
- The paint is a base coat to protect against corrosion during transportation and storage. Do
not damage paint protection.
Page 2 Rev. 0040101000 0410

498/658
Strainer
4.0 Description
4.1 Scope of applications
Strainers are used for "cleanin flowing mediums“.
ATTENTION !
- Refer to the data sheet for applications, limits on use and possibilities.
- Certain media require or preclude the use of special materials.
- The valves are designed for standard operating conditions. If conditions exceed
these requirements, e.g. aggressive or abrasive media, the operator should
state the higher requirements when ordering.
- Valves made from grey cast iron are not authorised for use in systems subject
to TRD 110.
The information complies to the Pressure Equipment Directive 97/23/EC.
It is the responsibility of the machine planner to ensure compliance.
The special markings on the valve must be taken into account.
Refer to the catalogue sheet to see which materials are used in standard versions.
Please contact the supplier or the manufacturer if you have any questions.
4.2 Operating principles

The medium flows through the strainer screen in the direction shown on the strainer and is
thereby cleaned.
Rev. 0040101000 0410 Page 3

499/658
Strainer
4.3 Diagram
rotated
rotated view
view
fig. 1: Strainer - Y fig. 2: Strainer - Y SE
rotated
view
fig. 3: Strainer - Y (1.4408)

Refer to the data sheet for information about materials with designations and figure
numbers.
4.4 Technical data - remarks

for
- Principal dimensions
- Pressure-temperature-ratings
- Valves with butt weld ends, etc. refer to datasheet.
Page 4 Rev. 0040101000 0410

500/658
Strainer
4.5 Marking
Details of the CE-marking on the valve:
CE-marking
0525 Notified body
Manufacturer Address of manufacturer:
Typ Type refer to item 11.0 Warranty / Guarantee
Bj. Year of manufacture
According to the Pressure Equipment Directive table 6, annex II, valves without safety
function are only allowed to bear the CE-marking DN32 onwards.
5.0 Installation
5.1 General notes on installation
The following points should be taken into account besides the general principles governing
installation work:
ATTENTION !
- Remove flange covers if present.
- The interior of valve and pipeline must be free from foreign particles.
- Note installation position with reference to flow direction, see mark on valve.
- Steam line systems should be designed to prevent water accumulation.
- Lay pipelines so that damaging transverse, bending and torsional forces are avoided.
- Protect valves from dirt during construction work.
- Connection flanges must mate exactly.
- Connecting bolts for pipe flanges should be mounted preferably from the
counter flange side (hexagon nuts from the valve side).
At DN15-32: If valves should be mounted directly to valves, the upper flange
connecting bolts should be preferably executed with studs and hexagon nuts on
both sides.
See data sheet for weights.
- Leave sufficient space to remove the screen basket during installation in
pipelines.
- Installation position:
a) The screen basket should never be at the top, otherwise the dirt will
fall back into the pipe.
b) If water hammer is possible due to condensation in steam lines,
never install the trap with the screen basket at the bottom, but install
it so that it is horizontal.
- Centre gaskets between the flanges.
- Install compensators to compensate for thermal expansion of the piping.
- Planners / construction companies or operators are responsible for positioning and
installing products.
- The valves are designed for application, not influenced from weather.
Rev. 0040101000 0410 Page 5

501/658
Strainer
- For application outside or in adverse environments like corrosion-promoting conditions
(sea water, chemical vapours, etc.), special constructions or protective measures are
recommended.
5.2 Installing valves with butt weld ends

Please note that only qualified persons using appropriate equipment and working in
accordance with technical rules are allowed to install fittings by welding.
The responsibility for this lies with the system owner.
Refer to the data sheet for information about the shape of the butt weld ends.
6.0 Putting the valve into operation
ATTENTION !
- Before putting the valve into operation, check material, pressure, temperature
and direction of flow.
- Regional safety instructions must be adhered to.
- Residues in piping and valves (dirt, weld beads, etc.) inevitably lead to leakage.
- Touching the valve when it is operating at high (> 50°C) or low (< 0°C) media
temperatures can cause injury.
Affix warning notice or protective insulation as appropriate!
Before putting a new plant into operation or restarting a plant after repairs or
modification, always make sure that:
- All works has been completed!
- The valve is in the correct position for its function.
- Safety devices have been attached.
7.0 Care and maintenance

The strainer screens must be cleaned regularly. Maintenance and maintenance-intervals
have to be defined by the operator and depends on the degree of dirt accumulation in the
system.
- If necessary, the strainer can be fitted with an additional start-up filter (e.g. filter with
supporting basket) to start up the system.
- Flush the plant thoroughly before starting it.
- The strainer requires little maintenance.
ATTENTION !
Refer to point 10.0 before opening the strainer.
- Contaminated strainers in suction-lines will result cavitation and damage the
pumps.
- Before reassembling the unit, remember that the bearing surface must be cleaned and a
new gasket (pos. 6) must be inserted.
- Set the strainer cover (pos. 2) in place.
- Tighten the hexagon nuts (pos. 4) evenly crosswise.
Page 6 Rev. 0040101000 0410

502/658
Strainer
Tightening torque‘s for hexagon nuts / bolts:
hexagon nuts / Torque
DN
bolts (Nm)
15- 32 M 10 20-35
40 M 12 20-35
50- 65 M 12 60-80
80-150 M 16 100-125
200 M 20 150-200
250-400 M 24 340-410
500 M 27 340-410
8.0 Troubleshooting
In the event of malfunction or faulty operating performance check that the installation and
adjustment work has been carried out and completed in accordance with these Operating
Instructions.
ATTENTION !
-
It is essential that the safety regulations are observed when identifying faults.
If malfunctions cannot be eliminate with the help of the following table

“9.0 troubleshooting table”, the supplier or manufacturer should be consulted.
9.0 Troubleshooting table

ATTENTION !
- read point 10.0 and 11.0 prior to dismantling and repair work!
- read point 6.0 before restarting the plant !
Fault Possible cause Corrective measures

No flow Flange covers have not been removed Remove flange covers
(7, Fig. 3) (7, Fig. 3)
Flow too low strainer clogged. Clean/replace screen.
Piping clogged. Check piping system.
Flange broken between Bolts tightened unevenly. Re-align piping and fit new valve!
unit and piping Mating flanges not properly aligned.
Rev. 0040101000 0410 Page 7

503/658
Strainer
10.0 Dismantling the valve or the top part

ATTENTION !
The following points must be observed:
- Pressureless pipe system.
- Medium must be cool.
- Plant must be drained.
- Purge piping systems in case of caustic, inflammable, aggressive or toxic
media.
11.0 Warranty / Guarantee

The extent and period of warranty cover are specified in the "Standard Terms and
Conditions of Albert Richter GmbH & Co. KG" valid at the time of delivery or, by way of
departure, in the contract of sale itself.
We guarantee freedom of faults in compliance with state-of-the-art technology and the
confirmed application.
No warranty claims can be made for any damage caused as the result of incorrect handling
or disregard of operating and installation instructions, datasheets and relavant regulations.
This warranty also does not cover any damage which occurs during operation under
conditions deviating from those laid down by specifications or other agreements.
Justified complaints will be eliminated by repair carried out by us or by a specialist
appointed by us.
No claims will be accepted beyond the scope of this warranty. The right to replacement
delivery is excluded.
The warranty shall not cover maintenance work, installation of external parts, design
modifications or natural wear.
Any damage incurred during transport should not be reported to us but rather to the
competent cargo-handling depot, the railway company or carrier company immediately or
else claims for replacements from these companies will be invalidated.
Technology for the Future.

GERMAN QUALITY VALVES
ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schloß Holte-Stukenbrock
Telephone (+49 5207) 994-0 Telefax (+49 5207) 994-158 or 159
Internet: http://www.ari-armaturen.com E-mail: info.vertrieb@ari-armaturen.com
Page 8 Rev. 0040101000 0410

504/658
Strainer
12.0 EC declaration of conformity

ARI-Armaturen Albert Richter GmbH & Co. KG,
Mergelheide 56-60, D-33756 Schloß Holte-Stukenbrock
im Sinne der
EG-Druckgeräterichtlinie 97/23/EG und
Hiermit erklären wir,
dass gemäß der oben genannten Druckgeräterichtlinie die nachfolgend aufgelisteten Pro-
dukte ausgeführt sind und nach Diagramm 6, Anhang II, Modul H der Druckgeräterichtlinie
von Lloyd´s Register Quality Assurance GmbH (BS-Nr. 0525), Am Sandtorkai 41,
D-20457 Hamburg, geprüft wurden.
Zertifikat-Nr: 50003/1
Schmutzfänger
Typ 050, 059, 080
Angewendete Normen:
DIN 3840
AD 2000 Merkblatt A4
- Gusseisen mit Kugelgraphit
- Stahlguss
- Schmiedestahl
Schloß Holte-Stukenbrock, den 11.01.2010
..................................................
(Brechmann, Geschäftsführer)
Rev. 0040101000 0410 Page 9

505/658
ARI-Strainer
Fig. 050
Strainer - Y-pattern with flanges (Grey cast iron, SG iron, Cast steel)
Figure Nominal pressure Material Nominal diameter

10.050 PN6 EN-JL1040 DN15-200
12.050 PN16 EN-JL1040 DN15-300
22.050 PN16 EN-JS1049 DN15-300
23.050 PN25 EN-JS1049 DN15-150
34.050 PN25 1.0619+N DN15-200
35.050 PN40 1.0619+N DN15-200
A supporting basket is necessary, with higher differential pressures, dependent on
clogging-up (DN >125 standard)
Test: • German TA - Luft TÜV-Test-No. 922-9204866
Selection of possible applications
Industry, power stations, flue gas purification plant, vapour facilities, recycling facilities,
shipbuilding, general plant manufacturing
(other applications on request)
Selection of possible flow media
Steam, gases, liquids, etc.
(other flow media on request)
Parts
Pos. Description Fig. 10./12.050 Fig. 22./23.050 Fig. 34./35.050
1 Body EN-JL1040, EN-GJL-250 EN-JS1049, EN-GJS-400-18U-LT GP240GH+N, 1.0619+N
2 Cover DN ≤150: EN-JL1040, EN-GJL-250 DN ≤65: EN-JS1049, EN-GJS-400- DN ≤65: P250 GH, 1.0460
DN >150: P265 GH, 1.0425 18U-LT DN >65: P265 GH, 1.0425
DN >65: P265 GH, 1.0425
3 Screen * X5CrNi18-10, 1.4301
3.1 Supporting basket DN >125: X5CrNi18-10, 1.4301
4 Stud 25CrMo4, 1.7218
5 Hexagon nut C35E, 1.1181
6 Gasket * Pure graphite (CrNi laminated with graphite)
* Spare part
Information / restriction of technical rules need to be observed!
Operating instructions can be ordered by phone +49 (0)5207 / 994-0 or fax +49 (0)5207 / 994-158 or -159.
ARI-Valves of EN-JL1040 are not allowed to be operated in systems acc. to TRD 110.
A production allowance acc. to TRB 801 No. 45 exists (acc. to TRB 801 No. 45 EN-JL1040 is not allowed.)
The engineer, designing a system or a plant, is responsible for the selection of the correct valve.
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600 730 850
H (mm) 90 100 115 125 150 160 180 215 235 275 305 390 540 680
H1 (mm) 135 150 180 205 235 250 285 330 365 425 480 610 915 1110
B (mm) 10 10 25 35 45 45 25 40 55 65 50 80 230 350
l1 (mm) 56 68 82 98 114 119 134 149 169 199 224 284 434 555
Ød1 (mm) 23 28 36 42 50 61,5 78,5 89,5 109,5 137,5 160 210 258 308
on request
Standard screen mesh width (mm) 1 1 1 1 1 1 1,25 1,25 1,6 1,6 1,6 1,6 1,6 1,6 possible in straight
Kvs-value 1) (m3/h) 6,9 10,8 17,8 26,1 36,7 61 98,6 146 234 376 394 652 1225 1873 through form
Zeta-value -- 1,7 2,2 2 2,5 3 2,7 2,9 3,1 2,9 2,8 5,2 6 4,2 3,7
Fine screen mesh width (mm) 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25 0,25
Kvs-value 1) (m3/h) 6,2 10,1 16,8 24,3 32,9 49,5 80,3 115 189 303 405 590 1231 1883
Zeta-value -- 2,1 2,5 2,2 2,8 3,8 4,1 4,4 4,9 4,4 4,5 4,9 7,3 4,1 3,6
Ratio of the free screen surface area to the area of
10 8,4 8,3 7,1 6,8 5,2 4,4 3,7 2,8 2,7 2,4 2,3 2,7 2,9
the nominal diameters.
Zeta-value ... range of tolerance for Kvs-values acc. to VDI/VDE 2173 Standard-flange dimensions refer to page 6
1)
Kvs-values based upon clean screen !
Face-to-face dimension FTF series 1 according to DIN EN 558
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
10.050 (kg) 2,5 3 4,5 5,5 7 9 13 19 26 38 54 110 -- --
12.050 (kg) 3 4 5 7 9 12 16 21 30 43 61 121 154 335 on request
22.050 (kg) 3,5 4 5,5 7 9 12 16 21 28 41 58 115 154 335 possible in straight
23.050 (kg) 3,5 4 5,5 7 9 12 16 21 32 47 64 -- -- -- through form
34./35.050 (kg) 4 5 6 8 10 13 19 24,5 35 51 71 144 -- --
506/658 Edition 12/10 - Data subject to alteration

ARI-Strainer
Flange dimensions / Pressure-temperature-ratings
Standard-flange dimensions Flanges acc. to DIN EN 1092-1/-2 (Flangeholes / -thickness tol. acc. to DIN 2533/2544/2545)
DN (mm) 15 20 25 32 40 50 65 80 100 125 150 200 250 300
PN6 ØD (mm) 80 90 100 120 130 140 160 190 210 240 265 320 -- --
PN6 ØK (mm) 55 65 75 90 100 110 130 150 170 200 225 280 -- --
PN6 n x Ød (mm) 4x11 4x11 4x11 4x14 4x14 4x14 4x14 4x18 4x18 8x18 8x18 8x18 -- --
PN16 ØD (mm) 95 105 115 140 150 165 185 200 220 250 285 340 405 460
PN16 ØK (mm) 65 75 85 100 110 125 145 160 180 210 240 295 355 410
PN16 n x Ød (mm) 4x14 4x14 4x14 4x18 4x18 4x18 4x18 8x18 8x18 8x18 8x22 12x22 12x26 12x26
PN25 ØD (mm) 95 105 115 140 150 165 185 200 235 270 300 360 425 485
PN25 ØK (mm) 65 75 85 100 110 125 145 160 190 220 250 310 370 430
PN40 ØD (mm) 95 105 115 140 150 165 185 200 235 270 300 375 450 515
PN40 ØK (mm) 65 75 85 100 110 125 145 160 190 220 250 320 385 480
Pressure-temperature-ratings acc. to DIN EN 1092-2

Material -60°C to <-10°C* -10°C to 120°C 150°C 200°C 250°C 300°C 350°C 400°C 450°C
EN-JL1040 6 (bar) -- 6 5,4 4,8 4,2 3,6 -- -- --
EN-JL1040 16 (bar) -- 16 14,4 12,8 11,2 9,6 -- -- --
EN-JS1049 16 (bar) on request 16 15,5 14,7 13,9 12,8 11,2 -- --
EN-JS1049 25 (bar) on request 25 24,3 23 21,8 20 17,5 -- --
Pressure-temperature-ratings acc. to manufacturers standard

1.0619+N 25 (bar) 18,7 25 23,9 22 20 17,2 16 14,8 8,2
1.0619+N 40 (bar) 30 40 38,1 35 32 28 25,7 23,8 13,1
1.0460 25 (bar) 18,7 25 23,9 22 20 17,2 16 14,8 10
1.0460 40 (bar) 30 40 38,1 35 32 28 25,7 23,8 16
Pressure-temperature-ratings acc. to DIN EN 1092-1

1.4408 16 (bar) 16 16 14,5 13,4 12,7 11,8 11,4 10,9 --
1.4408 25 (bar) 25 25 22,7 21 19,8 18,5 17,8 17,1 --
1.4408 40 (bar) 40 40 36,3 33,7 31,8 29,7 28,5 27,4 --
Intermediate values for max. permissible operational pressures can be determined by linear interpolation of the given temperature / pressure chart.
* Studs and nuts made of A4-70 (at temperatures below -10°C)
Please indicate when ordering

- Figure-No.
- Nominal pressure
Dimensions in mm
- Nominal diameter
Weights in kg
- Special design / accessories
1 bar =^ 105 Pa =^ 0,1 MPa
Example:
Kvs in m3/h
Figure 35050; nominal pressure PN40; nominal diameter DN100; with bleed screw..

ARI-Armaturen Albert Richter GmbH & Co. KG, D-33756 Schloß Holte-Stukenbrock,
Tel. +49 52 07 / 994-0, Telefax +49 52 07 / 994-158 or 159 Internet: http://www.ari-armaturen.com E-mail: info.vertrieb@ari-armaturen.com

ARI-Y-Strainer
Flow diagram
DN150-300 Standard screen

DN mesh width Zeta-value Kv-value
150 1,6 5,2 394
200 1,6 5,6 652
250 1,6 4,2 1225
300 1,6 3,7 1873
→ Volume flow rate in m3 / h (water)
→ Kv-value in m3 / h
→ ∆p in bar
Pressure drop in Pascal (10 Pascal 1mm WS (1mm WS = 9,8066 Pa) 1bar = 0,1MPa = 105Pa
DN15-40 Fine screen

DN mesh width Zeta-value Kv-value
15 1 +0,25 2,1 6,2
20 1 +0,25 2,5 10,1
25 1 +0,25 2,2 16,8
32 1 +0,25 2,8 24,3
40 1 +0,25 3,8 32,9
→ ∆p in bar

Automatik - Kugelhähne ( pneumatisch )
Automatic - ball valves ( pneumatic )
Baureihe
Zweiteilige Muffenkugelhähne aus Edelstahl AKP 87 E
Two - pieces stainless steel ball valves Rp ½ - Rp 2
PED
-0035
Technische Daten Kugelhahn • technical data ball valve
Material material
Gehäuse: Edelstahl 1.4408 body: stainless steel 1.4408
Kugel: Edelstahl 1.4408 ball: stainless steel 1.4408
Kugeldichtung: PTFE ball seal: PTFE
Schaltwelle: Edelstahl 1.4401 stem: stainless steel 1.4401
Spindeldichtung: PTFE/Viton stem seal: PTFE/viton
Temperaturbereich working temperature
Gas: -20° C bis max. + 60° C gas: - 20° C to max. + 60° C
allgemein: -20° C bis max. + 180° C generally: - 20° C to max. + 180° C
( abhängig vom Betriebsdruck ) ( depending on working pressure )
Achtung: Temperaturbereich des Antriebs beachten! note: temperature range of the actuator!
Verwendung suitable for
Gas, Öle, Druckluft, Wasser, Lösungsmittel, gas, oils, compressed air, water, solvents,
Kraftstoffe, aggressive Medien fuels, aggressive mediums
Zulassungen certification
PED CE-0085 BN 0204 PED CE-0085 BN 0204
DVGW PN16 Variante auf Anfrage DVGW PN16 version on request
Bemerkung remark
Druck-Temperaturdiagramm siehe Datenblatt Kugelhahn Pressure Temperature Chart acc. to data sheet ball valve
Technische Daten Drehantrieb • technical data actuator
Material material
Gehäuse: Aluminium eloxiert body: aluminium anodized
Welle: Stahl, chemisch vernickelt shaft: steel nickel plated
Kolben: Aluminium piston: aluminium
Dichtungen: Perbunan seals: perbunan
- 20° C bis + 90° C - 20° C to + 90° C
Steuermedium operating media
gefilterte Druckluft nach filtered air acc. to Pneurop / ISO class 4
Pneurop / ISO Klasse 4
Stand: Juli 2010 -Technische Änderungen vorbehalten - subject to change (without notice) -
509/658
1.6.66
Besondere Merkmale special features
• Keine Brücke und kein Mitnehmer notwendig. • No bracket and no coupler essential.
Der Antrieb wird direkt auf den Kugelhahn aufgesetzt. The pneumatic actuator will be mounted directly on the ball valve.
• Direkte Anflanschung von Magnetventilen nach Namur ist ab • Direct mounting of magnetic valves per Namur from 42.1 is also
42.1 möglich. ( Fabrikate: Airtec, Festo, Herion ). possible. ( Brands: Airtec, Festo, Herion ).
• Aufbau von Endschalterkästen ist ab DAD42.1 möglich. • suitable for mounting of switch box from DAD42.1.
Bemerkungen remarks
• geeignet für allgemeine Industrie • suitable for industrial purposes
• Die Baugruppe ist so bemessen, dass ein Mindeststeuerdruck • The dimension of the device is calculated with a control
von 6 bar bis max. 10 bar erforderlich ist. pressure rate from 6 bar up to 10 bar.
Auslegung mit kleineren Steuerdrucken auf Anfrage. lower control pressure dimensioning on request.
• Bei nichtschmierenden Medien ( z.B. Wasser ) und bei längerer • For non-greasing mediums (e. g. water) or/and
Stillstandzeit des Hahnes ist es möglicherweise notwendig, den long non working time it´s might be necessary to
nächst größeren Antrieb zu verwenden. In diesem Fall bitten wir choose a bigger actuator size. In this case please contact our
um Rücksprache. technical staff.
• Alle Kugelhähne mit DAD32.1 sind auch mit DAD42.1 lieferbar. • Ball valves with DAD32.1 are available with DAD42.1
• Verschiedene Schaltstellungen siehe Übersichtsblatt Seite 1.3.1 • Different switch positions see table on page 1.3.1
• Weitere technische Angaben siehe Datenblatt DAD/DAE Seite • furter technical details see data sheet DAD/DAE side 1.6.61
1.6.61
A C
ød SW
Bestellangaben ( Beispiel )
R
AKP 87E - 3/4“ - DAD 42.1
h
Baureihe
H
Nennweite
Wirkungsweise DAD = doppelt /
DAE = einfachwirkend
Antriebsgröße
Ordering data ( example )
D
AKP 87E - 3/4“ - DAD 42.1 l
L
series Druckluftanschlüsse und Schaltstellungen

Air pressure connections and valve positions
l = nutzbare Gewindetiefe
diameter AUF / open ZU / closed
l = length of thread
DAD = double / DAD42.1 oben /top thread unten / lower thread
mode of function
DAE = single acting DAD63.1 links / left rechts / right
size of actuator Maße in mm, dimensions in mm
DAE63.1 links / left rechts / right
Wirkungsweise: DAD = doppeltwirkend mode of function: DAD = double acting

DN LW PN D l L H h A C ød SW R Montageflansch Drehantrieb Gewicht
( bar )
±2 ~ zweiflach mounting flange actuator weight
Kugelhahn ISO 7/1 2 - flat DIN ISO 5211
ball valve DAD ~ kg
15 15 100 Rp 1/2 14,5 75 123,5 30 150 60 12 10 G 1/8 F 03 42.1 1,395
20 20 100 Rp 3/4 16,5 80 127,0 30 150 60 12 10 G 1/8 F 03 42.1 1,520
25 25 100 Rp 1 18,5 90 140,5 30 150 60 12 10 G 1/8 F 05 42.1 2,075
32 32 100 Rp 1 1/4 23,5 110 172,5 30 180 81,5 16 13 G 1/8 F 05 63.1 3,640
40 40 100 Rp 1 1/2 24,5 120 183,0 30 180 81,5 16 13 G 1/8 F 05 63.1 4,315
50 50 100 Rp 2 26,5 140 191,0 30 180 81,5 16 13 G 1/8 F 05 63.1 5,690
Wirkungsweise: DAE = einfachwirkend mode of function: DAE = single acting

DN LW PN D l L H h A C ød SW R Montageflansch Drehantrieb Gewicht
( bar )
±2 ~ zweiflach mounting flange actuator weight
Kugelhahn ISO 7/1 2 - flat DIN ISO 5211
ball valve DAE ~ kg
15 16 100 Rp 1/2 14,5 75 123,5 30 150 60 12 10 G 1/8 F 03 42.1-2F 1,480
20 20 100 Rp 3/4 16,5 80 127,0 30 150 60 12 10 G 1/8 F 03 42.1-2F 1,605
25 25 100 Rp 1 18,5 90 166,5 30 180 81,5 13 10 G 1/8 F 05 63.1-10F 3,290
32 32 100 Rp 1 1/4 23,5 110 172,5 30 180 81,5 13 10 G 1/8 F 05 63.1-10F 3,790
40 38 100 Rp 1 1/2 24,5 120 183,0 30 180 81,5 13 10 G 1/8 F 05 63.1-10F 4,460
50 50 100 Rp 2 26,5 140 191,0 30 180 81,5 13 14 G 1/8 F 05 63.1-10F 5,850
1.6.66 510/658
Peumatische Drehantriebe
Pneumatic actuators Baureihe
doppeltwirkend / einfachwirkend
double acting / single acting 32.1/ 42.1/ 63.1 DAD / DAE
Technische Daten Drehantrieb • technical data actuator
Material material
Gehäuse: Aluminium hart eloxiert body: aluminium hard anodized
Welle: Stahl, chemisch vernickelt shaft: steel nickel plated
Kolben: Aluminium piston: aluminium
Dichtungen: Perbunan seals: perbunan

- 20° C bis + 90° C - 20° C to + 90° C
Steuermedium operating media

gefilterte Druckluft nach Pneurop / ISO Klasse 4 filtered air acc. to Pneurop / ISO class 4
Steuerdruck operating pressure

max. 10 bar max. 10 bar
Stellzeit operating time

abhängig vom Drehmoment depending on torque
Besondere Merkmale special characteristics
• F- Bohrbild nach DIN ISO 5211 und Mitnehmerstern • actuator interface acc. to DIN5211
ermöglichen Direktaufbau auf Kugelhahn direct mounting possible
• Direkte Anflanschung von Magnetventilen nach • Direct mounting of magnetic valves per Namur
Namur ist ab Antriebsgröße 42.1 möglich. from size of actuator 42.1 is also possible.
(Fabrikate: Airtec, Festo, Herion). (Brands: Airtec, Festo, Herion).
• Aufbau von Endschalterkästen ist ab Antriebsgröße • suitable for mounting of switch box from size of
42.1 möglich. actuator 42.1
• Drehantrieb „einfachwirkend“ ab Antriebsgröße 42.1 • „single acting“ from size of actuator 42.1
Bemerkung remark
• geeignet für allgemeine industrielle Anwendungen • suitable for industrial purposes
Stand: Januar 2009 -Technische Änderungen vorbehalten - subject to change (without notice) - 1.6.61
511/658
A C
ød SW1
h2
M5x9
h1
Anschluss DAD 32.1
M5x6
B
32
24
24 32
Anschlüsse DAD 42.1 / 63.1

Anschlüsse nach M5
M
DIN ISO 5211/1
U M6
connection acc. to M8
DIN ISO 5211/1
SW2
TK4 (F07)
TK1 (F03)
TK3 (F05)
T
Luftverbrauch (Normvolumen) bei 1 bar Steuerdruck

(Schaltzyklus auf/zu)
Maße zu Aufbau von Endschalterkästen air consumption (standard volume) at 1 bar control pressure
dimension for mounting switch limit boxes (switching operation open/close)
Typ T U M Typ Q 1bar [l] Typ Q 1bar [l] Umrechnung: Luftverbrauch bei Steuerdruck p
conversion: air consuption at control pressure p
DAD 32.1 -- -- -- -- DAD 32.1 0,1 - - - - Q = 0,5 Q 1bar
(p+1)
DAD / DAE 42.1 30 80 M5 x 5 DAD 42.1 0,18 DAE 42.1 0,09
DAD / DAE 63.1 30 80 M5 x 8 DAD 63.1 0,6 DAE 63.1 0,3 Bestellbeispiel - ordering example
DAE - 63.1 - 10 F
Drehmoment doppeltwirkende Antriebe, torque double acting actuator
Typ Drehmoment, torque [Nm] D = doppeltwirkend/
double acting
3 bar 4 bar 5 bar 6 bar 7 bar 8 bar 9 bar 10 bar E = einfachwirkend/
DAD32.1 4,3 5,8 7,2 8,7 10,1 11,6 13,0 14,5 single acting
DAD42.1 7,5 10,0 12,5 15,0 17,5 20,0 22,4 24,9 Größe/ size
DAD63.1 25,2 33,7 42,1 50,5 58,9 67,3 75,8 84,2 Federanzahl/ quantity springs
Drehmoment einfachwirkende Drehantriebe, torque single acting actuator

Federmoment,
Federn, spring torque Nutzmoment, useful torque
Typ springs [Nm] [Nm]
4 bar 5 bar 6 bar 7 bar 8 bar 9 bar 10 bar
0° 90° 0° 90° 0° 90° 0° 90° 0° 90° 0° 90° 0° 90° 0° 90°
DAE42.1 2 5,0 8,0 5,0 2,0 7,5 4,5 10,0 7,0 12,5 9,5 15,0 12,0 17,4 14,4 19,9 16,9
8 12,0 19,2 21,7 14,5 30,1 22,9 38,5 31,3 46,9 39,7 55,3 48,1 63,7 56,5 72,2 65,0
10 15,0 24,0 27,1 18,1 35,5 26,5 43,9 34,9 52,3 43,3 60,7 51,7 69,2 60,2
DAE63.1 12 18,0 28,8 32,5 21,7 40,9 30,1 49,3 38,5 57,7 46,9 66,2 55,4
Typ DAD, doppeltwirkend/ double acting

Typ DAE, einfachwirkend (mit Federrückstellung)/ single acting ( with spring return) Maße in mm, dimensions in mm
Typ Gewicht Typ Gewicht A B h1 h2 C SW1 SW2 ød R Schnittstelle nach TK1 TK3 TK4
weight weight interface
~ kg ~ kg DIN ISO 5211
DAD 32.1 0,550 --- -- 115 46 14 7 49,5 10 9 12 G 1/8 F 03 36 - -
DAD 42.1 0,870 DAE 42.1 0,960 150 60 30 10 60 10 11 12 G 1/8 F 03 / F 05 36 50 -
DAD 63.1 1,950 DAE 63.1 2,100 180 86 30 15 81,5 13 14 16 G 1/8 F 05 / F 07 - 50 70
1.6.61
512/658
Namur-Magnetventil 3/2- und 5/2-Wege
solenoid valve acc. to Namur 3/2- and 5/2 way Baureihe
Für einfach- und doppeltwirkende Stellantriebe MV airtec
For single- and double-acting drives
3/2-Wege-Schaltbild
3/2-way diagram auch in
Ausführung
also avaiable in
version
5/2-Wege-Schaltbild
5/2-way diagram
Konstruktions-Merkmale Design features

Material: material:
Gehäuse: Aluminium eloxiert body: aluminium anodized
Innenteile: Al, St. rostfrei, Ms, Kunststoff parts: Al, St. stainless, Ms, plastic
Dichtung: Perbunan (NBR) seals: Perbunan (NBR)
Temperaturbereich: working temperature:
-10°* C bis + 70° C - 10°* C to + 70° C
*Bei Minustemperaturen aufbereitete, getrocknete Luft *With minus temperatures, use conditioned dry air.
verwenden. Bei Freiluftmontage alle Anschlüsse vor If installed in open air protect all connections
Eindringen von Feuchtigkeit schützen! against the penetration of moisture!
Betriebsmedium: Operating medium:
Gefilterte, geölte oder ölfreie Druckluft filtered, lubricated or non-lubricated air
Betätigung: Actuation:
Elektromagnetisch Solenoid operated
Durchflußrichtung: Flow direction:

festgelegt Fixed
Einbaulage: Mounting position:
Beliebig, vorzugsweise Magnet senkrecht Optional
Nennweite: Nominal size:
6 mm 6 mm
Anschlüsse: Port size:
G 1/4" bei 1, 3 und 5; Flansch nach Namur bei 2 u.3 G 1/4" at parts 1, 3 ,5; Namur flange at 2 and 3
Elektroanschluß: Electrical connection:
Steckerbild nach DIN 43650 Form B Connector interface to DIN 43650 form B
Betriebsdruck: Operating pressure:
max. 10 bar max. 10 bar
Bemerkung: remark:
Serienmäßige Handhilfsbetätigung Manual override is a standard feature
Befestigungsschrauben, Kodierstift und O-Ringe Scope of delivery: Mounting screws,
gehören zum Lieferumfang 2 O-rings and location pin
leicht austauschbarer Magnet Easily interchangeable solenoid system
Wartungsfrei Maintenance free
Stand: Oktober 2006 - Technische Änderungen513/658

vorbehalten · subject to change (without notice) - 1.6.71
Magnetventil airtec
Check Valve airtec KN-05-310-HN Magnetspule 4x90° drehbar KN-05-510-HN
Steckdose 180° umsteckbar
3/2-Wege-Schaltbild
3/2-way diagram
5/2-Wege-Schaltbild
5/2-way diagram
Maße in mm, dimensions in mm

V e n t il T y p V e n t il T y p A n s c h lu ß B e t ä t ig u n g N e n n w e it e B e t rie b s d ru c k N e n n d u rc h f lu ß G e w ic h t
v a lv e t y p e v a lv e t y p e P o rt s iz e F u n c t io n N o rm s iz e O p e ra t in g p re s s u re n o m in a l f lo w w e ig h t
1 , 3 (5 ) 2 (4 ) (b a r) m in . m ax. l /m in . (K g )
Fla n sc h
E le k tro m a g n e t
K N 05 310 3/2 G 1/4 fl a n g e 6 3 10 780 0,32
s o le n o id
N am ur
Fla n sc h
E le k tro m a g n e t
K N 05 510 5/2 G 1/4 fl a n g e 6 3 10 900 0,32
s o le n o id
N am ur
Anschlußseite 2 (4) nach Namur Betätigungsmagnet

Interface acc. to Namur Solenoid
SP-011 M-017
32
Schaltmagnet Typ Leistungsaufnahme Schutzart Temperatur Gewicht

Solenoid Type Current draw Protection class Temperature weight
Umgebung
24 V DC 230 V AC Fluid max. Ambience
(W) (VA) (°C) (°C) (Kg)
IP65
SP-011 4,2 7,0 / 4,0 VDE 0470 +50 0,12
EN 60529
-15 bis +50
EEx Zone 1
EEx m II T5
M017 3,35 3,23 +80 0,13
mit 3m Kabel
with cable 3m
KN 05-310-HN 24VDC EEx KN 05-310-HN 24VDC EEx

Ventil 3/2 oder 5/2 Valve 3/2 or 5/2
Spannung 24V oder 230V Voltage 24V or 230V
Schutzart IP 65 oder EEX (Angabe nur bei EEx nötig) Protection class IP 65 or EEx (specification only for EEx)
1.6.71 - Technische Änderungen 514/658

vorbehalten · subject to change (without notice) -
Positionsrückmelder
position indicator Baureihe
für Offen- und Geschlossenstellung END00320
for open and closed position

Werkstoffe: material:
Gehäusedeckel: Polycarbonat transparent cover: polycarbonat transparent
Gehäusesockel: Polyamid PA6 schwarz Housing (base): polyamid PA6 black
Schaltwelle: Polyamid PA6 schwarz axis: polyamid PA6 black
Dichtung: EPDM+NBR Seal: EPDM+NBR
Konsole: Edelstahl Bracket size: stainless steel

Standard -20° C bis + 80° C Standard - 20° C to + 80° C
Schutzart: Protection:
IP67 VDE 0470 / EN60529 IP67 VDE 0470 / EN60529
Anzeige und Schaltbereich: Indication and switching range:

0°...90° Schwenkwinkel 0°...90° pivoting angle
Einbaulage: Mounting position:
Beliebig, vorzugsweise senkrecht Optional
Anschlüsse /Befestigungsmaße: Mounting measurements:
VDI/VDE 3845 für Flanschbilder 30x80 mm Acc. toVDI/VDE 3845 for flange facing 30x80 mm
Kabeldurchführung: Cable gland:

M20x1,5 Verschraubung mit Zugentlastung; M20x1,5 With strain relief; Clamp range 6-12mm
Klemmbereich 6-12mm
Bemerkung: remark:
Schaltpunkte einstellbar. switch points adjustable.
Die eingestellte Position ist durch Verzahnung The fully adjustable serrated cames are locked
der Schaltnocken gegen unkontrolliertes verstellen together to ensure that the adjusted setting is
gesichert. secured .
Stand: November 2010 - Technische Änderungen515/658

vorbehalten · subject to change (without notice) - 1.6.92
24.7 79
124
18
62
39
30
80 30
alle Maße in mm, all dimensions in mm
Spannungs-
Typ/Bestell-Nr. Beschreibung bereich Strom-bereich Schutzart Schalt-funktion
Type/Order-No. Description Voltage range Current range Protection class Switching function Signal Signal
Mechanischer Wechselschalter
Cherry-Mikroschalter, mit Silberkontakt
Kontakte versilbert change over
mechanical cherry micro- 24V / DC max. 2,5A IP 67(Gehäuse) switches with Auf + zu
END00320 switch, silver plated 250V / AC max. 10A IP 67 (body) silver contacts open + close
Klemmenplan / wiring diagram
END00320
Bestellbeispiel ordering example

Positionsrückmelder position indicator
Endschalter-Typ proximity switch-type
END00320 END00320
1.6.92
516/658
517/658
518/658
Operating, Assembly and Maintenance Recommendation
for Ball Valves
Index: Page
1. General 2
2. Safety instructions 2
3. Transport 2
4. Storage 3
5. Functioning 3
6. Installation 3
7. Initial operation 4
8. Maintenance 4
9. Troubleshooting 4
-1-
519/658
1. General:
- When making inquiries or spare part orders please always quote our order no. and, if
possible, the ball valve type and year of manufacture.
- We assume no liability in cases of disregard of operating or safety instructions or of faulty
installation or maintenance.
- Please refer to all data on further automation equipment such as drives, actuators,
electrovalves, limit switches etc.
- Unfortunately, we are unable to take back customer-specific valves.
2. Safety instructions:
- Maintenance, assembly and repair work may only be carried out by duly authorised and
qualified personnel.
- The manufacturer assumes no liability for damages or any other occurrences resulting from
changes made without consulting the manufacturer or use of parts other than original parts.
- These operating instructions do not replace any national accident prevention regulations or
local safety regulations; they are invariably subordinate to these.
- Observe the following before carrying out any repair or maintenance work:
® Always turn off the power supply of the drives before carrying out repair or
maintenance work (danger of bruising!).
® Make sure that no-one puts the plant into operation.
® Evacuate the pipe, prevent pressure build-up or retention.
® Inform yourself on possible dangers emanating from residues of operating material;
wear safety gloves and goggles etc. as necessary.
® Let valves cool off if necessary.
® Ensure that limit values relating to pressure, temperature and the operating material are
not exceeded.
3. Transport:
- Valves should be transported to the building site in a firm packing.

- Do not attach cranes or elevators to the handle or to any mounted drive to prevent damage.
- Check valves for any transport damage immediately upon delivery and report as necessary.
We assume no liability for transport damages that have not been duly reported.
-2-
520/658
4. Storage:
- Ball valves must always be stored either completely opened or completely closed. We
advise storing them completely opened to prevent damage to the ball surface.
- Valves that are not needed immediately should be fitted with a protective cap and stored in a
well-aired, dry room.
5. Functioning:
- Ball valves serve as shut-off devices in plants, where they are screwed or welded into the
pipe system.
- Ball valves are OPEN/CLOSE devices which are generally opened and closed by rotation
through 90°. The closing direction according to DIN standards is achieved by rotating the
handele clockwise. They are not intended for throttling or regulating the flow of medium,
and intermediate positions are therefore not permissible.
- Granulate ball valves of the 400 and 190TR series are characterised by bearings located on
either side of the ball and valve sealing on one side only. Granulate ball valves have proven
themselves idelly suited to use with critical media which contain solids or are highly
viscous. The packing on the incoming side is not directly exposed to the flow. This prevents
product material from getting jammed between the ball and housing wall as the ball valve
closes. It is essential that the material always flows in the right direction through the ball
valve.
6. Installation:
- The piplines must be cleaned or flushed before installation, so that any residues and foreign
bodies do not get into the ball valves.
- Should the valves be dirty or contaminated, then set the ball previously to 45° and blow the
interior clean with oil-free comressed air. Then clean the housing.
- Lead the piplines free of stress up to valve to be installed.
- Ensure that the ball valves are in their open position.
- Place the fitting between the pipes using a crane or elevator if necessary. Tighten the flange
screws in opposite directions with the appropriate torque.
- Caution: There is only one permissible direction of flow through type 400 and 190TR
granulate ball valves. The valve should close clockwise and should be mounted facing
horizontally or vertically downward. The piping upstream and downstream of the valve
should be straight over a length of approx. 3x its nominal width, and the valve should be
easily accessible.
- Protect the interior parts of the valve before carrying out any welding (observe maximum
tolerable temperature of gasket!).
-3-
521/658
7. Initial operation
- Read and ensure compliance with all operating instructions and check that operating
conditions are as required and the valves has been installed correctly.
- Flush the piping with valves fully opened before testing their function.
- After completing the installation and before putting the valve into operation, check that it
works properly by opening and closing it several times.
- Make sure that the valve works perfectly and that it turns in the right direction.
8. Maintenance:
- The ball valves are designed so that when used as intended no maintenance work at all is
required over a period of 3 years.
- To test the function, the valves should be moved open and closed according to loading every
6 or 12 months thus to confirm safe and leak-free operation.
- It is advisable to check the flange and selector shaft packing for leakage after prolonged
operation.
- In the event of rough operating conditions flush the ball valve via the provided borings if
necessary.
9. Troubleshooting:
® Leakage at the selector shaft

This work can be done in the built-in condition and with the line under pressure.
However, it is prossible to do this work only under increased safety precautions. It should
also be observed that this work may be done under no circumstances at very high or very
low temperatures, with combustible media or with aggressive substances.
® Leakage at the ball
For this work the ball valve must be dismantled from the pipeline and only trained skilled
personnel should be entrusted with this work.
Please turn to us if you have any questions or before attempting repair in the event of
operating trouble.
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522/658
Flansch-Kugelhähne aus Stahl Baureihe
Flange-ball valves in steel
Kompaktausführung 79
Wafer-design DN 15 - DN 150 PN 16-40
PED
-0036
• zweiteiliges Gehäuse, verschraubt • two-piece ball valve, " screwed design "
• voller Durchgang • full port design
• Antistatik-Ausführung • antistatic-device
• ausblassichere Schaltwelle • blow out proof stem design
• silikonfrei • free of silicone
• Direktaufbau von Stellantrieben möglich • direct mounting of actuators is possible
• Abschließbar • lockable
• Druckausgleichsbohrung in Offenstellung • pressure compensation hole in open position
• Schaltwellendichtung tellerfedervorgespannt mit • plate spring forced packing additional O-Ring
zusätzlichem O - Ring
Material: material:
Gehäuse: Stahlguß 1.0619 body: carbon steel 1.0619
Kugel: Edelstahl 1.4408 ball: stainless steel 1.4408
Kugeldichtung: PTFE / TFM ball seal: PTFE / TFM
Schaltwelle: Edelstahl 1.4401 / 1.4408 stem: stainless steel 1.4401 / 1.4408
Packung: PTFE packing: PTFE
O-Ring: Viton O-ring viton

- 20° C bis + 180° C - 20° C to + 180° C
siehe Druck-Temperaturdiagramm see pressure temperature chart
Verwendung: suitable for

Öle, Druckluft, Wasser, Lösungsmittel, oils, compressed air, water, solvents, fuels
Kraftstoffe
Bemerkung remark
Flanschanschlussmaße nach EN 1092-1 (DIN 2501-1) flange dimensions acc.to EN 1092-1 (DIN 2501-1)
Stand: Januar 2008 - Technische Änderungen vorbehalten - subject to change (without notice) - 1.2.25
523/658
R
H1
K
H
d
z-N
D L
øA2
SW
øA1
Bestellbeispiel:ordering example:
Baureihe Nennweite Druckstufe
series diameter pressure rating
øB1
79 - 25 -16
øB2
Druck-Temperaturdiagramm
bar pressure temperature diagram
50
40
DN
15-
30 DN 80
PN
10 40
0
PN
40
20
DN 15-150 PN16
DN
DN 15
100 -8
-150 0
10 PN1 PN
6 16
0
-20 0 50 100 150 180
T (°C)
z= Anzahl der Löcher, number of holes Maße in mm, dimensions in mm
SIZE PN d L D K h H H1 N z SW øA1 øA2 øB1 øB2 R ISO Gewicht

±2 max. 5211 weight
DN Zoll bar ~kg
1
15 /2 40 15 42 95 65 9 48 77 M12 4 9 6 6 36 42 145 F03-F04 1,4
3
20 /4 40 20 44 105 75 9 53,5 82 M12 4 9 6 6 36 42 145 F03-F04 1,8
25 1 40 25 50 115 85 11 62 94 M12 4 11 6 7 42 50 175 F04-F05 2,4
32 11/4 40 32 60 140 100 11 72 104 M16 4 11 6 7 42 50 175 Fo4-F05 3,8
40 11/2 40 38 65 150 110 14 78 114 M16 4 14 7 9 50 70 194 F05-F07 4,8
50 2 40 50 80 165 125 14 86 120 M16 4 14 7 9 50 70 194 F05-F07 6,8
16 4 10,1
65 21/2 63,5 110 185 145 17 108 158 M16 17 9 11 70 102 265 F07-F10
40 8 11,4
16
80 3 76 120 200 160 17 116 165 M16 8 17 9 11 70 102 265 F07-F10
40 14,4
16 150 220 180 M16 22,7
100 4 95 22 139 182 8 22 -- 11 --- 102 380 F10
40 154 235 190 M20 27,0
125 5 16 118 180 250 210 27 176 224 M16 8 27 14 -- 125 --- 750 F12 33,5
150 6 16 142 225 285 240 27 192 268 M20 8 27 14 -- 125 --- 750 F12 50,6
1.2.25
524/658
Operating and Assembly Instructions for BEE flange ball valves
Field of application
BEE flange ball valves used as a shut-off valve for interruption e.g. release of the media.
Note:
The valve must be marked in line with the requirements of EN19
BEE flange ball valves are designed for loads which are appropriate to the intended use and other
foreseeable operating conditions that are considered to be reasonable. The following factors in
particular must be taken into consideration.
Pressure load: The pressure load must not exceed the pressure range specified.
Appropriate measures must be taken to avoid excess pressure or pressure impacts.
For the purpose of testing the valve can be impacted with 1.5x nominal pressure.
Temperature stress:
The temperature limits must be observed according to the type of seal and material. The data sheet
must be taken into consideration.
Resistance to the medium: All the materials are listed on the data sheet.
Their chemical compatibility must be guaranteed.
Reaction forces: Reaction forces and -moments in connection with supporting elements, pipeline
fixings, etc., may not exceed the moments specified in DIN EN 13774
The devices are equipped with an assembly flange according to DIN ISO 5211 for actuators. In case
of automatic ball valves in addition the Operating and Assembly Instructions of actuators, magnetic
valves, coils and position indicator are to be taken into consideration.
Design and Construction must guarantee the following:
Appropriate methods of support, fixing and alignment must be used to prevent the risk of overstressing
by e.g., inadmissible movement or excessive force on valves.
In the case of gaseous fluids that form condensate, suitable dehydration facilities must be provided to
prevent damage caused by water shock and corrosion. The risk of fatigue phenomena caused by
vibration of the pipeline system must be given due consideration.
Installation / Assembly
BEE flange ball valves are basically supplied in the open position. As a general rule they should also
be installed in the open position. The protective caps must be removed prior to assembly. They should
be assembled correctly using appropriate bolts and sealing materials.
Following installation, the pipe system must be flushed out in order to remove any residual matter and
to prevent possible damage to the ball seal.
Operation
To close: Turn the operating lever 90° clockwise.
To open: Turn the operating lever 90° anti-clockwise.
The notch of the switch spindle indicates the ball position - Open / Closed.
The ball valve may only be operated in open or closed position. Intermediate positions (control
function) can damage the ball seal. This can cause leakage in the shut-off function.
Maintenance
BEE flange ball valves are maintenance free
Wear
The wear depends on a considerable extent on the medium, frequency of switching actuations and
temperature stress.
For this reason various wearing factors can occur according to the particular application, necessitating
very different repair intervals.
Miscellaneous
Incorrect assembly and/or operation will invalidate the right to make claims under the warranty. In
case of repair the ball valve may only be opened in the manufacturer's plant.
-----------------------------------------------------------------------------------------------------------------
Declaration of the Manufacturer:
This product has been manufactured in accordance with the technical guidelines and DIN-EN
standards. The materials used to manufacture our products comply with the regulations according
to AD 2000.
Date: 28.01.2004
525/658

526/658
Ball valve
Figur 0200-02-04
Ball valve normal
Material: Brass to nickel

Connection:Internal thread
Size: 1/8" - 4"
Pressure
PN 40/16
ratings:
© Doden Armaturen KG - Rosenheimer Str. 11, 28219 Bremen

Telefon: (0421) 160 800 --- Telefax: (0421) 160 80 40
527/658

528/658
Wafer Type Check Valves
Instruction Manual
SR / HSR
ZRK / ZRL
ZRD
Technical modifications reserved 07/2008

Document no.: BA-1002
RITAG Ritterhuder Armaturen GmbH & Co. Phone +49 (0) 47 91-92 09-0
Armaturenwerk KG Fax +49 (0) 47 91-92 09-85 1
Industriestraße 7-9 eMail: contact@ritag.com
D-27711 Osterholz-Scharmbeck 529/658
Internet: www.ritag.com
Instruction manual
Content
1.1 Declaration of Conformity acc. to PED 97/23/EC (SR + ZRK) ........................................... 3
1.2 Declaration of Conformity acc. to PED 97/23/EC (ZRD) .................................................... 4
2. General Notes ................................................................................................................................ 5
3. Intended Use .................................................................................................................................. 5
4. Safety Instructions ........................................................................................................................ 5
4.1 Generaly Safety Instructions ........................................................................................................................... 5
4.2 Qualification of Personnel ................................................................................................................................ 5
Überschrift
4.3 Safety Instructions for the Operator ............................................................................................................ 6
Überschrift
4.4 Special Dangers ..................................................................................................................................................... 6
.
5. Transport and Storage .................................................................................................................. 7
6. Categorisation in acc. to PED 97/23/EC article 9 ................................................................... 7
7. Specification .................................................................................................................................. 7
7.1 Marking ..................................................................................................................................................................... 7
7.2 Drawings and Parts Lists ................................................................................................................................... 8
7.3 Functionality ............................................................................................................................................................ 9
8. Installation .................................................................................................................................... 10
8.1 General Information .......................................................................................................................................... 10
8.2 Operation Characteristics (Pressure/Temperature-Rating) ............................................................. 10
8.3 Range of Applications ....................................................................................................................................... 10
8.4 Installation Instructions ................................................................................................................................... 11
9. Initial Operation, Shut-down, Maintenance ............................................................................ 12
9.1 Initial Operation ................................................................................................................................................... 12
9.2 Pressure tests of pipeline sections ............................................................................................................. 12
9.3 Shutt-down ............................................................................................................................................................ 12
9.4 Maintenance .......................................................................................................................................................... 12
9.5 Elimination of Failures ..................................................................................................................................... 13
10. Spare Parts ................................................................................................................................ 14
11. Further information .................................................................................................................. 14
Annex I - Classification according to Pressure Equipment Directive ...................................... 15
Annex II - Pressure/Temperature Classification acc. to DIN EN 12516 ................................ 17
Annex III - Pressure/Temperature Classification acc. to ASME B16.34 ................................ 24
Instruction manual
1.1 Declaration of Conformity acc. to PED 97/23/EC (SR + ZRK)
Declaration of Conformity
in acc. to Pressure Equipment Directive 97/23/EC
Name and Address of Manufacturer
RITAG Ritterhuder Armaturen GmbH & Co. Armaturenwerk KG

Industriestr. 7-9
D-27711 Osterholz-Scharmbeck
Description of the Pressure Equipment
Type DN PN Module Type DN PN Module Type DN PN Module Type DN PN Module

SR10.16 125-200 6-16 A SR12.16 65-200 6-16 A ZRK4 65-200 6-16 A ZRL4 65-200 6-16 A
SR60.06 32-100 6 A SR70.16 65-100 6-16 A ZRK1 50-100 10-40 A1 ZRL1 50-100 10-40 A1
SR61.06 32-100 6 A ZRK1S 50-100 10-40 A1 ZRL1S 50-100 10-40 A1
SR20.40 32-100 6-40 A1 SR33.40 32-100 6-40 A1 ZRK2 50-100 10-40 A1 ZRL2 50-100 10-40 A1
SR20.40St 32-100 6-40 A1 SR34.40 32-100 6-40 A1 ZRK3 50-100 10-40 A1 ZRL3 50-100 10-40 A1
SR22.40 32-100 6-40 A1 SR35.40 32-100 6-40 A1 ZRK4 250,300 6-16 A1 ZRL4 250,300 6-16 A1
SR30.40 32-100 6-40 A1 SR55.40 32-100 6-40 A1 ZRK5 50-100 10-40 A1 ZRL5 50-100 10-40 A1
Sr31.40 32-100 6-40 A1 HSR20.160 32-100 63-160 A1
SR32.40 32-100 6-40 A1 HSR30.160 32-100 63-160 A1 ZRK1 125-600 10-40 H ZRL1 125-600 10-40 H
SR40.40 32-100 6-40 A1 SR50.40 32-100 6-40 A1 ZRK1S 125-600 10-40 H ZRL1S 125-600 10-40 H
SR20.40 125-200 6-40 H SR30.40 125-200 6-40 H ZRK2 125-600 10-40 H ZRL2 125-600 10-40 H
SR20.40ST 125-200 6-40 H SR34.40 125-200 6-40 H ZRK3 125-600 10-40 H ZRL3 125-600 10-40 H
SR22.40 125-200 6-40 H SR35.40 125-200 6-40 H ZRK4 350-600 6-16 H ZRL4 350-600 6-16 H
SR25.40St 250-350 6-40 H SR55.40 125-200 6-40 H ZRK5 125-600 10-40 H ZRL5 125-600 10-40 H
All valves in size DN ≤25 comply with article 3, paragraph 3 and are not permitted to be marked
neither with the CE characters nor with the notified body code.
Name and Address of the Notified Body
LRQA GmbH Hamburg

Mönckebergstrasse 27
20095 Hamburg
The signing manufacturer confirms by this declaration that design, manufacturing and inspection of
these pressure equipments meet the requirements of the Pressure Equipment Directive 97/23/EC.
Applied Harmonized Standards
EN 19, EN 558, EN 1092, EN 1503, EN 10213, EN 10272, EN 10273, EN 12266, EN 12516
Other Applied Standards and Technical Rules
AD 2000, DIN3230, DIN3840, VdTÜV1253, VdTÜV100, TRD110
08.01.2007 Herfried Schrader Qualitätsbeauftragter
Date Authorized Subscriber
Instruction manual
1.2 Declaration of Conformity acc. to PED 97/23/EC (ZRD)
Declaration of Conformity
in acc. to Pressure Equipment Directive 97/23/EC
Name and Address of Manufacturer
RITAG Ritterhuder Armaturen GmbH & Co. Armaturenwerk KG

Industriestr. 7-9
D-27711 Osterholz-Scharmbeck
Description of the Pressure Equipment
Type DN PN Module Type DN PN Module

ZRD G/K3 65 - 200 6 - 16 A ZRD G/API594 21/2" - 6" Class125, 150 A
ZRD G4/K3 65 - 200 6 - 16 A ZRD G4/API594 21/2" - 6" Class125, 150 A
ZRD 4/K3 65 - 200 6 - 16 A ZRD 4/API594 21/2" - 6" Class125, 150 A
ZRD 6/K3 65 - 200 6 - 16 A ZRD 6/API594 21/2" - 6" Class125, 150 A
ZRD G/K3 250, 300 6 - 16 A1 ZRD G/API594 8", 10" Class125, 150 A1
ZRD G4/K3 250, 300 6 - 16 A1 ZRD G4/API594 8", 10" Class125, 150 A1
ZRD 4/K3 250, 300 6 - 16 A1 ZRD 4/API594 8", 10" Class125, 150 A1
ZRD 6/K3 250, 300 6 - 16 A1 ZRD 6/API594 8", 10" Class125, 150 A1
ZRD 1/K3 50 - 100 6 - 40 A1 ZRD 1/API594 2" - 4" Class150, 300 A1
ZRD G/K3 350 - 600 6 - 16 H ZRD G/API594 12" - 24" Class125, 150 H
ZRD G4/K3 350 - 600 6 - 16 H ZRD G4/API594 12" - 24" Class125, 150 H
ZRD 4/K3 350 - 600 6 - 16 H ZRD 4/API594 12" - 24" Class125, 150 H
All valves in size DN ≤25 comply with article 3, paragraph 3 and are not permitted to be marked
neither with the CE characters nor with the notified body code.
Name and Address of the Notified Body
LRQA GmbH Hamburg

Mönckebergstrasse 27
20095 Hamburg
The signing manufacturer confirms by this declaration that design, manufacturing and inspection of
these pressure equipments meet the requirements of the Pressure Equipment Directive 97/23/EC.
Applied Harmonized Standards
EN 19, EN 558, EN 1092, EN 1503, EN 10213, EN 10272, EN 10273, EN 12266, EN 12516
Other Applied Standards and Technical Rules
AD 2000, DIN3230, DIN3840, VdTÜV1253, VdTÜV100, TRD110
08.01.2007 Herfried Schrader Qualitätsbeauftragter
Date Authorized Subscriber
Instruction manual
2. General Notes
This instruction manual applies to the above mentioned valves which are subject to the Quality Management
System Standard acc. to DIN/ISO9001 in both the manner of manufacturing as well as testing and which do
meet the basic safety requirements of Annex I of the Pressure Equipment Directive 97/23/EC. This instruction
manual is intended to support the user of above mentioned valves in installation, operation and maintenance.
Disregarding the following caution advices could evoke dangerous situations

which entail an inefficacy of the manufacturers’ warranty.
For any questions, please contact the manufacturer and also see chapter
11.
3. Intended Use
Wafer type check valves are solely destined for installation within a pipeline system in consideration of the
admitted pressure and temperature limits to avoid a backflow of the media.
It is the operators’ responsibility to examine the chemical resistance in relation to the specified operation
data.
All valid operation data are indicated in appendix II respectively in the technical data sheets of the relevant
types.
4. Safety Instructions
4.1 Generaly Safety Instructions
Those safety regulations applying to the pipeline system apply to the valves itself accordingly, i. e. any
national or international rules for accident prevention as well as possibly existing operators’ working-, production-
and safety regulations have to be considered. This instruction manual only points to those safety instructions
which have to be considered additionally.
4.2 Qualification of Personnel
Only qualified staff is permitted to install and maintain the valves. The operator is obliged to coordinate the
competencies, the responsibilities and the surveillance of his staff. Should the staff not have the necessary
knowledge, the operator must provide adequate additional training. The operator has to ensure that the
content of this instruction manual is comprehended in all its particulars.
Instruction manual
4.3 Safety Instructions for the Operator
Due to the fact that the following points are not in the responsibility of the valve manufacturer the operator has
to ensure when using the valves that
• the valves are solely used in the way described in chapter 3
• the pipeline system is installed in a professional manner. The wall thickness of the valve body is designed
in a way that tensions which do exist within the pipeline system are considered in a usual order of magnitude.
• the valves are properly installed between the flanges.
• an usual flow rate within the pipeline system is not exceeded during a continuous operation. For abnormal
service conditions, e. g. oscillation, water shock, cavitation or a medium that contains larger solid particles,
please contact RITAG for clarification.
• the valves are protected against touch when working at a temperature <0°C respectively >40°C.
Prevention from misusing the valves:

It has to be particularly ensured that the selected body materials and inner
parts of the valve are suited for the medium that is used. The manufacturer
assumes no liability for any damages caused by aggressive media.
4.4 Special Dangers
Before disassembling the valve the pipeline has to be depressurized, the

pipe has to be totally drained and released. Afterwards the flange screw
connections can be unscrewed and the valve can be dismantled.
Misusing this precaution means danger to the life of the operating personnel.
Instruction manual
5. Transport and Storage
The valves are provided ready for installation. They need to be treated, conveyed and stored carefully.Those
valves that are delivered with a protecting packing need to be stored within this packing up to the moment of
installation.
• In case of a direct storage at the installation location the valve has to be stored in a closed room and has
to be protected against any damaging impacts.
• It is recommended to use up any stock items first in order to achieve short storage periods.
• Those valves that are equipped with a soft sealing need to be protected against sunlight that might hit
this soft sealing or any other UV-radiation in order to avoid ageing.
• Lifting tools for transport are only to be fastened on the valve body. Inner parts may not be misused as
„carrying devices“.
6. Categorisation in acc. to PED 97/23/EC article 9
For details on the classification of our valves acc. to PED 97/23/EC, please refer to Annex I.
7. Specification
The sectional drawings shown in this chapter do exemplary illustrate the basic design of the valves. Detailed
information can be found in the technical data sheet of the specific valve type.
7.1 Marking
All valves are marked in acc. to PED 97/23/EC, TRB 801 No. 45 or EN19.
General Marking
Manufacturer RITAG
Valve type ...
Nominal diameter DN...
Nominal pressure PN..
Material ...
Batch no. (retraceability of the material) ...
Year of manufacture (month, year, e.g. 5.02) ...
CE-marking (starting from category I, see chapter 1 u. 6) CE
Code of the Notified Body (Module A1 und H) 0525
Stamp of inspector ...
Further special markings, e. g. plant identification code or project name could be additionally affixed on
request.
Instruction manual
7.2 Drawings and Parts Lists
Lift Check Valves

4
6 4
5 4 6
1 5 5
2 2 1
3 1 2
7 3 3
Item Denomination Item Denomination

1 Body 2 Plate/disc
3 Sealing (spare part) 4 Guiding plate
5 Spring 6 Guiding screw
7 Centering ring
Swing Check Valves
9
4
7
8
5
6
2
3
1
Item Denominatiom Item Denomination

1 Body 2 Plate
3 Sealing (spare part) 4 Hinge pin
5 Hinge, right 6 Hinge, left
7 Screw 8 Ring
9 Eye screw
Instruction manual
Duo Check Valves
1
3
2
4
11
8
9
6
10
12
5
7
Item Denomination Item Denomination

1 Body 2 Plate
3 Shaft 4 Sealing (spare part)
5 Spring (spare part) 6 Packing (spare part)
7 Ring 8 Pin retainer
9 Ring 10 Stop pin
11 Eye screw 12 Set screw
7.3 Functionality
Wafer type non-return valves are valves which are controlled by the backflow of the medium. The obturator
(disc, cone, plate) is first lifted and then opened by the flow. In the event of an incipient backflow (e. g. failure
of a pump) the obturator closes self-controlled by its dead weight. This closing process can optionally be
supported by using a spring.
Instruction manual
8. Installation
8.1 General Information
Positioning within the isometry of the pipeline as well as a proper installation of the valves is basically the
responsibility of the engineer or the operator. Any faults in engineering or installation could cause misfunction
of the valves and constitute a significant danger.
For the installation of the valves the same safety regulations are to be considered as for connecting pipelines
and its components.
Pipelines have to be laid in such a manner that shearing strain and bending
stress are not able to affect the valve body. The flange facings have to be in
a parallel position to each other. The facings need to be clean and
undamaged.
Valve bodies in material cast iron EN-JL1040, EN-JS1030 must not be

treated by sudden pressure (e. g. hammer blow) because components may
be destroyed.
9 <0°C respectively >40°C need to be protected
Valves working at temperatures
against touch.
8.2 Operation Characteristics (Pressure/Temperature-Rating)
For maximum permissible operating data in relation to pressure/temperature rating, please refer to Annex II.
8.3 Range of Applications
Industrial plants, heating systems, fluids, gases and vapour (see also fluid groups in table of article 6), hot
water heating systems DIN4751 / DIN4752, heat transmission plants DIN4754, steam boiler plants TRD110,
pressure vessel plants TRB801 No. 45. Potential restrictions by any technical body of legislation are to be
considered. The materials of the valves have to be applicative for the medium.
In case of pulsating flow (e.g. caused by piston compressors) the suitability of the selected valve type has to be
clarified with RITAG.
Instruction manual
8.4 Installation Instructions
The arrow indicating the flow direction and the flow direction itself need to run in the same direction.
For the valve to open a minimum dynamic pressure is required. Valves without spring can only be installed in
vertical lines with upward flow.
Installation in
horizontal vertikal pipeline
5xDN
Eye bolt
DN
DN
Eye bolt
2xDN
5xDN
Eye bolt
5xDN
Pump
Eye bolt indicates

top position of the valve
Wafer type non-return valves are designed for installation between two
pipeline flanges including appropriate flange sealings. The outer diameter
of the valve centres itself by the flange bolts. The fasteners require a
technical applicability in accordance to the service conditions. They have
to comply with the regulations and have to be tightened with the permissible
torque. Screws, nuts or flange sealings are not covered by the valve
manufacturers’ scope of supply.
Exception: Swing type check valves model ZRK have to be manually center-
lined.
Instruction manual
9. Initial Operation, Shut-down, Maintenance
9.1 Initial Operation
Materials and service conditions have to be compared with the pipeline system data before pressure test and
initial operation in order to check resistance and load.
For new plants or repairs the pipeline system has to be thoroughly rinsed in order to clean it from potential
welding residues or any other damaging solid particles.
9.2 Pressure tests of pipeline sections
Since non-return valves are always in a closed position within a filled pipeline section a testing overpressure
value of 1,1 x PS must not be exceeded (PS = NP = max. permissible working pressure).
Throughout the pressure test process the valve and the flange connections have to be examined regarding
any leaks. Leakages have to be immediately sealed by retightening all fasteners.
9.3 Shutt-down
If the system is out of operation for a lasting period all media which might change its
condition (i. e. polymerisation, crystallisation, solidification) have to be drained off the piping system. Rinse the
system if necessary.
9.4 Maintenance
The valves are maintenance-free. For safety reasons and in order to avoid unnecessary periods of interruption
the operator is advised to examine functionality and reliability of the valves within reasonable and regular
intervals (periods to be defined by the operator).
Safety instructions in chapter 4 are to be considered.
Instruction manual
9.5 Elimination of Failures
Failure definition Potential reasons Remedy
High leakage rate Contaminated seat facings Clean the seat facings, regrind
Deformation of disc/cone/ if necessary
plate by hammer blow Replace disc/cone/plate
Damaged seat ring Replace seat ring
Disc/cone/plate does not Recheck operating data,
close, cone is hanging, high reengineer all parts
activity rate causes a seizing
due to friction
Inappropriate noises Insufficient flow rate, turbulent Select reduced sizes

flow, decelerated starting of the Recheck the distance between
pump pipe bend and pump (5-7xDN)
Use lighter plates or springs
with reduced opening
pressure
Extend the period of running
up the pump
Leaks of stuffing box (ZRL-HG, Stuffing box is inadequately Retighten stuffing box
ZRD) preloaded Replace stuffing box packings
if necessary
No flow Valve is installed in the wrong Arrow of flow direction has to

way run in the same direction as
the flow itself.
Leaks of flange sealings Connection flanges are not Retighten fasteners

wired
Instruction manual
10. Spare Parts
For repair work any valve parts must only be replaced by spare parts from
the original supplier. Unauthorised conversion as well as spare parts
production cause an expiry of the declaration of conformity and may also
invalidate any warranty claims.
Any springs or o-rings (relevant for valves equipped with a soft sealing) can be ordered as spare parts. The full
marking of the valve body has to be specified in the purchase order.
11. Further information
For further information such as RITAG technical data sheets, repair instructions, certificates etc. please contact
us at www.ritag.com or send your mail to:
RITAG Armaturenwerk
Postfach 1332
D 27703 Osterholz-Scharmbeck
Industriestraße 7-9
D 27711 Osterholz-Scharmbeck
Tel. +49 (0) 4791 9209-0
Fax +49 (o) 4791 9209-85
E-Mail: contact@ritag.com
Instruction manual
Annex I - Classification according to Pressure Equipment Directive
Lift Check Valves SR / HSR
CE marking and declaration of conformity acc. to PED 97/23/EC
Nominal diameter
Type PN Fluidgroup 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350
SR10.16 16 2
SR12.16 16 2
SR70.06K 6 2
SR70.16 16 2
SR60.06 6 1 u. 2
SR20.40 40 1 u. 2
SR20.40St 40 1 u. 2
SR25.40 40 1 u. 2
SR22.40 40 1 u. 2
SR30.40 40 1 u. 2
SR31.40 40 1 u. 2
SR32.40 40 1 u. 2
SR33.40 40 1 u. 2
SR34.40 40 1 u. 2
SR35.40 40 1 u. 2
SR40.40 40 1 u. 2
SR50.40 40 1 u. 2
SR55.40 40 1 u. 2
HSR20.160 160 1 u. 2
HSR30.160 160 1 u. 2
Check Valves ZRK / ZRL
no valves in this size
without CE marking
with CE marking
Instruction manual
Annex I - Classification according to Pressure Equipment Directive
Check Valves Type ZRK and ZRD
Nominal diameter
Type PN Fluidgroup 50 65 80 100 125 150 200 250 300 350 400 450 500 600
10 1 u. 2
ZRK 1, ZRL 1, 16 1 u. 2
ZRL 5 25 1 u. 2
40 1 u. 2
10 1 u. 2
ZRK 1-S, ZRL 1- 16 1 u. 2
S 25 1 u. 2
40 1 u. 2
10 1 u. 2
16 1 u. 2
ZRK 2, ZRK 3
25 1 u. 2
40 1 u. 2
10 2
ZRK 4
16 2
without CE marking
with CE marking
Nominal diameter
Type PN Fluidgroup 50 65 80 100 125 150 200 250 300 350 400 450 500 600
10 1 u. 2
ZRD 1, ZRD 2, 16 1 u. 2
ZRD 3 25 1 u. 2
40 1 u. 2
ZRD G, ZRD4, 6 2
ZRD G-4, 10 2
ZRD G-4-g 16 2
without CE marking
with CE marking
Instruction manual
Annex II - Pressure/Temperature Classification acc. to DIN EN 12516
Working data for cast iron
max. working pressure (bar)

Material Temp. ( °C ) PN10 PN16
RT 10 16
100 10 16
EN-JL 1040 200 8 14,4
300 6 9,6
Working data for bronze

Material Temp. ( °C ) PN10 PN16
RT 10 16
CC483K 100 10 16
200 8 14
Working data for material group 3E0

Material Temp. ( °C ) PN10 PN16 PN25 PN40 PN63 PN100 PN160 PN250
RT 10 16 25 40 63 100 160 250
100 8,5 13,7 21,4 34,2 54 85,7 137,1 214,2
150 8,3 13,3 20,8 33,3 52,5 83,3 133,3 208,3
1.0460 200 7,7 12,4 19,4 31 48,9 77,6 124,1 194
1.0619 250 7 11,3 17,7 28,3 44,7 70,9 113,5 177,3
1.0425 300 6,4 10,2 16 25,7 40,5 64,2 102,8 160,7
1.0570 * 350 6 9,6 15,1 24,1 38,1 60,4 96,7 151,1
400 5,7 9,1 14,2 22,8 36 57,1 91,4 142,8
450 3,2 5,2 8,2 13,1 20,7 32,8 52,5 82,1
* only up to 300°C
Instruction manual

RT 10 16 25 40 63 100 160 250
100 10 16 25 40 63 100 160 250
150 10 15,2 23,8 38 60 95,2 152,3 238
200 10 14,5 22,7 36,3 57,3 90,9 145,5 227,3
1.0426 250 9,7 13,3 20,8 33,3 52,5 83,3 133,3 208,3
1.0481 300 8,8 12,2 19,1 30,6 48,3 76,6 122,6 191,6
350 8 11,3 17,7 28,3 44,7 70,9 113,5 177,3
400 7,3 10,2 16 25,7 40,5 64,2 102,8 160,7
450 4 6,4 10,1 16,1 25,5 40,4 64,7 101,1

RT 10 16 25 40 63 100 160 250
100 10 16 25 40 63 100 160 250
150 10 16 25 40 63 100 160 250
200 9,2 14,8 23,2 37,1 58,5 92,8 148,5 232,1
250 8,5 13,7 21,4 34,2 54 85,7 137,1 214,2
1.5415 300 7,6 12,1 19 30,4 48 76,1 121,9 190,4
1.5419 350 7 11,2 17,5 28 44,1 70 112 175
400 6,3 10,1 15,8 25,3 39,9 63,3 101,3 158,3
450 5,9 9,4 14,7 23,6 37,2 59 94,4 147,6
500 4,4 7 11 17,7 27,9 44,2 70,8 110,7
510 3,5 5,6 8,8 14 22,2 35,2 56,3 88
520 2,8 4,4 7 11,2 17,7 28 44,9 70,2
530 2,2 3,5 5,5 8,9 14,1 22,3 35,8 55,9
Instruction manual

RT 10 16 25 40 63 100 160 250
100 10 16 25 40 63 100 160 250
150 10 16 25 40 63 100 160 250
200 10 16 25 40 63 100 160 250
250 10 16 25 40 63 100 160 250
1.7335 300 9,1 14,7 22,9 36,7 57,9 91,9 147 229,7
1.7357 350 8,4 13,5 21,1 33,9 53,4 84,7 135,6 211,9
400 7,9 12,7 19,8 31,8 50,1 79,5 127,2 198,9
450 7,3 11,8 18,4 29,5 46,5 73,8 118 184,5
500 6,5 10,4 16,3 26 41,1 65,2 104,3 163
550 2,3 3,7 5,8 9,3 14,7 23,3 37,3 58,3
560 1,9 3 4,7 7,6 12 19 30,4 47,6
570 1,5 2,5 3,9 6,2 9,9 15,7 25,1 39,2

RT 10 16 25 40 63 100 160 250
100 10 16 25 40 63 100 160 250
150 10 16 25 40 63 100 160 250
200 10 16 25 40 63 100 160 250
250 10 16 25 40 63 100 160 250
300 10 16 25 40 63 100 160 250
350 9,7 15,6 24,4 39 61,5 97,6 156,1 244
1.7380 400 9,2 14,8 23,2 37,1 58,5 92,8 148,5 232,1
1.7383 450 8,8 14 22 35,2 55,5 88 140,9 220,2
1.7375 500 6,4 10,2 16 25,7 40,5 64,2 102,8 160,7
550 3,2 5,1 8 12,9 20,4 32,3 51,8 80,9
560 2,7 1,4 6,9 11 17,4 27,6 44,1 69
570 2,4 3,8 6 9,7 15,3 24,2 38,8 90,7
580 2 3,3 5,2 8,3 13,2 20,9 33,5 52,3
590 1,8 2,8 4,5 7,2 11,4 18 28,9 45,3
600 1,6 2,5 4 6,4 10,2 16,1 25,9 40,4
Instruction manual

RT 10 16 25 40 63 100 160 250
100 8,6 13,7 21,5 34,4 54,3 86,1 137,9 215,4
150 7,7 12,3 19,2 30,8 48,6 77,1 123,4 192,8
200 7 11,2 17,5 28 44,1 70 112 175
250 6,5 10,4 16,3 26 41,1 65,2 104,3 163
300 6 9,6 15,1 24,1 38,1 60,4 96,7 151,1
350 5,7 9,2 14,4 23 36,3 57,6 92,1 144
1.4306 400 5,5 8,8 13,8 22 34,8 55,2 88,3 138
1.4307 450 5,3 8,5 13,3 21,4 33,7 53,5 85,7 133,9
500 5,1 8,3 12,9 20,7 32,7 51,9 83 129,7
550 4,3 7 10,9 17,5 27,6 43,8 70 109,5
560 4 6,4 10,1 16,1 25,6 40,4 64,7 101,1
570 3,7 5,9 9,2 14,8 23,4 37,1 59,4 92,8
580 3,4 5,4 8,5 13,7 21,6 34,2 54,8 85,7
590 3 4,9 7,7 12,3 19,5 30,9 49,5 77,3
600 2,8 4,4 7 11,2 17,7 28 44,9 70,2

RT 10 16 25 40 63 100 160 250
100 9 14,5 22,7 36,3 57,3 90,9 145,5 227,3
150 8,1 13,1 20,4 32,7 51,6 81,9 131 204,7
200 7,4 11,9 18,6 29,9 47,1 74,7 119,6 186,9
250 6,9 11 17,2 27,6 43,5 69 110,4 172,6
300 6,4 10,2 16 25,7 40,5 64,2 102,8 160,7
350 6,1 9,8 15,3 24,5 38,7 61,4 98,2 153,5
1.4301 400 5,9 9,5 14,8 23,8 37,5 59,5 95,2 148,8
1.4308 450 5,8 9,3 14,5 23,3 36,7 58,3 93,3 145,8
500 5,7 9,1 14,2 22,8 36 57,1 91,4 142,8
550 4,3 7 10,9 17,5 27,6 43,8 70 109,5
560 4 6,4 10,1 16,1 25,5 40,4 64,7 101,1
570 3,7 5,9 9,2 14,8 23,4 37,1 59,4 92,8
580 3,4 5,4 8,5 13,7 21,6 34,2 54,8 85,7
590 3 4,9 7,7 12,3 19,5 30,9 49,5 77,3
600 2,8 4,4 7 11,2 17,7 28 44,9 70,2
Instruction manual

RT 10 16 25 40 63 100 160 250
100 9,9 15,8 24,7 39,6 62,4 99 158,4 250
150 9,3 14,9 23,3 37,3 58,8 93,3 149,3 233,3
200 8,8 14,1 22,1 35,4 55,8 88,5 141,7 221,4
250 8,4 13,4 21 33,7 53,1 84,2 134,8 210,7
300 7,9 12,7 19,8 31,8 50,1 79,5 127,2 198,8
1.4541 350 7,6 12,2 19,1 30,6 48,3 76,6 122,6 191,6
1.4550 * 400 7,4 11,8 18,5 29,7 46,8 74,2 118,8 185,7
1.4552 * 450 7,2 11,6 18,1 29 45,7 72,6 116,1 181,5
500 7 11,3 17,7 28,3 44,7 70,9 116,5 177,3
550 6,7 10,8 16,9 27 42,6 67,6 108,1 169
560 6,1 9,8 15,3 24,5 38,7 61,4 98,2 153,5
570 5,6 8,9 14 22,4 35,4 56,1 89,9 140,4
580 5 8,1 12,7 20,3 32,1 50,9 81,5 127,3
590 4,5 7,3 11,4 18,2 28,8 45,7 73,1 114,2
600 4 6,5 10,2 16,3 25,8 40,9 65,5 102,3
* max 500°C

RT 10 16 25 40 63 100 160 250
100 9,4 15,1 23,6 37,9 59,7 94,7 151,6 236,9
150 8,6 13,7 21,5 34,4 54,3 86,1 137,9 215,4
200 7,9 12,7 19,8 31,8 50,1 79,5 127,2 198,8
1.4404 250 7,4 11,9 18,6 29,9 47,1 74,7 119,6 186,9
1.4435 300 6,9 11 17,2 27,6 43,5 69 110,4 172,6
1.4458 350 6,6 10,5 16,5 26,4 41,7 66,1 105,9 165,4
400 6,4 10,2 16 25,7 40,5 64,2 102,8 160,7
450 6,2 10 15,6 25 39,4 62,6 100,1 156,5
500 6 9,7 15,2 24,3 38,4 60,9 97,5 152,3
Industriestraße 7-9 eMail: contact@ritag.com 27
Instruction manual

RT 10 16 25 40 63 100 160 250
100 10 16 25 40 63 100 160 250
150 9 14,5 22,7 36,3 57,3 90,9 145,5 227,3
200 8,4 13,4 21 33,7 53,1 84,2 134,8 210,7
250 7,9 12,7 19,8 31,8 50,1 79,5 127,2 198,8
300 7,4 11,8 18,5 29,7 46,8 74,2 118,8 185,7
1.4401 350 7,1 11,4 17,8 28,5 45 71,4 114,2 178,5
1.4408 400 6,8 10,9 17,1 27,4 43,2 68,5 109,7 171,4
1.4436 450 6,7 10,7 16,8 26,9 42,4 67,3 107,8 168,4
500 6,6 10,5 16,5 26,4 41,7 66,1 105,9 165,4
550 6,5 10,4 16,3 26 41,1 65,2 104,3 163
560 6,4 10,3 16 25,7 40,5 64,3 103 160,9
570 6,3 10,1 15,8 25,4 40 63,5 101,6 158,8
580 6,2 10 15,6 25 39,5 62,7 100,3 156,7
590 6,1 9,9 15,4 24,7 39 61,9 99 154,7
600 5,6 8,9 14 22,4 35,4 56,1 89,9 140,4

1.4571 RT 10 16 25 40 63 100 160 250
1.4581 100 10 16 25 40 63 100 160 250
150 9,8 15,6 24,5 39,2 61,8 98 156,9 245,2
200 9,3 14,9 23,3 37,3 58,8 93,3 149,3 233,3
250 8,8 14,1 22,1 35,4 55,8 88,5 141,7 221,4
300 8,3 13,3 20,8 33,3 52,5 83,3 133,3 208,3
350 8 12,8 20,1 32,1 50,7 80,4 128,7 201,1
400 7,8 12,4 19,5 31,2 49,2 78 124,9 195,2
450 7,6 12,2 19,1 30,6 48,3 76,6 122,6 191,6
500 7,5 12 18,8 30 47,4 75,2 120,3 188
550 7,4 11,9 18,6 29,9 47,1 74,7 119,6 186,9
560 7,4 11,8 18,5 29,6 46,6 74 118,5 185,1
570 7,3 11,7 18,3 29,3 46,2 73,3 117,3 183,3
580 6,7 10,7 16,7 26,8 42,3 67,1 107,4 167,8
590 6 9,7 15,2 24,3 38,4 60,9 97,5 152,3
600 5,5 8,8 13,8 22 34,8 55,2 88,3 138
Instruction manual

1.4462 RT 10 16 25 40 63 100 160 250
1.4362 100 10 16 25 40 63 100 160 250
1.4410 150 10 16 25 40 63 100 160 250
1.4517 200 10 16 25 40 63 100 160 250
1.4469 250 10 16 25 40 63 100 160 250
Working temperatures below 0° C can be found in AD 2000-W10
Instruction manual
Annex III - Pressure/Temperature Classification acc. to ASME B16.34
Working data for material group 1.1

Material Temp. ( °C ) 150 300 600 900 1500 2500
-29 to 38 19,6 51,1 102,1 153,2 255,3 425,5
50 19,2 50,1 100,2 150,4 250,6 417,7
100 17,7 46,6 93,2 139,8 233 388,3
150 15,8 45,1 90,2 135,2 225,4 375,6
A216 WCB 200 13,8 43,8 87,6 131,4 219 365
A515 Grade70 250 12,1 41,9 83,9 125,8 209,7 349,5
A105 300 10,2 39,8 79,6 119,5 199,1 331,8
A350 LF2 325 9,3 38,7 77,4 116,1 193,6 322,6
350 8,4 37,6 75,1 112,7 187,8 313
375 7,4 36,4 72,7 109,1 181,8 303,1
400 6,5 34,7 69,4 104,2 173,6 289,3
425 5,5 28,8 57,5 86,3 143,8 239,7

Material Temp. ( °C ) 150 300 600 900 1500 2500
-29 to 38 19,8 51,7 103,4 155,1 258,6 430,9
50 19,5 51,7 103,4 155,1 258,6 430,9
100 17,7 51,5 103 154,6 257,6 429,4
A106 GradeC 150 15,8 50,2 100,3 150,5 250,8 418,1
A216 WCC 200 13,8 48,6 97,2 145,8 243,2 405,4
A352 LC2 * 250 12,1 46,3 92,7 139 231,8 386,2
A352 LC3 * 300 10,2 42,9 85,7 128,6 214,4 357,1
A352 LCC * 325 9,3 41,4 82,6 124 206,6 344,3
350 8,4 40 80 120,1 200,1 333,5
375 7,4 37,8 75,7 113,5 189,2 315,3
400 6,5 34,7 69,4 104,2 173,8 289,3
425 5,5 28,8 57,5 86,3 143,8 239,7
* not to be used above 345°C
Instruction manual

Material Temp. ( °C ) 150 300 600 900 1500 2500
-29 to 38 18,4 48 96 144,1 240,1 400,1
50 18,2 47,5 94,9 142,4 237,3 395,6
100 17,4 45,3 90,7 136 226,7 377,8
150 15,8 43,9 87,9 131,8 219,7 366,1
A352 LCB * 200 13,8 42,5 85,1 127,6 212,7 354,4
A515 Grade70 250 12,1 40,8 81,6 122,3 203,9 339,8
A516 Grade65** 300 10,2 38,7 77,4 116,1 193,4 322,4
325 9,3 37,6 75,2 112,7 187,9 313,1
350 8,4 36,4 72,8 109,2 182 303,3
375 7,4 35 69,9 104,9 174,9 291,4
400 6,5 32,6 65,2 97,9 163,1 271,9
425 5,5 27,3 54,6 81,9 136,5 227,5
* * not to be used above 345°C ** not to be used above 425°C

Material Temp. ( °C ) 150 300 600 900 1500 2500
-29 to 38 19,8 51,7 103,4 155,1 258,6 430,9
50 19,5 51,7 103,4 155,1 258,6 430,9
100 17,7 51,5 103 154,4 257,4 429
150 15,8 49,7 99,5 149,2 248,7 414,5
200 13,8 48 95,9 143,9 239,8 399,5
250 12,1 46,3 92,7 139 231,8 386,2
300 10,2 42,9 85,7 128,6 214,4 357,1
A182 Grade F11 Cl.2 * 325 9,3 41,4 82,6 124 206,6 344,3
A217 WC6 * 350 8,4 40,3 80,4 120,7 201,1 335,3
375 7,4 38,9 77,6 116,5 194,1 323,2
400 6,5 36,8 73,3 109,8 183,1 304,9
425 5,5 35,2 70 105,1 175,1 291,6
450 4,6 33,7 67,7 101,4 169 281,8
475 3,7 31,7 63,4 95,1 158,2 263,9
500 2,8 25,7 51,5 77,2 128,6 214,4
538 1,4 14,9 29,8 44,7 74,5 124,1
550 1,4 12,7 25,4 38,1 63,5 105,9
575 1,4 8,8 17,6 26,4 44 73,4
600 1,4 6,1 12,2 18,3 30,5 50,9
* not to be use above 595°C
Instruction manual
Annex III - Pressure/Temperature Classificationacc. to ASME B16.34

Material Temp. ( °C ) 150 300 600 900 1500 2500
-29 to 38 19 49,6 99,3 148,9 248,2 413,7
50 18,3 47,8 95,6 143,5 239,1 398,5
100 15,7 40,9 81,7 122,6 204,3 340,4
150 14,2 37 74 111 185 308,4
200 13,2 34,5 69 103,4 172,4 287,3
A182 F304 * 250 12,1 32,5 65 97,5 162,4 270,7
A182 F304H 300 10,2 30,9 61,8 92,7 154,6 257,6
A240 F304 * 325 9,3 30,2 60,4 90,7 151,1 251,9
A240 F304H 350 8,4 29,6 59,3 88,9 148,1 246,9
A351 CF3 ** 375 7,4 29 58,1 87,1 145,2 241,9
A351 CF8 * 400 6,5 28,4 56,9 85,3 142,2 237
A479 F304 * 425 5,5 28 56 84 140 233,3
A479 F304H 450 4,6 27,4 54,8 82,2 137 228,4
475 3,7 26,9 53,9 80,8 134,7 224,5
500 2,8 26,5 53 79,5 132,4 220,7
538 1,4 24,4 48,9 73,3 122,1 203,6
550 1,4 23,6 47,1 70,7 117,8 196,3
575 1,4 20,8 41,7 62,5 104,2 173,7
600 1,4 16,9 33,8 50,6 84,4 140,7
* above 538°C only when carbon content is 0,04% or higher ** not to be used above 425°C
Instruction manual

Material Temp. ( °C ) 150 300 600 900 1500 2500
-29 to 38 19 49,6 99,3 148,9 248,2 413,7
50 18,4 48,1 96,2 144,3 240,6 400,9
100 16,2 42,2 84,4 126,6 211 351,6
150 14,8 38,5 77 115,5 192,5 320,8
A182 F316 * 200 13,7 35,7 71,3 107 178,3 297,2
A182 F316 H 250 12,1 33,4 66,8 100,1 166,9 278,1
A240 Grade316 * 300 10,2 31,6 63,2 94,9 158,1 263,5
A240 Grade 316H 325 9,3 30,9 61,8 92,7 154,4 257,4
A351 CF3A ** 350 8,4 30,3 60,7 91 151,6 252,7
A351 CF3M *** 375 7,4 29,9 59,8 89,6 149,4 249
A351 CF8A ** 400 6,5 29,4 58,9 88,3 147,2 245,3
A351 CF8M * 425 5,5 29,1 58,3 87,4 145,7 242,9
A479 F316 * 450 4,6 28,8 57,7 86,5 144,2 240,4
A479 F316H 475 3,7 28,7 57,3 86 143,4 238,9
500 2,8 28,2 56,5 84,7 140,9 235
538 1,4 25,2 50 75,2 125,5 208,9
550 1,4 25 49,8 74,8 124,9 208
575 1,4 24 47,9 71,8 119,7 199,5
600 1,4 19,9 39,8 59,7 99,5 165,9
* above 538°C only when carbon content is 0,04% or higher ** not to be used over 345°C
*** not to be used over 425°C

Material Temp. ( °C ) 150 300 600 900 1500 2500
-29 to 38 15,9 41,4 82,7 124,1 206,8 344,7
50 15,3 40 80 120,1 200,1 333,5
100 13,3 34,8 69,6 104,4 173,9 289,9
A182 F304L * 150 12 31,4 62,8 94,2 157 261,6
A182 F316L 200 11,2 29,2 58,3 87,5 145,8 243
A240 Grade 304L * 250 10,5 27,5 54,9 82,4 137,3 228,9
A240 Grade316L 300 10 26,1 52,1 78,2 130,3 217,2
A479 Grade304L * 325 9,3 25,5 51 76,4 127,4 212,3
A479 Grade316L 350 8,4 25,1 50,1 75,2 125,3 208,9
375 7,4 24,8 49,5 74,3 123,8 206,3
400 6,5 24,3 48,6 72,9 121,5 202,5
425 5,5 23,9 47,7 71,6 119,3 198,8
450 4,6 23,4 46,8 70,2 117,1 195,1
* not to be used over 425°C
Instruction manual

Material Temp. ( °C ) 150 300 600 900 1500 2500
-29 to 38 19 49,6 99,3 148,9 248,2 413,7
50 18,6 48,6 97,1 145,7 242,8 404,6
100 17 44,2 88,5 132,7 221,2 368,7
150 15,7 41 82 122,9 204,9 341,5
200 13,8 38,2 76,6 114,9 191,5 319,1
250 12,1 36 72 108,1 180,1 300,2
A182 F321 * 300 10,2 34,1 68,3 102,4 170,7 284,6
A240 F321 * 325 9,3 33,3 66,6 99,9 166,5 277,6
A479 Grade 321 * 350 8,4 32,6 65,2 97,8 163 271,7
A182 F321H ** 375 7,4 32 64,1 96,1 160,2 266,9
A240 F321H ** 400 6,5 31,6 63,2 94,8 157,9 263,2
A479 Grade 321H ** 425 5,5 31,1 62,3 93,4 155,7 259,5
450 4,6 30,8 61,7 92,5 154,2 256,9
475 3,7 30,5 61,1 91,6 152,7 254,4
500 2,8 28,2 56,5 84,7 140,9 235
538 1,4 25,2 50 75,2 125,5 208,9
550 1,4 25 49,8 74,8 124,9 208
575 1,4 24 47,9 71,8 119,7 199,5
600 1,4 20,3 40,5 60,8 101,3 168,9
* not to be used above 538°C
** above 538°C only when material is heat treated (über 1095°C)
Zwischenflansch-Rückschlagventil SR 20.40-St
Wafer Type Check Valve
Einsatzgrenzen (Pressure/Temperature Ratings)
TMA (°C) -10 200 300

PN 40 PMA (bar) 16 33 24
Leckrate nach DIN 3230 Teil 3, BO3 (met., PTFE) oder BO1 (NBR, EPDM, FKM)
Leakage acc. to DIN 3230 part 3, BO3 (met., PTFE) or BO1 (NBR, EPDM, FKM)
Werkstoffe (Materials)
Gehäuse/Body Platte/Discs Feder/Spring

1.0570 (DN 15 - 40) 1.4301 1.4571 1) DN 15 - 100
1.0421 (DN 50 - 100) 1.4301 1.4571 1) PN 6 - 40
1
) bei Temperaturen über 300°C bitte Nimonic-Feder wählen
1
) when exceeding 300°C operating temperature please use an Nimonic spring Verwendung
• Neutrale Flüssigkeiten
Elastische Dichtung möglich • Öle
Elastic seat rings available • Luft
• Fluidgruppe 1 gemäß
DGRL 97/23/EG
Öffnungsdrücke (Opening Pressures)
Application
Ohne Feder/ • Neutrally Fluids
• Oil
DN PÖ (mbar) without spring • Air
↔ ↑ ↓ ↑ • Fluidgroup 1 acc. to
PED 97/23/EC
15 20 24 16 4
20 20 24 16 4
25 20 24 16 4
32 20 24 16 4
40 20 24,5 15,5 4,5
50 20 25 15 5
65 20 25,5 14,5 5,5
80 20 26,5 13,5 6,5
100 20 26,5 13,5 6,5
↔ ↑ ↓ = Durchflussrichtung/Flow direction
Technische Änderungen vorbehalten 09/2002

Zwischenflansch-Rückschlagventil SR 20.40-St
Wafer Type Check Valve
Maße und Gewichte (Dimensions and Weights)
Maße/dimensions in mm
DN L D1 D2 d0 d1 kg
(PN6) (PN10-40)
15 16 43 51 15 28 0,15
20 19 53 61 20 33 0,25
25 22 64 71 25 41,5 0,30
32 28 76 82 32 51,5 0,60
40 31,5 86 92 40 58,5 0,80
50 40 96 108 48,5 71,5 1,30
65 46 116 127 63 90 2,00 Baulänge nach EN 558-1, Reihe 49
80 50 132 142 77 100 2,30 Face/Face dimension acc. to EN 558-1, line 49
100 60 152 162 96 126 3,50
Passend zwischen Flansche EN 1092-1, Form B1
For fitting between flanges acc. to EN 1092-1, form B1
Druckverlustdiagramm (Pressure Drop Chart)
Teilöffnung = instabiler Bereich Vollöffnung = stabiler Bereich
Die Diagrammwerte gelten für Wasser bei 20°C. Sie resultieren partial opening = instable range full opening = stable range
aus Messungen an Ventilen beim Einbau in horizontaler Leitung. 1000
Beim Einbau in vertikaler Leitung ergeben sich im Teilöffnungs-

bereich unbedeutende Abweichungen. Um Druckverluste bei
anderen Medien zu ermitteln, ist zuvor der äquivalente Wasser-
volumenstrom nach folgender Formel zu berechnen: 100
100 80
65
Graph readings apply to water at 68° F (20° C). They result from 50
messurements on valves installed in horizontal pipes. 40
For installation in vertical pipes insignificant devitations occur 32
in the partial opening. In order to determine pressure losses for 10

25
other media the equivalent water flow has to be calculated before 20
applying the following formula: 15
ρ 1
¤W = ¤
Volumenstrom / volume flow w [m3/h]
1000
¤W [m3/h] äquivalenter Wasservolumenstrom

equivalent water flow
ρ [kg/m3]
0,1
Dichte des Mediums (Betriebszustand)
density of medium at working conditions
¤ [m3/h] Volumenstrom des Mediums (Betriebszustand)
flow of medium at working conditions
10 20 30 40 50 60 70 80 100 200 300 400 500 600 800 1000
Druckverlust / pressure drop ∆p [mbar]
Technische Änderungen vorbehalten 09/2002

Armaturenwerk KG Fax +49 (0) 47 91-92 09-85
RK... D

Betriebsanleitung
Rückschlagventile RK
 Installation Instructions
808519-07 Non-Return Valves RK
F Instructions de montage et de mise en service
Clapets de retenue RK
E Instrucciones de montaje y servicio
Válvulas de retención RK
I Manuale di Istruzioni
Valvole di non ritorno RK
 Инструкция по эксплуатации
Обратные клапаны RK
 Gebruiksaanwijzing
559/658
Terugslagkleppen RK
Safety Note 
The equipment must only be installed and commissioned by qualified and adequately
trained personnel. Maintenance and retrofitting must only be performed by entrusted
personnel who – through adequate training – have achieved a recognized level of
competence.
Usage for the intended purpose 

The non-return valves RK are automatic-stop check valves and designed for use in
pipes in order to prevent the backflow of fluid. The admissible pressure and temperature
ratings as well as the chemical and corrosive influences of the fluid on the pressure
equipment must be taken into account. Check the chemical resistance and suitability of
the valve for the operating conditions in question.
Attention 
The name plate specifies the technical characteristics of the equipment.
Do not commission or operate
560/658a device without a name plate!
Danger 
The valve is under pressure during operation.
When loosening flanged connections or sealing plugs, hot water, steam,
corrosive fluids or toxic gases may escape. This presents the risk of severe
burns and scalds to the whole body or severe cases or poisoning.
Installation and maintenance work should only be carried out when the
system is depressurized.
The valve becomes hot or extremely cold during operation. This presents
the risk of severe burns to hands and arms. Installation and maintenance
work should only be carried out at room temperatures.
Sharp edges on internals present a danger of cuts to hands. Always wear
industrial gloves for installation and maintenance work.
ATEX Directive 94/9/EC, 1999/92/EC 

The equipment does not have its own potential source of ignition and is therefore not
subject to the Directive 94/9/EC.
The equipment can be used in the following explosive zones: 0, 1, 2, 20, 21 and 22.
The equipment does not require an Ex561/658
marking.
Technical Data 
For pressure ratings see marking or name plate (pressure class PN/Class, material
number, sticker for soft seal, spring material)
Observe lower temperature ratings for equipment with elastic seals and certain spring
materials.
Typ PN / CL DN PMA / TMA [bar] / [°C]

RK 70 6 /- 15 - 100 6 / -30 0.5 / 130
RK 70 6 /- 125 - 200 6 / -10 0.5 / 130
RK 71 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 15 - 100 16 / -60 13 / 250
RK 41 16 /- 125 - 200 16 / -10 13 / 300
RK 44 16 /- 15 - 100 16 / -200 13 / 250
RK 44 16 /- 125 - 200 16 / -10 13 / 250
RK 44S 16 /- 15 - 100 16 / -200 16 / 90
RK 76 40 / 300 15 - 100 49.6 / -10 31.6 / 300
RK 86 40 / 300 15 - 100 51 / -10 36.9 / 350
RK 86 40 / 300 125 - 200 51 / -10 34.5 / 400
RK 86A 40 / 300 562/658
15 - 200 49.6 / -200 24 / 550
Technical Data – continued – 
Typ PN / CL DN PMA / TMA [bar] / [°C]
RK 16A 40 / 300 15 - 100 49.6 / -200 24 / 550
RK 16C 40 / 300 15 - 100 49.6 / -200 29.3 / 400
RK 26A 40 / 300 15 - 100 49.6 / -200 25 / 550
RK 49 160 / – 15 - 65 160 / -10 110.8 / 550
RK 49 160 / – 80 - 200 160 / -10 55.3 / 530
RK 29A 63 / – 15 - 200 63 / -200 44.2 / 500
RK 29A 100 / – 15 - 200 100 / -200 70.2 / 500
RK 29A 160 / – 15 - 200 160 / -200 112.4 / 500
RK 29A 250 / – 15 - 200 250 / -200 175.6 / 500
RK 29A 320 / – 15 - 200 320 / -200 224.7 / 500
RK 29A 400 / – 15 - 200 400 / -200 280.9 / 500
RK 29A – / 400 15 - 200 66.2 / -200 37.6 / 500
RK 29A – / 600 15 - 200 99.3 / -200 56.6 / 500
RK 29A – / 900 15 - 200 148.9 / -200 84.7 / 500
RK 29A – / 1500 15 - 200 248.2 / -200 140.9 / 500
RK 29A – / 2500 563/658
15 - 200 413.7 / -200 235 / 500
Description 
Non-return valve RK with spiral centering ring or self-centering body. Installation in any
position. Exception: Valves without spring can only be installed in vertical lines with
upward flow.
1 Non-return valve with spiral centering ring
2 Non-return valve with body centering cams
3 Non-return valve with self-centering body
4 Position of guide ribs (horizontal installation)
564/658
Installation 
TOP
1 2 3
565/658 4
Name Plate / Marking 
Type: RK ...
DN:... Type: RK ...
PN:... DN:...
.......... PN:...
..........
Type: RK ... Type: RK ...

DN:... DN:...
PN:... PN:...
.......... ..........
1/02  2002
1  2002
02 566/658
Declaration of Conformity 
We hereby declare that the pressure equipment RK... conforms to the following European
Directive:
n Pressure Equipment Directive (PED) 97/23/EC of 29 May 1997 (except for equipment
excluded from the scope of the PED according to section 3.3).
n Applied conformity assessment procedure: Annex III, Module H, verified by the
Notified Body 0525.
This declaration is no longer valid if modifications are made to the equipment without
consultation with us.
Bremen, 11th February 2005
GESTRA AG
Head of the Design Dept. Quality Assurance Manager

Uwe Bledschun Lars Bohl
(Academically qualified engineer) (Academically qualified engineer)
567/658
GESTRA® www.gestra.de
E

GESTRA ESPAÑOLA S.A
Luis Cabrera, 86-88


GESTRA Polonia Spolka z.o.o.
Ul. Schuberta 104
E-28002 Madrid PL - 80-172 Gdansk
Tel. 0034 91 / 5 15 20 32 Tel. 0048 58 / 3 06 10 - 02
Fax 0034 91 / 4 13 67 47, 5 15 20 36 0048 58 / 3 06 10 - 10
E-mail: aromero@flowserve.com Fax 0048 58 / 3 06 33 00
E-mail: gestra@gestra.pl


Flowserve GB Limited
Abex Road Flowserve Portuguesa, Lda.
Newbury, Berkshire RG14 5EY
P
Av. Dr. Antunes Guimarães, 1159
Tel. 0044 16 35 / 4 69 99 Porto 4100-082
Fax 0044 16 35 / 3 60 34 Tel. 00351 22 / 6 19 87 70
E-mail: gestraukinfo@flowserve.com Fax 00351 22 / 6 10 75 75
E-mail: jtavares@flowserve.com
I Flowserve S.p.A.
Flow Control Division  Flowserve GESTRA U.S.
Via Prealpi, 30 2341 Ampere Drive
l-20032 Cormano (MI) Louisville, KY 40299
Tel. 0039 02 / 66 32 51 Tel. 001 502 / 267-2205
Fax 0039 02 / 66 32 55 60 Fax 001 502 / 266-5397
E-mail: infoitaly@flowserve.com
568/658 E-mail: FCD-Gestra-USA@flowserve.com
GESTRA AG
Postfach 10 54 60, D-28054 Bremen
Münchener Str. 77, D-28215 Bremen
Telefon 0049 (0) 421 / 35 03 - 0
Telefax 0049 (0) 421 / 35 03 - 393
E-Mail gestra.ag@flowserve.com
Internet www.gestra.de
569/658
808519-07/1106cs · 1999 GESTRA AG · Bremen · Printed in Germany

570/658
GESTRA® DISCO Non-Return Valves Non-Return Valves
RK 76
Issue Date: 10/00

PN 6/10/16/25/40
DN 15-100 mm
(1/2 - 4˝ )
RK 76
A2
Application for liquids, gases and vapours.
Pressure/Temperature Rating
[mm] 15 –100
Nominal sizes DN [in] 1/2 – 4˝
Nominal pressure PN 401 )
D∅
Max. service pressure [barg] 40 35 32 28
for RK 76 [psig] 580 508 464 406
[°C] 20 100 200 300

Related temperature [°F] 68 212 392 572
Minimum temperature 2 ) – 10 °C (14 °F)

1
) Also rated for ANSI class 300, but see flange details below.
2
) Minimum temperature at nominal pressure rating. L
Tight shut-off in accordance with DIN 3230, part 3, leakrate BN2/BO3.
Connections of wafer-type valves 3)

Valves for universal fitting between flanges to
DIN BS ASME
DIN 2501 (BS 4504) BS 10 ASME B 16.1 class 125 FF
PN 6/10/16/25/40 tables D, E, F, H, J 4 ) ASME B 16.5 class 150/300 RF
BS 4504
3
) With universal centering ring.
4
) Tables D/E, DN 65 mm and DN 80 mm (2 1/2 and 3˝): Choose nominal size one size smaller each.
Dimensions
[mm] 15 20 25 32 40 50 65 80 100
DN
[in] 1
/2 3
/4 1 1 1/4 1 1/2 2 2 1/2 3 4
Dimensions L 5) 16 19 22 28 31.5 40 46 50 60
in mm D 45 55 65 75 85 98 118 134 159
Weight [kg] 0.18 0.3 0.45 0.7 0.9 1.5 2.1 3.4 5.2
5
) Overall length according to DIN EN 558-1, series 49 (=
^ DIN 3202, part 3, series K4)
Materials
DN 15-100 mm (1/2 – 4˝ ) DIN reference ASTM equivalent
Body, seat
G-X 8 CrNi 13 1.4008 A 217-CA 15
and guide ribs
Valve disc, spring retainer A 182 F 316

X 6 CrNiMoTi 17 12 2 1.4571
Spring A 313 Type 316
Centering ring X 12 CrNi 17 7 1.4310 Type 302
571/658
Non-Return Valves GESTRA GmbH
A2
RK 76
PN 6/10/16/25/40
DN 15-100 mm
(1/2 - 4˝ )
P. O. Box 10 54 60, D-28054 Bremen
Hemmstraße 130, D-28215 Bremen
Tel. +49 (0) 421 35 03-0
Fax +49 (0) 421 35 03-393
Internet www.gestra.de
Opening pressures Pressure Drop Chart

. . Ú
Differential pressures at zero volume flow The curves given in the chart are valid for water VW = V ·
1000
at 20 °C. To read the pressure drop for other .
DN Opening pressures in mbar fluids the equivalent water volume flowrate VW = Equivalent water volume flow
must be calculated and used in the graph. in l/s etc.
Direction of flow
with springs The values indicated in the chart are applicable Ú = Density of fluid (operating condition)
to spring-loaded valves with horizontal flow. in kg/m3 etc.
[mm] [in] With vertical flow insignificant deviations .
1 occur only within the range of partial opening. V = Volume of fluid (operating condition)
15 /2 25 22.5 20 in l/s etc.
3
20 /4 25 22.5 20
25 1 25 22.5 20
32 11/4 27 23.5 20
40 1 1/2 28 24.0 20
50 2 29 24.5 20
65 2 1/2 30 25.0 20
80 3 31 25.5 20
100 4 33 26.5 20
1 mbar ^
= 0.0145 psi ^
= 10 mm w.g. ^
= 0.4 in w.g.
When selecting valve please consider

Partial opening Full opening
= instable range = stable range
Imp.
gal / min m3/h l/s DN
mm
Enquiry Specification
GESTRA DISCO non-return valves RK76.
Wafer design with extremely short overall
length to DIN EN 558-1, table 11, series 49
^
= DIN 3202, part 3, series K4)
Suitable for fitting between flanges to DIN,BS
or ASME FF.
Indications on pressure, nominal size (DN),
body material.
Order Specifications
Type RK 76, DN . .
Metal-to-metal
Fluid, flowrate, pressure and temperature.
Type of pipe flanges.
Note
The valves should not be used on compressors
or where pulsating flow exists.
For these applications please consult us.
Volume flow Vw
bar
Supply in accordance with our general terms

of business.
Technical modifications reserved.

Pressure drop ∆ p 1 US gallon 0.833 Imp. gallon
© 1998 GESTRA GmbH · BREMEN · Printed in Germany
810294-01/1000
572/658
Valves
RHDI Non return valve

Female BSPP thread (ISO 1179-1) / Female BSPP thread (ISO 1179-1)
PN (bar) 1)
Weight
Series T1 DN D1 L1 L2 L3 S1 S2 g/1 piece Order code* CF 71
L3) G11/18 3.5 19 42.5 12.0 8.0 19 19 76 RHDI1/8 400 400
G 1/4 3.5 19 51.0 16.0 12.0 19 19 82 RHDI1/4 400 400
G 3/8 7.5 24 60.0 17.0 12.0 24 27 157 RHDI3/8 400 400
G 1/2 11.5 32 72.0 20.0 15.0 32 36 344 RHDI1/2 315 315
G 3/4 15.0 41 84.0 22.0 16.5 41 46 664 RHDI3/4 250 250
G1 19.0 46 95.0 25.5 19.0 46 50 821 RHDI1 250 250
G 11/4 24.0 60 110.0 28.0 21.5 60 60 1581 RHDI11/4 250 250
G 11/2 29.0 65 114.0 28.5 22.0 65 70 1919 RHDI11/2 250 250
1) Pressure shown = item deliverable
3) L = light series
PN (bar)
= PN (MPa)
10
Delivery without nut and ring. Information on ordering complete
fittings or alternative sealing materials see page I7.
Order code suffixes

Material Suffix Example Standard
surface sealing material
and material (no additional.
suffix needed)
Steel, zinc plated.,
*Please add the suffixes Cr(VI)-free CF RHDI1/8CF NBR
below according to the material/
Stainless steel 71 RHDI1/871 VIT
surface required.
O18 Catalogue 4100-8/UK
573/658
Valves
RVP Non return valve cartridge
X1) Supporting ring PTFE

X2) O-ring NBR
X3) Sealing disc NBR
PN (bar)1)
Valve L1 Weight
ITL DN D1 D2 ± 0,15 L2 L3 O-ring Supporting ring g/1 piece Order code* CF 71
+0.12
6-L/6 & 8-S 3.5 12.945 ± 0.055 13 +0.05 23.15 9.5 6.0 8.3×2.4 SRA 13-2.05-1.0 21 RVP13 420 400
+0.12
8-L/10-S 5.5 15.945 ± 0.055 16 +0.05 26.65 9.5 6.5 11.3×2.4 SRA 16-2.05-1.0 32 RVP16 420 400
+0.142
10-L/12-S 7.5 19.935 ± 0.065 20 +0.065 30.15 9.5 6.5 15.3×2.4 SRA 20-2.05-1.0 54 RVP20 420 400
+0.149
12-L/14-S 9.5 23.935 ± 0.065 24 +0.065 35.15 12.0 7.5 18.2×3 SRA 24-2.6-1.0 80 RVP24 420 315
+0.149
15-L/16-S 11.5 26.935 ± 0.065 27 +0.065 38.15 12.0 7.5 21.2×3 SRA 27-2.6-1.0 105 RVP27 420 315
+0.18
18-L/20-S 15.0 34.92 ± 0.08 35 +0.08 44.65 12.0 9.5 29.2×3 SRA 35-2.5-1.0 204 RVP35 420 250
+0.18
22-L/25-S 19.0 39.92 ± 0.08 40 +0.08 50.65 12.0 11.0 34.2×3 SRA 40-2.5-1.0 275 RVP40 420 250
+0.18
28-L/30-S 24.0 46.92 ± 0.08 47 +0.08 60.15 13.0 13.0 41.2×3 SRA 47-2.6-1.5 412 RVP47 250 250
+0.22
35-L/38-S 29.0 54.905 ± 0.095 55 +0.1 70.15 16.0 13.0 44.2×5.7 SRA 55-5.1-1.5 607 RVP55 250 250
1) Pressure shown = item deliverable
PN (bar)
= PN (MPa)
10
Order code suffixes

suffix needed)
Steel, zinc plated.,
*Please add the suffixes Cr(VI)-free CF RHP13CF NBR
Stainless steel 71 RHP1371 VIT
surface required.
574/658
Valves
I-TL Internal parts of non return valve
X1) poppet
X2) sealing disc (smooth side to the poppet)
X3) cover disc
X4) spring
X5) passage disc
PN (bar)1)
Tube Weight
Series O.D. D1+0.1 D2+0.1 D3+0.1 L1±0.1 L2 Hub g/1 piece Order code* CF 71
L/S/S 06/06/08 3.5 7.5 8.6 8.2 2.0 1.0 2 ITL06L/06+08S * *
L/S 08/10 5.5 10.2 11.6 11.0 2.0 1.7 4 ITL08L/10S * *
L/S 10/12 7.5 13.0 14.1 14.0 2.0 2.3 7 ITL10L/12S * *
L/S 12/14 9.5 16.7 18.1 16.5 2.5 2.9 13 ITL12L/14S * *
L/S 15/16 11.5 19.5 20.6 19.0 2.5 3.5 18 ITL15L/16S * *
L/S 18/20 15.0 25.2 27.1 22.5 3.0 4.4 37 ITL18L/20S * *
L/S 22/25 19.0 30.8 32.6 27.0 3.0 5.5 54 ITL22L/25S * *
L/S 28/30 24.0 38.6 40.6 32.5 3.5 7.3 107 ITL28L/30S * *
L/L/S 35/38/42 29.0 45.7 48.1 37.5 3.5 8.9 144 ITL35L+42l/38S * *
* = item deliverable
Order code suffixes

suffix needed)
Steel, zinc plated,
*Please add the suffixes Cr(VI-free CF ITL06L/06+008S NBR
Stainless steel 71 ITL06L71/06+008S VIT
surface required.
575/658

576/658
Safety valves SAFE
SAFE SAFE-P
(Series 900) (Series 920)
SAFE-TC SAFE-TCP/TCS
(Series 940) (Series 960/950)
Contents
1.0 General information on operating 7.1 Setting instructions ................................................11
instructions ..................................................... 2 7.1.1 Removing the cap ........................................11
2.0 Notes on possible dangers........................... 2 7.1.2 Changing the set pressure
2.1 Significance of symbols ..........................................2 “without” spring change .............................. 12
7.1.3 Changing the set pressure
2.2 Explanatory notes on safety information .................2
“with” spring change ................................... 12
3.0 Storage and transport .................................. 3 7.2 Representation .................................................... 14
4.0 Description..................................................... 3
8.0 Troubleshooting .......................................... 15
4.1 Scope of applications ..............................................3
9.0 Troubleshooting table ............................... 15
4.2 Operating principles ................................................3
10.0 Dismantling the valve or the top part ..... 17
4.3 Diagram...................................................................4
4.3.1 Parts list ..........................................................5
11.0 Warranty / Guarantee ................................ 17
4.4 Technical data - remarks .........................................6
12.0 EC declaration of conformity ................... 18
4.5 Marking .................................................................7
5.0 Installation...................................................... 8
5.1 General notes on installation...................................8
6.0 Putting the valve into operation................. 10
7.0 Care and maintenance ................................ 11
Rev. 0040401000 1210 englisch

577/658
SAFE, SAFE-P, SAFE-TC, SAFE-TCP/TCS

and repair.
ATTENTION !
Non-compliance with operating instructions is dangerous!

Read the operating instructions before installation, operation,
maintenance or disassembly and adhere to them strictly.

Information marked with the above symbol and “ATTENTION ! ” describe practices, a
failure to comply with which can result in serious injury or danger of death for users or third
parties or in material damage to the system or the environment. It is vital to comply with
these practices and to monitor compliance.
to property.
Page 2 Rev. 0040401000 1210

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ATTENTION !
- At -20°C to +65°C.
4.0 Description
Safety valves are used to protect pressurised systems.
ATTENTION !
state the higher requirements when ordering
to TRD 110.
- When media in Fluid Group 1 are used, seal exteriors must be designed so that
they pose no danger to humans or the environment.
- Open safety valves (open bonnet / open cap) are not permissible for fluids,
dusty atmospheres, open air use or for any Group 1 fluids in accordance with
Pressure Equipment Directive 97/23/EC.
Safety valves are safety devices designed to prevent the pressure in any pressurised
system from exceeding the maximum permissible pressure by more than the permissible
tolerance of, usually +10%.
Rev. 0040401000 1210 Page 3

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4.3 Diagram
Fig. 901 Fig. 941 Fig. 961
fig. 1
Fig. 902 / 912 / 903 / 904 / 922 / 924 / 945 / 946
WEDI Bellow
Lever Disc series 950 Bellow series 940

Fig. 951/952; 961/962
fig. 2
Page 4 Rev. 0040401000 1210

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4.3.1 Parts list
Pos. Description Pos. Description

1 Body 32 Hex. nut
2 Seat (not changeable) 33 Lift bolt
2 Screwed seat (SAFE-TC) 34 Screw
3 Stud 35 Lift fork
4 Spindle guide 36 Lifting lever
7 Gasket 37 Spring
8 Hex. nut 38 Screw
9 Lift limitation ring 39 Bolt
10 Spindle ring 40 Split pin
11 Bonnet, closed 41 Lever open
12 Disc unit 42 Bonnet, open
13 Lifting aid 43 Bellow
14 Spindle 44 Ring
15 Gasket 45 Ring
16 Spring type straight pin 47 Ball
17 Adjusting screw 48 Retaining ring
18 Ball 55 Bellow unit
19 Spindle cap 59 Protective rim
20 Parallel pin 60 Spacer
21 Lock nut 61 Coupling
22 Hex. head screw 62 Weight
23 Lead seal 63 Guide bush
25 Snap ring 65 Coupling
26 Spring plate 66 O-Ring
27 Gasket 67 Lift button
28 Cap, closed 68 Spring type straight pin
29 Cap open 70 Balanced piston
31 Ring
Refer to the data sheet for information about materials.
Rev. 0040401000 1210 Page 5

581/658
for
- Pressure-temperature-ratings, etc. refer to datasheet.
Series 900: DN 20/32 - DN 150/250, 1”x2“ - 6”x10”

EN-JL1040, EN-JS1049, 1.0619+N, 1.4408, SA 216 WCB
PN 16/16, PN 40/16, ANSI 150/150, ANSI 300/150
Approval acc. to:
Figure 901, 902, 911, - DIN EN ISO 4126-1, VdTÜV leaflet 100, AD2000-A2 and
912 TRD 421.
Application letter D/G and F
- ASME Code Section VIII-Division 1 (UV-Stamp)
Figure 903, 904, 990 -VdTÜV leaflet 100, -100/4, TRD 721, DIN EN 12828.
Application letter D/G/H and D (for Figure 904, 990)
Series 920: DN 20 - DN 100

EN-JL1040, 1.0619+N, 1.4408
PN 16, PN 40
Approval acc. to:
Figure 921-924 - DIN EN ISO 4126-1, VdTÜV leaflet 100, AD2000-A2 and
TRD 421.
Series 940: DN 15 - DN 25 (G 1/2“ - G 1“)

EN-JS1049, 1.4408
PN 40
Approval acc. to:
Figure 941-943 - DIN EN ISO 4126-1, VdTÜV leaflet 100, AD2000-A2 and
TRD 421.
Figure 945-946 -VdTÜV leaflet 100, -100/4, TRD 721, DIN EN 12828.
Application letter D/G/H and D
Series 950/960: DN 15 - DN 25 (G 1/2“ - G 1“)

EN-JS1049, 1.4581
PN 100
Approval acc. to:
Figure 951-953 - DIN EN ISO 4126-1, VdTÜV leaflet 100, AD2000-A2.
Figure 961-963 Application letter D/G and F
Accessories: Stainless steel bellow for back-pressure compensation;

elastomer bellow; soft sealing disc; lock bush; proximity switch;
heating jacket; test gag; rupture disc; support tongues;
removable lifting aid
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4.5 Marking
Fig.-No./Type Type-test
Safety valve (TÜV) approved No. Kdr CE-marking
Manufacturer d0
Notified
body
Approval
Set pressure Adjusting services
Serial-No.
Soft sealed disc: Year of manufacture

E = EPDM -35°C up to 150°C
V = Viton (FPM) -25°C up to 180°C
N = Neoprene -30°C up to 125°C
NB-stamp
Safety valve (ASME) Size (inch) UV-stamp CE-marking
Manufacturer
Notified
body
Fig.-No./Type
Capacity
Fig. 3: Set pressure
Units:
Type test plates SCFM = air
lb/hr = steam
gal/min = water
Address of manufacturer: refer to item 11.0 Warranty / Guarantee
Set pressure
Mechanic No.
BA/BQ
Logo of external approvals
Fig. 4: Body (outlet)

Series with thread connections are marked on the body.
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5.0 Installation
installation work:
ATTENTION !
- The interior of valve and pipeline must be free from foreign particles
- Note installation position with reference to flow, see mark on valve.
- Steam line systems should be designed to prevent water accumulation
- Lay pipelines so that damaging transverse, bending and torsional forces are
avoided.
both sides.
- Valve mountings such as actuators, handwheels, bonnets must not be used to
- The blow-off line shall be sufficiently large to ensure that the internal back-
pressure while blowing-off does not exceed 10% (on reqest max. 15%) of the
set pressure. (Exception: safety valves with metallic bellow for back-pressure
compensation).
- If back pressure exceeds 10% (on request max. 15%) of set pressure, the
safety valve must be fitted with a metallic bellow seal for back pressure
compensation. The maximum back pressure must be specified by the
manufacturer. If necessary a leak detector should be provided to monitor the
back pressure compensating metallic bellow seal, but the leak detector must
not block ventilation.
- The ventilation hole in the bonnet of safety valves with a metallic bellow seal
must remain open as a matter of principle, although in the case of Group I fluids
(PED 97/23/EC) a non-isolatable pipeline must be connected to remove the
medium safely (without back pressure if the bellow seal is damaged. Ventilation
must not be blocked by any leak detector used.
- No pipe sections or screws must protrude into the spring bonnet through the
inspection connection. Blockage hazard!
- The drainage system shall be adequate to remove the condensate.
- Blockage of the drainage system by dirt or foreign bodies shall be avoided.
- Freezing, sticking or blocking of the safety valve must be avoided at all costs. If
necessary use a heating jacket and/or stainless steel bellow with or without a
rupture disk.
- Safety valves shall be installed with upright spindle, not series 950 when
marked, “Einbau nur horizontal (Installation only horizontal)”, then they must be
installed horizontally.
Page 8 Rev. 0040401000 1210
584/658
- Flange gaskets shall be fitted concentrically and not restrict the flow cross
section.
- Keep the shaft of the spindle-unit free from paint (open bonnet / cap).
- Blow-off lines shall be laid with gradient.
- The ratio pao/po shall be taken into account when dimensioning the system.
- Safety valves shall be equipped with support tongues to absorb high reaction
forces.
- Pressure losses in the line to the safety valve shall not exceed 3%.
- Ensure that adequate drip pans are used if setting media in Fluid Group
pursuant to PED 97/23/EC.
recommended.
- Refer to appropriate TRD 421, AD2000-A2, DIN, ASME Code rules for piping and
installation.
- Remove transport fasteners and protective caps for inlet and outlet immediately before
installation.
- Water shall be drained from the safety valve and blow-off line via the blow-off line
(drainage points always at the lowest point).
Support
Bellow
Drip pan
Drainage Drainage at lowest point
fig. 5
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585/658

ATTENTION !
- Before putting the valve into operation, check material, pressure, temperature,
direction of flow and also check that the data of the valve are correct for the
plant
(refer to type test plate)
- Remove any test gag from cap and close opening with stopper.
- Remove protective caps and lever lock before putting the valve into operation
- Freezing, sticking or blocking of the safety valve must be avoided at all costs. If
necessary use a heating jacket and/or stainless steel bellow without a rupture
disk. (Note point 5 “Installation”).
- When operating without a blow-off line, medium may spurt from the valve outlet.
Injury hazard!
- Blowing off may generate loud flow noise.
- Medium may be discharged from the ventilation or inspection hole in the spring
bonnet (safety valves with stainless steel bellows and heating valves)
Injury hazard!
- Hot vapour may be discharged if the spring bonnet is open.
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Maintenance and maintenance-intervals have to be defined by the operator according to
the requirements.
ATTENTION !
- Too frequent lifting for test purposes can increase wear of the sealing surfaces!
- The safety valve must be lifted from time to time in line with current regulations
(by ≥ 85% from the set pressure) to ensure that the valve works correctly.
(The intervals at which this must be done depends on various factors so that no
generally applicable interval can be specified)
- Original parts only should be fitted as spares as a matter of policy.
- In safety valves with an open spring bonnet there is a danger of being crushed
between the spring windings during lifting and setting.
- Lift the safety valve stem briefly (releasing the lever suddenly) to eliminate slight leaks due
to particles between the seat and disc.
- If this does not eliminate the leak, the sealing surfaces of the seat and/or disc have been
damaged.
This can only be rectified at our works or by an authorised contractor.
- With valves corresponding to Figures 901, 921 and 941, the lever must always be
returned to the original position after lifting the safety valve.
- With Fig. 951 and 961 the lift button must be pressed down again after lifting.
- The manufacturer accepts guarantee liabilities only if tampering by third parties is
prevented.
7.1 Setting instructions
ATTENTION !
The following work must only be carried out by authorised specialist workshops
or at the operator’s own responsibility with monitoring by an independent agency
(e.g. TÜV).
7.1.1 Removing the cap
ATTENTION !
If there is back pressure or during setting/lifting, medium may be discharged from
the open bonnet, or into the adjusting screw area if the bonnet is closed.
ATTENTION !
When changing to the cap without lifting device (series 911, 923, 943), the
spindel cap (pos. 19) must be removed.
Open caps
- Remove slit pin (pos. 40), bolt (pos. 39).
- Extract lifting lever (pos. 41).
- Remove screw (pos. 38).
- Unscrew cap (pos. 29).
Closed caps
- Press lifting lever (pos. 36) towards bonnet (pos. 11) and against stop.
- Unscrew cap (pos. 28).
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587/658
Closed cap series 960/950
- Remove spring type straight pin (pos. 68)
- Remove lift button (pos. 67) or lifting lever (pos. 36)
- Unscrew cap (pos. 28)
7.1.2 Changing the set pressure “without” spring change
ATTENTION !
- When changing the set pressure in a pressurised system bear in mind vapour
discharge if bonnet is open, in adjusting screw area if bonnet is closed.
- Note spring setting range.
- Check the spring range.
- Spindle (pos. 14) must be held fast by all alterations.
- Loosen lock nut (pos. 21).
- Turn adjusting screw (pos. 17) clockwise to increase and anticlockwise to reduce the set
pressure.
- Secure spring setting by tightening lock nut (pos. 21).
- Assemble lifting device.
7.1.3 Changing the set pressure “with” spring change
ATTENTION !
- Depressurise the system before dismantling or opening the safety valve.
- For removing the cap refer to 7.1.1.

- Extract parallel pin (pos. 20) and lift off the spindle cap (pos. 19).
- Slacken locknut (pos. 21) and relieve spring (pos. 37) by turning adjusting screw (pos. 17)
anticlockwise.
- Unscrew nuts (pos. 8) at flange connection and remove bonnet (pos. 11/42).
Fig. 940: loosen coupling (pos. 61)
Fig. 950/960: loosen bonnet (pos. 11)
ATTENTION !
- With higher set pressures, the two nuts (pos. 8) on the longer studs (pos. 3)
must be removed last and simultaneously!
- Remove top spring-plate (pos. 26) and spring (pos. 37).
- Extract spindle (pos. 14) with disc (pos. 12/12a), guide plate (pos. 4/4a) and bottom
spring-plate (pos. 26).
- Clean seat (pos. 2) and disc (pos. 12).
- Insert spindle (pos. 14) with disc (pos. 12), guide plate (pos. 4), spring-plate (pos. 26) and
different spring (pos. 37).
Page 12 Rev. 0040401000 1210

588/658
- when carrying out any adjustment work hold the spindle (pos. 14) firm to prevent it
twisting.
ATTENTION !
- Torques must be observed:
M10 16-25 Nm screw joint BR940 100 Nm
M12 30-40 Nm screwed seat BR940 180 Nm
M16 70-90 Nm bonnet BR950/960 60 Nm
M20 150-175 Nm
- Check spring marking in accordance with manufacturer’s data.

- Note spring setting range.
- Change seals.
- Fit bonnet (pos. 11/42) and reset the set pressure; make sure spring setting range is
appropriate.
- Secure spring setting by means of lock nut (pos. 21).
- Assemble lifting device.
- If necessary, replace both spring plates (pos. 26) and use longer studs (pos. 3) when
fitting a spring for a higher set pressure.
- Further information obtainable from the manufacturer.
Only for series 900

ATTENTION !
When changing the set pressure and fitting a new spring, note that safety valves
with set pressures between 0.2 and 1.5 bar have a greater lift.
Therefore:
Set pressure in the range Spring change only in
the range
0.2 to 1.5 bar 0.2 to 1.5 bar
> 1.5 bar > 1.5 bar
Only for series 950:

ATTENTION !
Safety valves for horizontal application, must also to be set in a
horizontal position (≤ 4.9 bar).
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589/658
7.2 Representation
SAFE-TCS
SAFE-TCP
SAFE-TC
Bellow
Closed cap
Open cap
fig. 6
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590/658
8.0 Troubleshooting
Instructions.
ATTENTION !
-


ATTENTION !

Safety valve does not Flange covers not removed. Remove flange covers.
respond,
Test gag still in place. Remove test gag.
no flow
Spring blocked. Remove pipe or screw projecting into
bonnet through inspection connection.
Set pressure too high. Reset (point 8.1) or replace the safety
valve.
Stainless steel bellow defective, Replace the safety valve.
no back-pressure compensation.
Back-pressure not taken into account. Reset (point 8.1) or, if necessary,
replace the safety valve.
The use of a stainless steel bellow to
compensate for back-pressure should
be considered.
Medium viscous or sticky Use bellow / heating jacket. Insert
rupture disc upstream if necessary.
The valves and piping must be Heating !

protected against freezing and
solidifying media.
Stem cannot be lifted. Pressure less than 85% of set It must be possible to lift the spindle at
pressure. over 85% of the set pressure.
Safety valve seat leaking. Working pressure higher than 90% of Working pressure must be less than
set pressure. 90% of the set pressure.
At low pressures: lever not in neutral Press lever into neutral position
position with closed cap. (towards bonnet).
Safety valve flattering. Refer to separate point “Flattering”.
Medium contaminated; foreign body Raise spindle briefly or, if necessary,
between seat and disc. replace safety valve.
Use of a soft sealing disc should be
considered.
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Flange broken. Damage during transport. Replace safety valve.
Flange bolts not evenly tightened. Replace safety valve.
Transfer of forces such as bending or Install free of tension.
torsional forces.
Pressure surges. Safety valve not installed at highest Install safety valve at highest point.
point.
Valve drainage inadequate or not fitted. Install drainage system a required by
regulations.
Valve constantly blows off. Transport fastening not removed. Remove transport fastening (red screw
above cap, Figure 990).
Spring corroded by medium and Replace safety valve.
broken. In the case of vapour, select open cap
or bonnet if possible.
Injury owing to medium. Danger of injury from medium (e.g. Replace safety valve.
liquids) emerging from valve. Select design with closed bonnet and
cap.
Install a guard if necessary.
Injury from vapour discharge Install a guard if necessary
(open bonnet / cap)
Flattering. Pressure loss >3% in line to valve. Reduce resistance by chamfering or
radius in connection socket. Select
larger line if necessary.
Poor welding (root pass), gaskets at Change conditions.
inlet and outlet flanges too small or not
concentric.
Safety valve capacity too high. Install smaller safety valve.
Burner capacity too low. Install smaller safety valve.
Blow-off line too long or diameter too Use larger diameter or back-pressure
small. compensation by stainless steel
bellow.
Inlet and/or outlet socket too small. Install with dimensions larger than DN
of inlet and outlet lines.
Back-pressure higher than 10%. Install stainless steel bellow for
pressure compensation.
Capacity too low. Safety valves not applied unsuitable for Select and install suitable safety
plant conditions. valves.
Safety valve not applied in line with Adjust conditions.
current DIN, AD, TRD, etc. rules.
Page 16 Rev. 0040401000 1210

592/658

ATTENTION !
media.

appointed by us.
The manufacturer will accept warranty liability only if there has been no third party
tampering.

Rev. 0040401000 1210 Page 17

593/658

as defined by
the Pressure Equipment Directive 97/23/EC
Herewith we declare,
that according to the above mentioned Pressure Equipment Directive (PED) the below listed
products comply and have been approved according to Module H1 and also EC type test according
to module B+D through Lloyd´s Register Quality Assurance GmbH (BS-No. 0525),
Am Sandtorkai 41, D-20457 Hamburg.
Certificate-No: 50003/2
Safety valves Safety valves

SAFE series 900 SAFE-P series 920
Type 901,911,912,902,903,904,990 Type 921,922,923,924
Applied standards : Applied standards :
DIN EN ISO 4126-1 DIN EN ISO 4126-1
AD 2000 Code of Practice A2 AD 2000 Code of Practice A2
- Cast iron with spher. graphite - Cast steel
- Cast steel TRD 421, TRD 721
TRD 421, TRD 721 VdTÜV 100, DIN 3840
VdTÜV 100, DIN 3840
ASME Code Section VIII-Div. 1
Safety valves Safety valves
SAFE-TC series 940 SAFE-TCP/TCS series 950/960
Type 941,942,943,945,946 Type 951,952,953,961,962,963
Applied standards : Applied standards :
DIN EN ISO 4126-1 DIN EN ISO 4126-1
- Cast iron with spher. graphite - Cast iron with spher. graphite
- Cast steel - Cast steel
TRD 421, TRD 721 VdTÜV 100, DIN 3840
VdTÜV 100, DIN 3840
Schloß Holte-Stukenbrock, 11.01.2010
...................................................
(Brechmann, Managing director)
Page 18 Rev. 0040401000 1210

594/658
ARI-SAFE-TCP
Fig. 961 / 962 / 963
ARI-SAFE-TCP - Standard safety valve D/G/F

67.961 / 962 / 963 PN100 1.4581/EN-JS1049 DN15 - 25
57.961 / 963 PN100 1.4581 DN15 - 25
Figure Temperature range Thread
67.961 / 962 / 963 -10°C to +300°C DIN ISO 228 Part 1
57.961 / 963 -60°C to +300°C DIN ISO 228 Part 1
Type-test approval
Standard safety valve: TÜV · SV · . . -1041 · D/G(Fig. 961/962/963)
Standard safety valve: TÜV · SV · . . -1041 · F (Fig. 961/963)
Set gauge pressure refer to „Capacity“.
Requirement
Acc. to EN ISO 4126-1, VdTÜV-leaflet 100, AD2000-A2
Construction
Safety valve, spring loaded, direct loaded
Sizing
For steam, air and water see capacity tables,
calculation acc. to EN ISO 4126-1, TRD 421 and AD2000-A2.
Details required
• Medium gasform: Mass flow (kg/h), molar mass (kg/kmol), temperature (°C), set gauge
pressure (bar), back gauge pressure (bar)
• Medium liquid: Mass flow (kg/h), density (kg/m3), viscosity, temperature (°C), Set gauge
pressure (bar), back gauge pressure (bar)
Order data:
ARI-SAFE-TCP - Safety valve,
Fig. ... .961 Fig. ... .962 Figure ....., DN ... / ..., PN .. / .., Material ........, Set gauge pressure .... bar
closed lifting device open lifting device
Chemical Industry, processing industry, plant manufacturing
1.4581/EN-JS1049: Steam, neutral gases, vapours and liquids
1.4581: Steam, aggressive gases, vapours and liquids
without metal bellow
Superimposed back no backpressure allowed

pressure
Built up back pressure max. 10% from set pressure (gauge) (higher on request)
Fig. ... .963

gastight cap alternative with lever
24 595/658 Edition 12/10 - Data subject to alteration

ARI-SAFE-TCP
Fig. 961 / 962 / 963
Dimensions and weights
DN (mm) 15 20 25
G (inch) 1/2“ x 1/2“ 1/2“ x 3/4“ 3/4“ x 1/2“ 3/4“ x 3/4“ 3/4“ x 1“ 1“ x 1“
d0 (mm) 12 12 12 12 12 12
A0 (mm2) 113 113 113 113 113 113
GE (inch) 1/2“ 1/2“ 3/4“ 3/4“ 3/4“ 1“
GA (inch) 1/2“ 3/4“ 1/2“ 3/4“ 1“ 1“
b (mm) 15 15 16 16 16 18
l (mm) 42 47 42 47 50 50
l1 (mm) 34 34 34 34 34 34
H (mm) 189 189 189 189 189 189
X (mm) 100 100 100 100 100 100
Weight (kg) 1,2 1,2 1,2 1,2 1,2 1,2
Further connections on request.
Spring ranges: Standard design (barg)

DN15 - DN25
0,2 - 0,25
0,26 - 0,5
0,52 - 1
1,05 - 1,4
1,45 - 2,95
3 - 4,9
5 - 12
12,1 - 20
20,1 - 27
27,1 - 35
35,1 - 45
45,1 - 59
59,1 - 100
Parts
Pos. Description Fig. 67.961/962/963 Fig. 57.961/963
1 Body GX5CrNiMoN19-11-2, 1.4581
4 Spindle guide X6CrNiMoTi17-12-2, 1.4571
11 Bonnet, closed EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMoN19-11-2, 1.4581
12 Disc unit X6CrNiMoTi17-12-2, 1.4571
14 Spindle * X6CrNiMoTi17-12-2, 1.4571
17 Adjusting screw X2CrNiMo17-12-2, 1.4404
27 O-ring FPM
28 Cap, closed GX5CrNiMoN19-11-2, 1.4581
29 Cap, open GX5CrNiMoN19-11-2, 1.4581
30 Cap, gastight EN-GJS-400-18U-LT, EN-JS1049 GX5CrNiMoN19-11-2, 1.4581
36 Lever, closed (optional) EN AC-4420 (Al)
37 Spring * FDSiCr X10CrNi18-8, 1.4310
65 Coupling X6CrNiMoTi17-12-2, 1.4571
66 O-ring FPM
67 Lift button X6CrNiMoTi17-12-2, 1.4571
* Spare parts
Edition 12/10 - Data subject to alteration 596/658 25

ARI-SAFE-TCP
Capacity Fig. 961 / 962 / 963
Capacity saturated steam / air / water incl. 10% overpressure
I Saturated steam (kg/h) II Air 0°C and 1.013 bara (Nm3/h) III Water 20°C (t/h)
DN 15 DN 20 DN 25
G1/2“ x G1/2“ G3/4“ x G1/2“ G1“ x G1“
Set gauge
pressure G1/2“ x G3/4“ G3/4“ x G3/4“
in bar
G3/4“ x G1“
do (mm) 12 12 12
I II III I II III I II III
0,2 14 16 0,62 14 16 0,62 14 16 0,62
0,5 24 29 0,98 24 29 0,98 24 29 0,98
1 35 44 1,39 35 44 1,39 35 44 1,39
2 56 71 1,97 56 71 1,97 56 71 1,97
3 75 96 2,41 75 96 2,41 75 96 2,41
4 96 125 2,78 96 125 2,78 96 125 2,78
5 116 150 3,11 116 150 3,11 116 150 3,11
6 135 176 3,41 135 176 3,41 135 176 3,41
7 153 201 3,68 153 201 3,68 153 201 3,68
8 172 227 3,93 172 227 3,93 172 227 3,93
9 191 252 4,17 191 252 4,17 191 252 4,17
10 210 277 4,40 210 277 4,40 210 277 4,40
11 229 303 4,61 229 303 4,61 229 303 4,61
12 248 328 4,82 248 328 4,82 248 328 4,82
13 267 354 5,01 267 354 5,01 267 354 5,01
14 286 379 5,20 286 379 5,20 286 379 5,20
15 304 405 5,39 304 405 5,39 304 405 5,39
16 323 430 5,56 323 430 5,56 323 430 5,56
17 342 455 5,73 342 455 5,73 342 455 5,73
18 361 481 5,90 361 481 5,90 361 481 5,90
19 380 506 6,06 380 506 6,06 380 506 6,06
20 399 532 6,22 399 532 6,22 399 532 6,22
25 494 659 6,95 494 659 6,95 494 659 6,95
30 590 786 7,62 590 786 7,62 590 786 7,62
686 913 8,23 686 913 8,23 686 913 8,23
← max. set pressure stainless steel version
35
40 784 1040 8,79 784 1040 8,79 784 1040 8,79
45 883 1165 9,33 883 1165 9,33 883 1165 9,33
50 983 1295 9,83 983 1295 9,83 983 1295 9,83
55 1085 1420 10,31 1085 1420 10,31 1085 1420 10,31
60 1185 1550 10,77 1185 1550 10,77 1185 1550 10,77
65 1290 1675 11,21 1290 1675 11,21 1290 1675 11,21
70 1400 1800 11,63 1400 1800 11,63 1400 1800 11,63
75 1500 1930 12,04 1500 1930 12,04 1500 1930 12,04
80 2055 12,44 2055 12,44 2055 12,44
85 2185 12,82 2185 12,82 2185 12,82
90 2310 13,19 2310 13,19 2310 13,19
95 2438 13,5 2438 13,5 2438 13,5
100 2565 13,76 2565 13,76 2565 13,76
Certified coefficient of discharge Kdr (Values for D/G variable: < 4 bar)
Kdr 15 20 25
D/G 0,30
F 0,23
26 597/658 Edition 12/10 - Data subject to alteration

ARI-SAFE-TCP
Notes

Stop valve with gland seal
STOBU® PN16-160
Contents
1.0 General information on operating 5.4 Installing valves with limit switches ........................ 8
instructions ..................................................... 2 6.0 Putting the valve into operation .................. 8
2.0 Notes on possible dangers........................... 2 7.0 Care and maintenance.................................. 9
2.1 Significance of symbols ..........................................2 8.0 Troubleshooting .......................................... 10
2.2 Explanatory notes on safety information .................2 9.0 Troubleshooting table .................................11
3.0 Storage and transport .................................. 2 10.0 Dismantling the valve or the top part ..... 12
4.0 Description..................................................... 3 11.0 Warranty / Guarantee ................................ 12
4.1 Scope of applications ..............................................3 12.0 EC declaration of conformity ................... 13
4.3 Diagram...................................................................4
4.4 Technical data - remarks .........................................5
4.5 Marking ...................................................................5
5.0 Installation...................................................... 6
5.1 General notes on installation...................................6
5.2 Installing valves with butt weld ends .......................7
5.3 Installing valves with balancing plugs ...................7
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STOBU®

and repair.
ATTENTION ! Warning of general danger.
...

Information marked with the above symbol and “ATTENTION!” describe practices, a failure
to comply with which can result in serious injury or danger of death for users or third parties
or in material damage to the system or the environment. It is vital to comply with these
practices and to monitor compliance.
to property.

ATTENTION !
- At -20°C to +65°C.
Page 2 Rev. 0040102000 0711
600/658
STOBU®
4.0 Description
Valves are used for „shut-off and/or throttling of media“.
ATTENTION !
to TRD 110.

The valve is closed by turning the hand wheel clockwise (valve plug/seating function).
ATTENTION !
Do not use tools to increase the torque on the hand wheel.
The valve stem is sealed by a bellow and an outer safety stuffing box.
Tighten the stuffing box if required.
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STOBU®
4.3 Diagram
rotated
view
rotated
view
rotated
rotated view
view
fig. 1: STOBU straight through PN40 fig. 2: STOBU angle pattern PN40
1.0619+N 1.0619+N
rotated
view
rotated view
rotated
view
rotated view
fig. 3: STOBU straight through PN16/25 fig. 4: STOBU-straight through PN40

EN-JL1040 / EN-JS1049 butt weld ends 1.0619+N
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STOBU®
rotated view rotated view

rotated view rotated view
fig. 5: STOBU-DG PN63-160 fig. 6: STOBU-DG SE PN63-160

1.0460 / 1.7335 1.0460 / 1.5415 / 1.7335
Refer to the data sheet for information about materials with designations and figure
numbers.

for
- Pressure-temperature-ratings
- Valves with butt weld ends, etc. refer to datasheet.
4.5 Marking
CE-marking
0525 Notified body
Manufacturer Address of manufacturer:
Typ Type refer to item 11.0 Warranty / Guarantee

PS max. allowable pressure
TS max. allowable temperature
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STOBU®
5.0 Installation
installation work:
ATTENTION !
- Note installation position with reference to flow, see mark on valve.
avoided.
both sides.
- Valves can be installed with the stem pointing in any direction, but the prefered
stem position is vertical.
- Valves should be installed upside down only, if the medium being handled is
clean.
- Keep the thread and shaft of the stem free from paint.
- Centre gaskets between the flanges.
- Lockable stop valves must be installed in such a way that the stem is vertical
and the flow agent enters under the taper. If the valves are installed in pipelines
in positions other than specified, they must be fitted with a closing spring.
- Design with loose plug
A plug damper should be used in critical applications, immediately downstream
of pumps, compressors, etc., where severe turbulence and pulsating pressure
surges may occur.
Through the damper function of the loose plug, the negative influence of
pressure shocks and high turbulences, are not transferred onto the valve.
recommended.
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STOBU®
5.2 Installing valves with butt weld ends
Please note that only qualified persons using appropriate equipment and working in
accordance with technical rules are allowed to install fittings by welding.
The responsibility for this lies with the system owner.
Refer to the data sheet for information about the shape of the butt weld ends.
The valves must be welded in closed position.
5.3 Installing valves with balancing plugs

ATTENTION !
ARI stop valves must be equipped with pressure balancing plugs if the
differential pressures listed in the table below are exceeded in the closed state.
Valves with pressure balancing plugs should be installed so that the pressure of
the medium acts on the plug (pos. 3) and the stem is vertically upright.
ATTENTION !
Note direction of flow.
fig. 7
Valves with pressure balancing plugs have to be installed with medium flowing over the
plug (pos. 3) as indicated by flow direction arrow on valve body.
Working principles:
When the valve is closed, anticlockwise rotation of the hand wheel lifts the pilot plug
(pos. 3.1) off the larger balancing plug (pos. 3). This allows the medium to pass through the
plug and equalizes the pressure of the medium under the plug (pos. 3). After the pressures
have been equalized within the values stated in the table below, the valve can be opened
by turning the valve further.
Balancing plug DN 125 150 200 250 300 350 400 500
Pressure difference ΔP 25 bar 21 bar 14 bar 9 bar 6 bar 4,5 bar 3,5 bar 1,5 bar
- Pressure balancing plugs are fully effective only in closed line section.
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STOBU®
- The pressures of the medium on either side of the plug cannot be equalized if the medium
is discharged into “open air”.
- If adequate pressure equalisation cannot be achieved using a pressure balancing plug,
other design solutions must be used instead (e.g. a bypass line).
5.4 Installing valves with limit switches

The valves with limit switches must be connected up as shown in the plans of the plant on
the basis of their working principles.
ATTENTION !
- Touching the valve when it is operating at high (> 50 °C) or low (< 0 °C) media
Affix warning notice or protective insulation as appropriate.
- All works has been completed.
When putting the valve into operation, the tightness of the stuffing box seal (pos. 6) must be
checked.
If the valve stem (pos. 4) leaks, gradually tighten the stuffing box seal (pos. 6) evenly in
increments by means of the hexagon nuts (pos. 19) until leaking stops (refer also to item
7.0 Care and maintenance).
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STOBU®

Maintanance and maintenance-intervals have to be defined by the operator according to
the requirements.
fig. 8: Pattern with hinged bolts

- Observe safety instructions!
- Keep the stem well greased!
- Lubricant: e.g. Klüberpaste HEL 46-450 (at valves for oxygen: Oxigenoex FF 250)
to order at: Klüber Lubrication München KG, Postfach 701047, D-81310 München
or a lubricant wich is suitable for the application.
ATTENTION !
Pay attention, that the lubricant is suitable for the media.
- If the valve stem (pos. 4) leaks, gradually tighten the stuffing box seal (pos. 6) evenly in
increments by means of the hex. nuts (pos. 19) until leaking stops.
ATTENTION !
- Retighten the stuffing box packing if required and re-pack it in good time.
- For safety reasons we recommend that valves only be repacked when
depressurised.
- Refer to point 10.0 and 11.0 before dismantling the valve.
- Replace stuffing box packings only after the system has cooled down and the pressure in
the plant has been relieved.
In the case of corrosive or aggressive mediums, drain and ventilate the valve before
replacing the packing.
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STOBU®
- Valve service life can be improved by leakage checks.
- When cutting the new packing (pos. 6) from

the roll, make sure that the ends are cut with
a slant
fig. 9: Split packing ring (pos. 6)

Mounting of the bonnet:
- Before reassembling the unit, remember that the bearing surface must be cleaned and a
new gaskets (pos. 9) must be inserted.
- Set the cover in place
- Tighten the hexagon nuts (hexagon screws for valves of cast iron) evenly crosswise.
- Tightening torque‘s for hexagon nuts / screws:
hexagon nuts / Torque

PN DN
hexagon screws (Nm)
16 - 40 15 - 32 M 10 15-30
40 - 65 M 12 35-50
80 - 100 M 16 75-100
125 - 150 M 16 80-120
200 M 20 150-200
250 - 400 M 24 340-410
500 M 27 340-410
63 - 160 10 - 25 M 16 50
32 - 50 M 20 150
8.0 Troubleshooting
Instructions.
ATTENTION !
-

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STOBU®

ATTENTION !

No flow Valve closed. Open valve.
Flange covers not removed. Remove flange covers.
(pos. 25; fig.1-2) (pos. 25; fig.1-2)
Little flow Valve not sufficiently open. Open valve.
Dirt sieve clogged. Clean / replace sieve.
Piping system clogged. Check piping system.
Valve difficult to move or Stem (pos. 4) dry (pos. fig. 6) Grease stem (pos. 4) (fig. 6)
cannot be opened (Lubricant: see page 9)
Stuffing box too tight (pos. 6; fig. 1-4) Slacken hex. nuts of stuffing box gland
(pos. 15) slightly, but not sufficiently to
cause leakage (fig. 1-4)
Wrong direction of rotation Turn in correct direction (anticlockwise
to open valve).
Valve stem leaking Stuffing box gland (pos. 15) slack Tighten stuffing box gland (pos. 15)
(fig. 1-4). until leakage stops.
-Hex. nut (fig. 1-4).
If necessary, renew packing in stuffing
box seal (pos. 6). Observe warnings
(Fig. 6)!
Leakage across valve Valve not properly closed. Pull hand wheel tight without tools.
seat. Seat (pos. 1.2) / plug (pos. 3) damaged Replaced valve, consult supplier/man-
by foreign particles. ufacturer.
(fig. 1-4).
Pressure difference too high. Use a valve with balancing plug
(see point 5.3).
Medium contaminated Clean valve.
(suspended solids). Install dirt screen upstream of valve.
Valve with throttling plug + Locking device has been tightened. Release locking device.
position indicator + lock-
ing device cannot be
opened.
Rattling / banging Nominal diameter of the valve in com- Choose smaller nominal diameter
of the plug design with pliance to the flow rate is to big Use a plug damper execution: see
„loose plug“ medium
- high flow turbulences; Alter the system
- the valve with loose plug is mounted Use a plug damper execution: see
directly by a centrifuged pump; medium
- behind pressure reduction stations;
- behind pipe elbows;
- in compact plants;
- expansion joints are missing;
- the pump is not mounted on a
damper;
- there is no flow stabilizing pipe length;
- there is no start-up bypass line
Flange broken between Bolts tightened unevenly. Re-align piping and fit new valve!
valve and piping. Mating flanges not properly aligned.
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STOBU®

ATTENTION !
media.

Conditions of Albert Richter GmbH & Co. KG“ valid at the time of delivery or, by way of
appointed by us.

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STOBU®

EC declaration of conformity acc. to Pressure Equipment Directive 97/23/EC
Herewith we declare:

that the below listed products are meeting the following requirements.
Description of the products:
Stop valve with gland seal ARI-STOBU®

Nominal Nominal Certificate-
Type Fluid group Module Applied standards
pressure diamter No.:
005 PN16-40 DN 15-300 I H
006 PN16-40 DN 15-500 I H
DIN 3840
007 PN16-40 DN 15-500 I H AD 2000 leaflet A4
50003/1
009 PN16-40 DN 15-200 I H (EN-JS1049, 1.0619+N,
1.0460, 1.4408)
306 PN16-40 DN 15-500 I H
307 PN16-40 DN 15-500 I H
005 PN 63-160 DN 10 -50 I A1 DIN EN 12516-2

-- AD 2000 leaflet A4
006 PN 63-160 DN 10 -50 I A1 (1.0460, 1.5415, 1.7335)
Name and adress of the authorizing, monitoring, notified body:
Lloyd’s Register Quality Assurance GmbH

Am Sandtorkai 41, D-20457 Hamburg
No. of the notified body:
0525
...................................................
Rev. 0040102000 0711 Page 13

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ARI-STOBU®
Fig. 006 / 306
Stop valve - straight through with flanges and gland seal (Grey cast iron, SG iron)

12.006 PN16 EN-JL1040 DN15-300
12.306 PN16 EN-JL1040 DN15-300
22.006 PN16 EN-JS1049 DN15-350
22.306 PN16 EN-JS1049 DN15-350
23.006 PN25 EN-JS1049 DN15-150
23.306 PN25 EN-JS1049 DN15-150
Fig. 306: Trim made of RG/MS:
CuZn35Ni3Mn2AlPb, CW710R code number 02
CuSn10-Cu, CC480K code number 03
(max. operating temperature: 180°C, code number acc. to DIN 86251)
Test:
• DN15-300 optional: German TA-Luft TÜV-Test-No. 922-9204866 (refer to page 16)
At high differential pressures a balancing plug is necessary!
(not possible at Fig. 306, observe max. differential pressure!)
(refer to page 13)
Industry, power stations, flue gas purification plant, vapour facilities, recycling facilities,
shipbuilding, general plant manufacturing
Steam, gases, liquids, etc.
Parts
Pos. Description Fig. 12.006 Fig. 12.306 Fig. 22./23.006 Fig. 22./23.306
1 Body EN-JL1040, EN-GJL-250 EN-JS1049, EN-GJS-400-18U-LT
1.2 Seat ring X20Cr13+QT, 1.4021+QT CuSn10-Cu, CC480K code X20Cr13+QT, 1.4021+QT CuSn10-Cu, CC480K code
number 03 number 03
2 Bonnet EN-JL1040, EN-GJL-250 EN-JS1049, EN-GJS-400-18U-LT
3 Plug DN ≤200: CuZn35Ni3Mn2AlPb, DN ≤200: CuZn35Ni3Mn2AlPb,
X20Cr13+QT, 1.4021+QT CW710R code number 02 X20Cr13+QT, 1.4021+QT CW710R code number 02
DN >200: P265 GH, 1.0425 CuSn10-Cu, CC480K code DN >200: P265 GH, 1.0425 CuSn10-Cu, CC480K code
number 03 number 03
4 Stem X20Cr13+QT, 1.4021+QT CuSn8, CW453K X20Cr13+QT, 1.4021+QT CuSn8, CW453K
(burnished) code number 03 (burnished) code number 03
(burnished) (burnished)
5 Handwheel EN-JL1040, EN-GJL-250 (FE 13 epoxy-coating)
6 Packing ring Pure graphite
7 Hexagon bolt 5.6 --
7 Stud -- 25CrMo4, 1.7218
8 Hexagon nut -- C35E, 1.1181
9 Gasket Pure graphite (CrNi laminated with graphite)
ARI-Valves of EN-JL1040 are not allowed to be operated in systems acc. to TRD 110.
A production allowance acc. to TRB 801 No. 45 exists (acc. to TRB 801 No. 45 EN-JL1040 is not allowed.)
Dimensions
DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350
L (mm) 130 150 160 180 200 230 290 310 350 400 480 600 730 850 980
H (mm) 185 185 205 205 230 230 270 305 355 395 450 570 685 770 860
ØC (mm) 120 120 140 140 160 160 180 200 225 250 400 520 520 520 640
Travel (mm) 9 9 13 13 21 19 28 32 36 52 56 73 80 110 116
Kvs-value (m3/h) 4,2 7,4 12 19 31 47 77 120 188 288 410 725 1145 1635 2220
Zeta-value -- 4,6 4,7 4,3 4,6 4,3 4,5 4,8 4,5 4,5 4,7 4,8 4,9 4,8 4,8 4,9
Zeta-value ... range of tolerance for Kvs-values acc. to VDI/VDE 2173 Standard-flange dimensions refer to page 15
Face-to-face dimension FTF series 1 according to DIN EN 558
Weights
Figure-No. DN 15 20 25 32 40 50 65 80 100 125 150 200 250 300 350
12.006 / 306 (kg) 3,5 4 5 6,8 9,3 12,2 18 24,5 35 55 77 145 243 341 --
22.006 / 306 (kg) 3,9 4,3 5,4 7 9,5 12,9 18,4 24,5 36 56 78 122 247 336 451
23.006 / 306 (kg) 3,9 4,3 5,4 7 9,5 12,9 18,4 24,5 36 56 78 122 -- --

ARI-STOBU® Regulating plug
Flow diagram
DN15 / PN6-40
valve compl. Handwheel Zeta-value Kv-value
opened rotations
0,5 324 0,5
1 81 1
Handwheel rotations
1,5 31,6 1,6
2 14,1 2,4
2,5 7,9 3,2
3 5,3 3,9
max. permissible differential pressure in throttling function

2,0 bar.
max. permissible flow speed:
Liquids ≤ 4 m/s,
Gas and vapours ≤ 60 m/s
Condition: The flow must be free from cavitation.
Flow characteristic
→ ∆p in bar
Pressure drop in Pascal (10 Pascal 1mm WS (1mm WS = 9,8066 Pa) 1bar = 0,1MPa = 105Pa → Handwheel rotations
valve compl. DN20 / PN6-40

opened
Handwheel Zeta-value Kv-value
rotations
0,5 400 0,8
1 70,9 1,9
Handwheel rotations
1,5 26,6 3,1

2 13,8 4,3
2,5 8,2 5,6
3 5,2 7,0

2,0 bar.
Liquids ≤ 4 m/s,
Flow characteristic
→ ∆p in bar
→ Handwheel rotations
Edition 12/07 - Data subject to alteration 613/658 Data sheet 006002 (englisch (english))
ARI-STOBU® Regulating plug
Flow diagram
DN25 / PN6-40
rotations
0,75 434 1,2
1 142 2,1
1,5 48,2 3,6
valve compl. 2 21,4 5,4
opened
2,5 11,4 7,4
3,25 5,7 10,5

2,0 bar.
Handwheel rotations
Liquids ≤ 4 m/s,
Flow characteristic
→ ∆p in bar
Pressure drop in Pascal (10 Pascal 1mm WS (1mm WS = 9,8066 Pa) 1bar = 0,1MPa = 105Pa → Handwheel rotations
DN32 / PN6-40
rotations
1,25 465 1,9
1,5 317 2,3
valve compl.
opened 2 137 3,5
3 43,6 6,2
3,5 15,5 10,4
4 4,6 19
Handwheel rotations

2,0 bar.
Liquids ≤ 4 m/s,
Flow characteristic
→ ∆p in bar
→ Handwheel rotations

Butterfly valves
BR 012 - ZESA ® BR 013 - GESA ®
BR 014 - ZIVA ®-Z BR 015 - ZIVA ®-G

Contents
1.0 General information on operating 5.4 Retrofitting the THErmo-Appliance
instructions ................................................... 2 (ZESA THEA / GESA THEA) ................................. 9
2.0 Notes on possible dangers........................... 2 5.5 Converting or retrofitting lever
(ZIVA-Z / ZIVA-G) ................................................. 10
2.1 Significance of symbols ..........................................2
2.2 Explanatory notes on safety information .................2 6.0 Putting the valve into operation .................11
3.0 Storage and transport .................................. 2 7.0 Care and maintenance.................................11
7.1 Changing seat and O-ring seal
4.0 Description..................................................... 3
(ZIVA-Z / ZIVA-G) ................................................. 12
4.1 Scope of applications .............................................3
8.0 Troubleshooting .......................................... 13
4.3 Diagram - assembly ................................................49.0 Troubleshooting table ................................ 13
4.4 Technical data - remarks .........................................6 10.0 Dismantling the valve or the top part ..... 14
11.0 Warranty / Guarantee ................................ 14
4.5 Marking ...................................................................6
5.0 Installation...................................................... 7 12.0 EC declaration of conformity ................... 15
5.1 General remarks on installation ..............................7
5.2 Installation of accessories .......................................7
5.3 Conversion from notch lever to lock lever ...............8
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ZESA® / GESA® / ZIVA®-Z / ZIVA®-G

and repair.
ATTENTION !

Information marked with the above symbol and “ATTENTION!” describe practices, a failure
to comply with which can result in serious injury or danger of death for users or third parties
or in material damage to the system or the environment. It is vital to comply with these
practices and to monitor compliance.
to property.

ATTENTION !
- At -20°C to +65°C.
Page 2 Rev. 0040201000 0410

616/658
4.0 Description
Butterfly valves are used for “interruption or restriction of the flow of liquids and gases”.
ATTENTION !
to TRD 110.

The valve is closed by turning the disc shaft clockwise.
The shaft moves through 90°.
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4.3 Diagram - assembly
rotated view
Material designation:
EP = EPDM or
NBR or
FPM
fig. 1: Butterfly valve ZESA® / GESA®
Material designation:
EP = EPDM or
NBR or
FPM
Bild 2: Butterfly valve ZIVA®-Z / ZIVA®-G

Refer to the data sheet for information about materials with designations and figure numbers.
Page 4 Rev. 0040201000 0410

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Actuation arrangements
fig. 3: Notch lever ZESA® / GESA®

- The detent pin of the lower lever must be fully disengaged to move the lever.
fig. 4: Lock lever ZESA® / GESA®

- The star knob screw must be slackened before and tightened again after moving the
lever.
fig. 5: Notch lever ZIVA®-Z / ZIVA®-G

- The detent pin of the lower lever must be fully disengaged to move the lever.
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Position indicator
Lock nut
fig. 6: Worm gear ZESA®/GESA® and ZIVA®-Z/ ZIVA®-G

- Gear type (actuation by hand wheel, clockwise for closing).
The CLOSE-position can be adjusted by ± 5° by a stop screw.
The stop screws are self-sealing and self-locking (refer to Fig. 7).
- Refer to separate operating and maintenance manual for drive (electric or pneumatic).

for
- Pressure-temperature-ratings, etc. refer to data sheet.
4.5 Marking
CE-marking
0525 Notified body
Manufacturer Adress of the manufacturer:
Typ Type refer to point 11.0 Warranty / Guarantee
Page 6 Rev. 0040201000 0410

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5.0 Installation
5.1 General remarks on installation
installation work:
ATTENTION !
- The direction of flow need not be taken into account.
avoided.
- Flooding of the butterfly valve is not permissible.
- The shaft can be in any position except for DN350 up to DN600 (horizontal
shaft).
- No gaskets required between flanges, flexible gaskets are not allowed.
- The butterfly valve must be installed in open position if possible, but the disc
should not protrude beyond the housing.
- Large actuators with horizontal application must be supported.
- Avoid damage to the rubber sheathing during handling, storage and installation.
- Do not heat the valve (e.g. by welding, grinding, etc.) above its service
temperature (refer to data sheets).
- Protect actuators from excessive ambient temperatures
(refer to operating instructions for actuator).
- If the butterfly valve is in operation as a pipeend valve, regard DIN EN 294
point 5.

recommended.
5.2 Installation of accessories

Optional accessories (e.g. limit switches) supplies with valves must be fitted as required for
their functions as shown in the plants of the plant.
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5.3 Conversion from notch lever to lock lever
window
fig. 7
The notch lever cap (pos. 7) can be used for the conversion.
- Set notch lever (pos. 50) to notch position 4.
- Slacken socket screw (pos. 50.2 / SW 5 of 6 mm AF).
- Remove notch lever (pos. 50).
ATTENTION !
The position of the valve disc is not positively located!
- Dismantle notch lever cap (pos. 7) and use a screwdriver to break out the window.
- Put the cap, with the nut (pos. 19) in it, in place and tighten it.
- Set the lock lever (pos. 50.1) in position as shown in the diagram.
- Tighten the socket screw (pos. 50.2).
- Insert star knob screw (pos. 60) through the hole at the end of the lock lever (pos. 50.1)
and screw into the hex. nut (pos. 19).
If the lock lever must be on the same side as the original notch lever, the notch lever cap
must be turned through 180°.
For the angle limit stop, an additional nut can be placed in the cap for a locking screw.
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5.4 Retrofitting the THErmo-Appliance (ZESA®THEA / GESA®THEA)
fig. 8
- Remove sticker from the hole in the lever (pos. 50).
- Insert the THEA temperature indicator (pos. 58) into the hole down to the stop.
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5.5 Converting or retrofitting lever (ZIVA®-Z / ZIVA®-G)

Retrofit in butterfly valve with free shaft end:
fig. 9
ATTENTION !
- Do not remove shaft blowout protection (pos. 26) under pressure.
(see point 10.0 Dismantling the valve or the top part)
- The valve disc is not fixed in position without an actuating element!
- Slacken setscrew (pos. 50.1),

- Mount notch lever (pos. 50) on shaft end together with the notch disc (pos. 16)
(notch lever aligned with notch disc),
- Turn notch lever (pos. 50) until drillings in notch disc (pos. 16) and body are aligned,
- Assemble and tighten cheese-head screw (pos. 21) and nut (pos. 20),
- Tighten set screw (pos. 50.1).
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ATTENTION !

Maintanance and maintenance-intervals have to be defined by the operator according to
the requirements.
ATTENTION !
- It is advisable to actuate the valve at least once a month.
- When used as an end-blockage, a safety precaution (e.g. plug-in disc, blind
flange etc.) is demanded by maintenance works.
Rev. 0040201000 0410 Page 11

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7.1 Changing seat and O-ring seal
(ZIVA®-Z / ZIVA®-G)
fig. 10
- Observe safety instructions
- Grease seat (pos. 2) when changing
Lubricant: e.g. Berusoft 30 valve grease
obtainable from: Carl Bechem GmbH, Weststrasse 120, D-58089 Hagen
or a lubricant suitable for this application.
ATTENTION!
- Always ensure that the lubricant is compatible with the medium.
- It is not safe to replace the O-ring seal (pos. 11) until the system has cooled
down and the plant is pressureless.
- For safety reasons we recommend that the O-ring seal (pos. 11) only be
changed when disassembled.
- Prior to disassembling the butterfly valve note points 10.0 and 11.0.
- When the butterfly valve is activated there is a crushing hazard between valve
disc and body.
- Maintenance work inside the pipeline (large nominal diameters) should only be
carried out when the butterfly valve is safely deactivated (disconnect actuator
from power supply).
Page 12 Rev. 0040201000 0410

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8.0 Troubleshooting
Instructions.
ATTENTION !
-


ATTENTION !

No flow Valve closed. Open valve.
Little flow Valve not sufficiently open. Open valve.
Strainer sieve clogged. Clean / replace sieve.
Piping system clogged. Check piping system.
Valve is impossible or diffi- Service conditions (e.g. medium, tem- Replace valve. Consult supplier or
cult to open or close perature) outside permissible limits. manufacturer.
Power failure. Check power supply.
Wrong direction of rotation. Turn in correct direction

(clockwise for opening).
Valve leaking Not properly closed. Close valve properly or readjust limit
switch/stop screw.
Pressure difference too high. Check plant.
Medium contaminated. Clean valve.

Install strainer sieve upstream of valve.
Lining/collars (Fig. 1-2, item 2) or valve Replace valve. Consult supplier or

disc (Fig. 1-2, item 3) damaged by for- manufacturer.
eign bodies or medium
Valve with locking device Locking device tightened. Slacken locking device.
cannot be opened
Rev. 0040201000 0410 Page 13

627/658

ATTENTION !
media.

appointed by us.

Page 14 Rev. 0040201000 0410

628/658

as defined by
the Pressure Equipment Directive 97/23/EC
Herewith we declare,
that according to the above mentioned Pressure Equipment Directive (PED) the below
listed products comply and have been approved according to table 6, annex II, module H
through Lloyd´s Register Quality Assurance GmbH (BS-Nr. 0525), Am Sandtorkai 41,
D-20457 Hamburg.
Certificate-No: 50003/1
Butterfly valves ZESA® / GESA®
Type 012, 013
Butterfly valves ZIVA®-Z / ZIVA®-G

Type 014, 015
Applied standards:
DIN 3840
...................................................
Rev. 0040201000 0410 Page 15

629/658

630/658
ARI-GESA®
Fig. 013
Butterfly valve with threaded eyelets (SG iron)

21.013 PN10 EN-JS1030 DN25-500
22.013 PN16 EN-JS1030 DN25-500
Washer: 1.4581
Stem: • 1.4021+QT
• 1.4571
Seat: • EPDM -10 °C to +130 °C
• NBR -10 °C to +80 °C
• FPM - 10 °C to + 150 °C (not for hot water useable)
max. gauge press.: 16 bar (DN25-150)
10 bar (DN200-500)
Actuation • Notch lever
arrangement: • Lock lever
(refer to page 6-11) • Worm gear
• Electric actuator
• Pneumatic actuator
Test:
Sealing leakage test DIN EN 12266-1 Leakage rate A
(DIN 3230 T3 Leakage rate 1)
DVGW-Registration EPDM for water Reg.-No. DW-6201BR0244,
acc. to DIN EN 1074-1/-2
incl. desinfection inspection,
DVGW VP646 and DVGW W270 for drinking water
Cold -and cooling water installations, Heating installations, Drinking water and domestic
water, Waste water, Swimming pool-installations, Power stations, Gas installations,
Shipbuilding, etc.
Cold water, warm water, hot water, drinking water, process water, etc.
Parts
Pos. Description Fig. 20./21./22.012
1 Body EN-GJS-400-15, EN-JS1030
2 Seat EPDM 73 / NBR 73 / FPM 73
3 Disc GX5CrNiMoN19-11-2, 1.4581
4 Pivot X20Cr13+QT, 1.4021+QT X6CrNiMoTi17 12 2, 1.4571
5 Stem X20Cr13+QT, 1.4021+QT X6CrNiMoTi17 12 2, 1.4571
6 Taper pin X6CrNiMoTi17 12 2, 1.4571
8 Insulating cap * PA 6
9 Gasket * CU
10 Hexagon head screw plug * 5.8-A2G
11 O-ring * EPDM 73 / NBR 73 / FPM 73
14 Parallel bush P1
* Spare part
DN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
L (mm) 33 33 33 43 46 46 52 56 56 60 68 78 78 102 127
H (mm) 128 128 134 140 150 158 179 196 212 246 273 302 358 407 495
E (mm) 58 58 66 69 81 100 109 124 140 167 203 232 258 287 354
l (mm) 15 15 15 15 15 15 15 18 18 18 24 24 26 42 42
SW (mm) 11 11 11 11 11 11 11 17 17 17 22 22 22 30 30
Kvs-value (m3/h) 26 26,5 49,6 116 259 377 763 1030 1790 3460 5070 7430 10320 13290 21180
Zeta-value -- 0,93 2,4 1,7 0,75 0,43 0,46 0,27 0,37 0,25 0,21 0,24 0,23 0,23 0,23 0,22
Weights (kg) 1,8 18 2 2,8 3,2 4,8 6,2 8,8 11 15,6 24,8 36 55,6 85 146
Standard-flange dimensions refer to page 5
Face-to-face dimension FTF series 20 acc. to DIN EN 558-1

ARI-GESA®
Construction / Installation variations / Flange dimensions
DN25-65 DN80-150 DN200
DN250-300 DN350-500
Pressure-temperature-ratings
Material PN -10°C to 120°C 130°C 150°C
EN-JS1049 16 bar 16 15,8 15,5
Intermediate values for max. permissible operational pressures can be determined by linear interpolation
of the given temperature / pressure chart.
GESA®-Wafer-type-valve GESA®-Pipe-end-valve
welding neck flanges welding neck flanges
PN 10 / PN 16 PN 10 / PN 16
DIN EN 1092-1 / 11 / B1 DIN EN 1092-1 / 11 / B1
(for slip-on-flanges acc. to DIN EN 1092-1 use ZIVA) (for slip-on-flanges acc. to DIN EN 1092-1 use ZIVA)
Hexagon screw Hexagon screw
DIN EN ISO 4016 W.-Nr. 4.6 DIN EN ISO 4016 W.-Nr. 4.6
When used on end of line applications, a safety precaution (blind flange, etc.) is recommended.
To ensure the seat tightness, a blind or counter flange is necessary.
The installation between, to above deviating flanges, is not or under special care possible. Please consult us.
For all installation, modification or maintenance work, please observe regulations in force and the ARI-operating instructions.
Standard-flange dimensions / Hexagon screw (Quantity, Thread, Length)

DN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
PN10 ØK (mm) 85 100 110 125 145 160 180 210 240 295 350 400 460 515 620
PN10 nxM (mm) 4xM12 4xM16 4xM16 4xM16 4xM16 8xM16 8xM16 8xM16 8xM20 8xM20 12xM20 12xM20 16xM20 16xM24 20xM24
PN10 Quantity (pcs.) 8 8 8 8 8 16 16 16 16 16 24 24 32 32 40
PN10 Thread M12 M16 M16 M16 M16 M16 M16 M16 M20 M20 M20 M20 M20 M24 M24
PN10 Length (mm) 30 30 30 35 35 40 40 45 45 50 55 55 60 70 85
PN16 ØK (mm) 85 100 110 125 145 160 180 210 240 295 355 410 470 525 650
PN16 n x Ød1 (mm) 4xM12 4xM16 4xM16 4xM16 4xM16 8xM16 8xM16 8xM16 8xM20 12xM20 12xM24 12xM24 16xM24 16xM27 20xM30
PN16 Quantity (pcs.) 8 8 8 8 8 16 16 16 16 24 24 24 32 32 40
PN16 Thread M12 M16 M16 M16 M16 M16 M16 M16 M20 M20 M24 M24 M24 M27 M30
PN16 Length (mm) 30 30 30 35 35 40 40 45 45 50 55 60 60 75 100
Edition 08/10 - Data subject to alteration 632/658

ARI-ZESA® / ARI-GESA®
Notch lever / Lock lever / Worm gear
with lever
Notch lever
For diameters larger than DN 125 we recommend using a gear mechanism. Gear
recommended for inaccessible installation (see below).
(till valve center)

Lock lever
• Cap convertable for lock lever
• Variable adjustment (with 0 - 90° angle positioning) (With variable adjustment)
(till valve center)
For diameters larger than DN 125 we recommend using a gear mechanism. Gear
recommended for inaccessible installation (see below).
Worm gear
• With variable adjustment
• Self-locking
Stop screw
Lock nut
Position indicator
(till valve center)
The SHUT-position can be adjusted to ±5° by a locking screw.
Parts
Pos. Description Fig. 20./21./22.012; 21./22.013
7 Lever cap * PA 6
8 Insulating cap * PA 6
20 Hexagon nut * 5-A2B
21 Pan head screw * 8.8-A2B
50 Notch lever DC01, 1.0330 (surface treatment)
50 Clamp lever DC01, 1.0330 (surface treatment)
50 Worm gear
* Spare part

DN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
H1 (mm) 187 187 193 199 209 217 238 263 279 313 -- -- -- -- --
P1 (mm) 184 184 184 184 184 184 184 273 273 273 -- -- -- -- --
H2 (mm) 217 217 223 229 239 247 268 285 301 335 428 457 513 603 691
P2 (mm) 152 152 152 152 152 152 152 152 152 152 278 278 278 320 320
ØC (mm) 125 125 125 125 125 125 125 125 125 125 250 250 250 315 315
Type of gear SE07 SE07 SE07 SE07 SE07 SE07 SE07 SE07 SE07 SE07 SE10 SE10 SE10 SE12 SE12
ZESA® with lever (kg) 1,8 1,8 2,0 2,4 3,0 3,6 4,4 7,4 9,4 13,4 -- -- -- -- --
GESA® with lever (kg) 2,2 2,2 2,4 3,2 3,6 5,2 6,6 9,6 11,8 14,9/16,4 -- -- -- -- --
ZESA® with gear (kg) 3,3 3,3 3,5 3,9 4,5 5,1 5,9 8,5 10,5 14,5 24,4 34,4 49 75,6 120
GESA® with gear (kg) 3,7 3,7 3,9 4,7 5,1 6,7 8,1 10,7 12,9 16/17,8 29,8 41 61 97 157

ARI-ZESA® / ARI-GESA®
Capacity chart / Difference between disc outside-diameter and face-to-face
Kvs-value and Zeta-value

DN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
Kvs-value (m3/h) 26 26,5 49,6 116 259 377 763 1030 1790 3460 5070 7430 10320 13290 21180
Zeta-value -- 0,93 2,4 1,7 0,75 0,43 0,46 0,27 0,37 0,25 0,21 0,24 0,23 0,23 0,23 0,22
opening angle disc
close open
indication - lever
Difference between disc outside-diameter and face-to-face

DN 25 32 40 50 65 80 100 125 150 200 250 300 350 400 500
B (mm) -- -- 5 5 11 18 25 36 48 71 91 112 132 147 188
D (mm) -- -- 26 29 49 68 88 115 142 194 243 292 333 383 486

Edificio Genebre. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
genebre@genebre.es - www.genebre.es
ARTICULO: 2221
Válvula de Aguja extremos roscados.
Threaded ends Needle valve.
Características Features
1. Válvula de Aguja. 1. Needle valve.
2. Construcción en acero carbono ASTM A105 2. Made of Carbon steel ASTM A105.
3. Extremos roscados según DIN 2999 std. 3. Threaded ends according DIN 2999 std.
4. Estopada de eje en PTFE + Grafito. 4. Stem Packing PTFE + Graphite.
5. Presión máxima de trabajo 3000 Lbs. 5. Max. Working pressure 3000 Lbs.
6. Rango Presión / Temperatura: 6. Pressure / Temperature Range:
1/4"-1/2” = 220 Bar / 260 ºC. 1/4"-1/2” = 220 Bar / 260 ºC.
3/4"-1" = 220 Bar / 240 ºC. 3/4"-1" = 220 Bar / 240 ºC.
Nº Denominación / Name Material Acabado

Superficial/Surface
Treatment
1 Cuerpo / Body ASTM A-105 Cincado / Zinc golden
2 Bonete / Bonnet ASTM A-105 Cincado / Zinc golden
3 Tuerca prensaestopas / Nut ASTM A-105 Cincado / Zinc golden
4 Aguja / Needle Inox. A182 F6 / S.S. A182 F6 ------
5 Eje / Stem Inox. A182 F6 / S.S. A182 F6 ------
6 Estopada / Stem packing Teflón + graffito / PTFE + graphite ------
7 Prensaestopas / Packing nut ASTM A-105 Cincado / Zinc golden
8 Volante / Handwheel Aluminio / Alluminium Pintado / Painted
9 Tuerca / Nut Acero Carbono / Carbon Steel Cincado / Zinc
10 Arandela / Washer Acero Carbono / Carbon Steel Cincado / Zinc
GENEBRE S.A. FECHA DE REVISIÓN: 20/02/2009 NUMERO DE REVISIÓN: 5
635/658
Edificio Genebre. Av. de Joan Carles I, 46-48
08908 L'Hospitalet de Llobregat. Barcelona (Spain)
genebre@genebre.es - www.genebre.es
DIMENSIONES GENERALES / GENERAL DIMENSIONS
Ref Medida/ PN Dimensiones/Dimensions (mm) Peso/

Size (Lbs) Weight
E H L K V (Kg)
2221 02 1/4" 3000 25 85 50 3 63 0.260
2221 03 3/8” 3000 30 100 55 4 63 0.360
2221 04 1/2" 3000 34 115 60 6 72 0.530
2221 05 3/4" 3000 40 120 70 8 72 0.760
2221 06 1” 3000 45 138 75 9 80 1.175
DIAGRAMA DE PERDIDAS DE CARGA / HEAD LOSSES DIAGRAM
(H2O – 20 ºC Flujo Horizontal / Horizontal flow).
GENEBRE S.A. FECHA DE REVISIÓN: 20/02/2009 NUMERO DE REVISIÓN: 5
636/658
Sight Flow Indicator (straight line )
with flanged-Connection acc. to DIN - PN 16, PN 25 and PN 40
DIN 3237
NORIS
Cast Iron GG 25 ( EN-GJL-250 ) max 16 bar
Cast Steel GS-C 25 ( 1.0619 / GP240GH )
Stainless Steel WN 1.4408 Bauform 880
Application:
The flow indicators are used for optical control of fluids and gases,
for horizontal and vertical pipe lines. Also available with internal
spinner or flap.
Installation:
Optional; Take care of flow direction
Operating conditions:
Working pressure: max. 16 / 25 / 40 bar
Working temperature: max. 150°C or 280°C
Certificate: ( Option )
Acc. to EN 10204 - 2.2 or 3.1
Options:
with - ANSI-flanges
- Butt weld ends
- Spinner or Flap
- Heating jacket
- Sight glass light - fittings
Materials:
Body GG 25 GS-C 25 1.4408
GG 25 / GS-C 25 / 1.4408 /
Covers S235JRG2 S235JRG2 1.4301
Screws 4.6 / 5.6 gal. A4-70
Borosilicate glass DIN 7080 ( 280°C )
Glasses Soda lime glass DIN 8902 ( 150°C )
Gaskets Graphite, (or other materials)
Dimensions:
Ordering example: Glass plate
Sight Flow Indicators Bauform 880, DN D BL d1 d2 S
GG 25, with borosilicate glass DIN 7080 PN 16 PN 25 PN 40
DN 50, PN 16 15 95 130 32 45 10 10 10
20 105 150 32 45 10 10 10
25 115 160 48 63 10 12 15
32 140 180 48 63*** 10 12 15
40 150 200 65 80 12 15 20
50 165 230 80 100 15 20 25
65 185 290 80 100 15 20 25
80 200 310 100 125 20 25 30
100 220(235) * 350 125 150 25 30 35
125 250(270) * 400 150 175 25 30 a.A.
150 285(300) * 480 175 200 30 ** 35 a.A.
200 340(360/375)* 600 175 200 30 ** 35 a.A.
250 405(425/450)* 730 175 200 30 ** 35 a.A.
DN 65 - 250 * D in () acc. to PN 25 / PN 40
( Covers round ) ** 16 bar only with borosilicate glass possible
*** by GG25 glass plate Ø 80x12
DN 15 - 50
( Covers square )
Modifications reserved
NORIS ARMATUREN Burkenstein GmbH & Co. KG

06/06
Neumeyerstraße 13 Telefon: +49 (0) 911 / 52 150 63 Internet: Noris-Armaturen.de

D-90411 Nürnberg Telefax: +49 (0) 911 / 52 24 40 E-Mail: Noris@Noris-Armaturen.de
E880
637/658

638/658
Mechanical
temperature measurement
Machine glass thermometers

Model 32, V-Form
WIKA data sheet TM 32.02
for further approvals

see page 5
Applications
■■ Universal application
■■ Machine building
■■ Vessel construction
■■ Central and large heating systems
■■ Plant construction
Special features
■■ Insensitive to vibrations
■■ Non-toxic thermometric liquid
■■ Measuring ranges from -30 ... +200 °C
Machine glass thermometer model 32, 90° angle version
Description
The model 32 machine glass thermometer is mainly used in

industrial applications such as machine building and also in
heating, air-conditioning and refrigeration technology.
It is notable for its high accuracy and very long service life
(since there is no mechanical wear).
WIKA data sheet TM 32.02 ∙ 01/2013 Page 1 of 5
639/658
Standard version Nominal size 110 x 30 mm
Nominal size in mm Connection type

110, 150 and 200 Design E, male thread
Measuring principle ■■ Straight design per DIN 16181

Liquid expansion Threaded connection
- G ½ B, M20 x 1.5 (form B per DIN)
Error limit - G ⅜ B, M16 x 1.5 (form B1 per DIN)
DIN 16195 Threaded connections screwed into housing
Insertion length l1 = 30, 40, 63, 100, 160, 250 mm
Permissible working pressure at the stem Copper alloy
Max. 6 bar
■■ 90° angle version per DIN 16182
Stem Threaded connection

Ø 10 mm - G ½ B, M20 x 1.5 (form S per DIN)
Ø 6.5 mm for NS 200 x 36 with union nut M24 x 1.5 - G ⅜ B, M16 x 1.5 (form S1 per DIN)
Threaded connectors inserted into housing, removable
Case Insertion length l1 = 30, 40, 63, 100, 160, 250 mm
Aluminium, brass-coloured, anodised Copper alloy
■■ 135° angle version

Scale setting
Threaded connection
printed with special ink, protected by anodised finish
- G ½ B, M20 x 1.5
- G ⅜ B, M16 x 1.5
Thermometer glass insert
Threaded connections screwed into housing
Rod shape, prismatic capillary
Insertion length l1 = 30, 40, 63, 100, 160, 250 mm
Copper alloy
Thermometric liquid
Blue, wetting
Nominal size 150 x 36 mm Nominal size 200 x 36 mm
Connection type Connection type

Design E, male thread Design E, male thread
■■ Straight design per DIN 16185 ■■ Straight design per DIN 16189
Threaded connection Threaded connection
- G ½ B, M20 x 1.5 (form B per DIN) - G ½ B, M20 x 1.5 (form B1 per DIN)
- G ¾ B, M27 x 2 - G ¾ B, M27 x 2 (form B per DIN)
Threaded connections screwed into housing Threaded connections screwed into housing
Insertion length l1 = 63, 100, 160, 250 mm Insertion length l1 = 63, 100, 160, 250 mm
Copper alloy Copper alloy
■■ 90° angle version per DIN 16186 ■■ 90° angle version per DIN 16190
- G ½ B, M20 x 1.5 (form S per DIN) - G ½ B, M20 x 1.5 (form S1 per DIN)
- G ¾ B, M27 x 2 - G ¾ B, M27 x 2 (form S per DIN)
Threaded connectors inserted into housing, removable Threaded connectors inserted into housing, removable
■■ 135° angle version ■■ 135° angle version

- G ½ B, M20 x 1.5 - G ½ B, M20 x 1.5 (form B1 per DIN)
- G ¾ B, M27 x 2 - G ¾ B, M27 x 2 (form B per DIN)
Threaded connections screwed into housing Threaded connections screwed into housing
Page 2 of 5 WIKA data sheet TM 32.02 ∙ 01/2013
640/658
Scale ranges
Nominal size Scale range Scale spacing Error limit
in mm in °C in °C in °C
NS 110 - 30 ... +50 1 2
0 ... 60 1 1.5
0 ... 100 2 2
0 ... 120 2 2
0 ... 160 4 4
0 ... 200 5 5
NS 150 -30 ... +50 1 2
0 ... 60 1 1.5
0 ... 100 2 2
0 ... 120 2 2
0 ... 160 2 4
0 ... 200 2 4
NS 200 -30 ... +50 1 2
0 ... 60 1 1.5
0 ... 100 1 2
0 ... 120 1 2
0 ... 160 2 4
0 ... 200 2 4
Models
Nominal size in mm Model Connection location DIN
NS 110 G 3200 straight DIN 16181
W 3201 90° angle DIN 16182
W 3202 135° angle -
W 3211 90° angle DIN 16186
W 3212 135° angle -
W 3221 90° angle DIN 16190
W 3222 135° angle DIN 16191
Options (for all nominal sizes)

■■ Dual scale °F/°C - 90° angle version per DIN 16190
■■ Other scale ranges Union nut
■■ Threaded connections from other materials - G ½, M20 x 1.5 (form C1 per DIN)
■■ Thermowells in accordance with DIN from copper alloy, - G ¾, M27 x 2 (form C per DIN)
steel, stainless steel or other materials - M24 x 1.5 (form F per DIN)
■■ Connection design (selectable): Design 3, union nut Adapter inserted into housing, removable
■■ Variants Insertion length l1:
- Straight design per DIN 16189 - Form C1: l1 = 89, 126, 186, 276, 426 mm
Union nut - Form C: l1 = 93, 130, 190, 280, 430 mm
- G ½, M20 x 1.5 (form C1 per DIN) - Form F: l1 = 155, 215, 275, 295, 355, 415 mm
- G ¾, M27 x 2 (form C per DIN) Union nut and copper alloy adapter, pipe st. 35
- M24 x 1.5 (form F per DIN)
Adapter screwed into housing, removable - 135° angle version per DIN 16191
Insertion length l1: Union nut
- Form C1: l1 = 89, 126, 186, 276, 426 mm - G ½, M20 x 1.5 (form C1 per DIN)
- Form C: l1 = 93, 130, 190, 280, 430 mm - G ¾, M27 x 2 (form C per DIN)
- Form F: l1 = 155, 215, 275, 295, 355, 415 mm - M24 x 1.5 (form F per DIN)
Union nut and copper alloy adapter, pipe st. 35 Adapter screwed into housing, removable
Insertion length l1:
- Form C1: l1 = 89, 126, 186, 276, 426 mm
- Form C: l1 = 93, 130, 190, 280, 430 mm
- Form F: l1 = 155, 215, 275, 295, 355, 415 mm
Union nut and copper alloy adapter, pipe st. 35
641/658
Dimensions in mm
Connection design E, male thread

straight 90° angle 135° angle
3073092.01
3073106.01
3073114.01
Connection design 3, union nut (only with NS 200)
straight 90° angle 135° angle
3073122.01
3073130.01
3073181.01
NS Dimensions in mm Weight
a1 a2 B Ød Ø d1 G G1 H H1 SW in kg
110 44 20 30 10 22 G⅜B - 110 130 22 0.25
44 20 30 10 21 M16 x 1.5 - 110 130 22 0.25
44 20 30 10 26 G½B - 110 130 27 0.25
44 20 30 10 25 M20 x 1.5 - 110 130 27 0.25
150 46 21 36 10 26 G½B - 150 170 27 0.30
46 21 36 10 25 M20 x 1.5 - 150 170 27 0.30
46 21 36 10 32 G¾B - 150 170 32 0.30
46 21 36 10 32 M27 x 2 - 150 170 32 0.30
200 46 21 36 10 26 G½B G½ 200 220 27 0.35
46 21 36 10 25 M20 x 1.5 M20 x 1.5 200 220 27 0.35
46 21 36 10 32 G¾B G¾ 200 220 32 0.35
46 21 36 10 32 M27 x 2 M27 x 2 200 220 32 0.35
46 21 36 6.5 - - M24 x 1.5 200 220 32 0.35
Page 4 of 5 WIKA data sheet TM 32.02 ∙ 01/2013
642/658
Approvals
■■ GL 1), ships, shipbuilding (e.g. offshore), Germany

■■ CRN, safety (e.g. electr. safety, overpressure, ...), Canada
1) For straight and 90° angle versions
Approvals and certificates, see website
Ordering information
Model / Nominal size / Scale range / Connection design / Length l1 / Options
© 2008 WIKA Alexander Wiegand SE & Co. KG, all rights reserved.
The specifications given in this document represent the state of engineering at the time of publishing.
We reserve the right to make modifications to the specifications and materials.

01/2013 GB
WIKA Alexander Wiegand SE & Co. KG

Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Tel. (+49) 9372/132-0
Fax (+49) 9372/132-406
E-mail info@wika.de
www.wika.de
643/658

644/658
Mechanical
pressure measurement
Bourdon tube pressure gauge

Model 213.53, liquid filling, stainless steel case
WIKA data sheet PM 02.12
Applications
■■ For measuring points with high dynamic pressure loads or
vibrations
■■ For gaseous and liquid media that are not highly viscous
or crystallising and will not attack copper alloy parts
■■ Hydraulics
■■ Compressors, shipbuilding
Special features
■■ Vibration and shock resistant
■■ Especially sturdy design
■■ NS 63 and 100 with German Lloyd and Gosstandart
approval
■■ Scale ranges up to 0 ... 1000 bar
Bourdon tube pressure gauge, model 213.53.100,
lower mount
Description Pressure limitation

NS 50, 63: Steady: 3/4 x full scale value
Design Fluctuating: 2/3 x full scale value
EN 837-1 Short time: Full scale value
NS 100: Steady: Full scale value
Nominal size in mm Fluctuating: 0.9 x full scale value
50, 63, 100 Short time: 1.3 x full scale value
Accuracy class Permissible temperature

NS 50, 63: 1.6 Ambient: -20 ... +60 °C
NS 100: 1.0 Medium: +60 °C maximum
Scale ranges Temperature effect

NS 50: 0 ... 1 to 0 ... 400 bar When the temperature of the measuring system deviates
NS 63, 100: 0 ... 0.6 to 0 ... 1000 bar from the reference temperature (+20 °C): ■
or all other equivalent vacuum or combined pressure and Max. ±0.4 %/10 K of the span
vacuum ranges
Ingress protection
IP 65 per EN 60529 / lEC 529
WIKA data sheet PM 02.12 ∙ 05/2011 Page 1 of 2
Data sheets showing similar products:

Standard version with liquid filling; model 113.53; see data sheet PM 01.08
645/658
Process connection Case
Cu-alloy, Natural finish stainless steel, with pressure relief at case
lower mount (LM) or back mount (BM), circumference, 12 o'clock.
NS 50, 63: G ¼ B (male), 14 mm flats O-ring seal between case and connection.
NS 100: G ½ B (male), 22 mm flats Scale ranges ≤ 0 ... 16 bar with compensating valve to vent
case.
Pressure element
NS 50, 63:
Bezel ring
< 60 bar: Cu-alloy, C-type
Crimp ring, glossy finish stainless steel, triangular bezel
≥ 60 bar: Cu-alloy, helical type
NS 100:
Filling liquid
< 100 bar: Cu-alloy, C-type
Glycerine 99.7 %
≥ 100 bar: Stainless steel 316L, helical type
Movement
Cu-alloy
Options
■■ Measuring system and movement from stainless steel
Dial
(model 233.53)
NS 50, 63: Plastic ABS, white, with pointer stop pin
■■ NS 100: Zero adjustment (in front)
NS 100: Aluminium, white, black lettering
■■ Increased medium temperature with special soft solder
Pointer - NS 50, 63: 100 °C
NS 50, 63: Plastic, black - NS 100: 150 °C
NS 100: Aluminium, black ■■ Ambient temperature resistant -40 ... +60 °C with silicone
oil filling
Window
■■ Panel mounting flange, stainless steel, for back connection
Plastic, crystal-clear
■■ Surface mounting flange, stainless steel (not NS 50)
■■ Mounting clamp (for back connection)
Dimensions in mm
Lower mount (LM) Centre back mount (CBM) 1) Lower back mount (LBM) 2)
1224557.01
12245491.01
1) With NS 50, 63 12245492.01

2) With NS 100
NS Dimensions in mm Weight in kg
a b ± 0.5 b2 ± 0.5 D1 D2 e f G h±1 SW
50 12 30 55 55 50 5.5 - G¼B 48 14 0.15
63 13 32 56 68 62 6.5 - G¼B 54 14 0.21
100 15.5 48 81.5 107 100 8 30 G½B 87 22 0.80
Process connection per EN 837-1 / 7.3
Model / Nominal size / Scale range / Connection size / Connection location / Options
Page 2 of 2 WIKA data sheet PM 02.12 ∙ 05/2011

05/2011 GB

Tel. (+49) 9372/132-0
Fax (+49) 9372/132-406
E-mail info@wika.de
www.wika.de
646/658
Technisches Datenblatt
Druckstoßminderer
Pressure reducers
Zur Dämpfung von stoßartig auftretenden For the absorbility of impulsive pressure load at the
Druckbelastungen an Manometern. Werkstoff: manometer. Material: brass, steel and stainless steel
Messing, Stahl und Edelstahl 1.4571. Temperatur: 1.4571 Temperature: brass 120°C steel 200°C 1.4571
Messing 120°C Stahl 200°C 1.4571 200°C. 200°C
Druckstoßminderer, Material: Messing, Stahl, 1.4571

pressure reducer, material: brass, steel, 1.4571
Figur A L1 / mm L2 / mm L3 / mm S1 / mm S2 / mm Material Art.Nr.
88 G1/4 46 13 11 19 12 Messing 10088021
88 G1/2" 61,5 20 18 27 14 Messing 10088041
88 G1/4" 47 14 11 19 12 Stahl 10088022
88 G1/2" 60 20 18 27 14 Stahl 10088042
88 G1/4" 47 13 11 19 12 1.4571 10088023
88 G1/2" 60 20 18 27 14 1.4571 10088043
647/658

648/658
Shut-off valve for pressure measuring instruments
Design
DIN 16271 DN 3.5 PN 400 -20 up to 200 °C
1. Applications
This work standard is valid to in the fittings and metal works produced shut-off valves for pressure measuring
instruments per DIN 16 271 (and similar) and specifies whose dimensions, materials, pressure and temperature
ranges, and other data.
2. Dimensions and disign
Form A per DIN 16271 Form B per DIN 16271

with LH/RH union with shaft for the mounting bracket
Maße in mm
Thread per DIN 13 T13

DIN ISO 228 T1
ANSI B1.20.1
d1 d2 d3 l1 l2 t
G1/4 G1/4 5.5 13 12 5
G1/2 G1/2
7 20 17 7
M20x1.5 M20x1.5
1/2"NPT 1/2"NPT - 19+1 - -
Technical modifications and delivery possibilities are reserved

© DODEN ARMATUREN KG
Rosenheimer Straße 11 28219 Bremen
TEL (0421) 160 80 0
649/658
Design
DIN 16271 DN 3.5 PN 400 -20 up to 200 °C
3. Material assignment
1)
3.1 Depending on the thread size of pressure and temperature range
Material Connecting Nominal Tempera- Design
thread pressure ture range
Code
d1 / d2 [bar] [°C]
G1/4 250 bronzed
G1/2 -10 or
Carbon steel
M20x1.5 400 up to zinc-plated
10St
1/2"NPT +120
G1/4 250
Stainless steel G1/2 -40
shiny
20St M20x1.5 400 up to
1/2"NPT +120
G1/4 125
shiny
G1/2 -10
Brass or
M20x1.5 250 up to
20Ms nickel-plated
1/2"NPT +120
1) Note the pressure reductions at higher temperatures!
3.2 Component parts

Material Carbon steel Stainless steel Brass
Code 10St 20St 20Ms
Body 1.0460 2.0540
1.4104 1.4104
Needle
1.4034 hard. 1.4571 1.4034 hard.
Bottom ring 1.0038 1.0038
Packing graphite PTFE
Packing gland
Union nut
LH/RH union 1.0715 1.4571 1.0715
Screw cap
lens-type sealing ring
Nipple 1.0038 2.0401
Hand wheel plastic, black
Vent screw 1.4104 1.4571 1.4104
Special threads, custom-built models and DVGW version on enquiry at the manufacturer.
Table for the medium „Oxygen““

max. max.
Supplementary
operating operating Packing Miscellaneous conditions
code
pressure temperature
3) 100 bar virgin PTFE Material: brass (Cu>55%) or carbon steel
P1
60 °C pure graphite Antiseize: acc. to the list of the non metallic
3) 250 bar
P2 BAM tested materials of the BAM (stand 31.08.94)
3) If ordering without nominal pressure indication, the "P1" version will be delivered.
Technical modifications and delivery possibilities are reserved

© DODEN ARMATUREN KG
Rosenheimer Straße 11 28219 Bremen
TEL (0421) 160 80 0
650/658
Accessories

Model 910.11, brass, steel or stainless steel
WIKA data sheet AC 09.02
Applications
■■ Shut-off and throttle valve for pressure measuring

instruments, for measuring liquids, gases and vapours
■■ In stainless steel version for aggressive media, also in
aggressive environments
■■ Process industry: Machine building, general plant
construction, chemical/petrochemical, power plants,
mining, on- and offshore and environmental technology
Special features
■■ Shut-off valve without test connection per DIN 16270

(with vent screw)
■■ Shut-off valve with test connection per DIN 16271
(with vent screw) Shut-off valve per DIN 16270,
■■ Shut-off valve with separate isolating test connection per LH-RH adjusting nut / male G ½, PN 250
DIN 16272
■■ Nominal pressures to 400 bar
Description
Form A version of the shut-off valves is supplied with LH/

RH union, and Form B version with shaft for the mounting
bracket, with nipple and union nut. Shut-off valves with a test
connection are intended for the simultaneous connection
of operating pressure measuring instruments and test
connection pressure gauges to the pressure pipeline. With
shut-off valves per DIN 16271, the test pivot is sealed by a Shut-off valve with separately isolated test
lens-type sealing ring and a screw cap placed on top; with connection per DlN 16272, LH/RH union/male G ½,
valves per DIN 16272, the test pivot is separately isolated by with test pivot M20 x 1.5, PN 400
an additional valve spindle. Shut-off valves are silicone-free.
WIKA data sheet AC 09.02 ∙ 12/2011 Page 1 of 4
Data sheets showing similar devices:

Stopcocks for lower pressures; model 910.10; see data sheet AC 09.01
651/658
Standard version Options
Pressure connection ■■ Free from oil and grease

G ½, test connection M20 x 1.5 ■■ Acceptance test certificate per DIN 50049 / EN 10204 3.1
■■ DVGW version, PN 100, DlN 16270
Valve body ■■ Connection M20 x 1.5, ½ NPT
Brass: PN 250, temperature range -10 up to +120 °C ■■ With bellows sealing up to PN 100
Carbon steel: PN 400, temperature range -10 up to +120 °C ■■ Design per NACE
Stainless steel: PN 400, temperature range -20 up to +200 °C
Needle and seating Versions for oxygen use

Corrosion and acid resistant stainless steel
■■ With PN 100 bar to max. 60 °C
Packing ■■ With PN 160 bar to max. 60 °C
PTFE ■■ With PN 250 bar to max. 60 °C
■■ With PN 230 bar to max. 200 °C (graphite packing)
Hand wheel
Heat-resistant plastic With steel or stainless steel valve body
■■ With special packing (pure graphite) up to 250 °C
Nominal pressures ■■ Up to PN 640 bar
See table below
Design Connection PN in bar Material Order no.

Form A Form B
DIN 16270 G½ 250 Ms 9090169 9095098

G½ 400 St 9090177 9095101
G½ 400 1.4571 9090967 9095110
DIN 16271 G½ 250 Ms 9090975 9095128

G½ 400 St 9090983 9095136
G½ 400 1.4571 9091157 9095144
Test connection M20 x 1.5
DIN 16272 G½ 250 Ms 9090991 9095152
G½ 400 St 9091009 9095160
G½ 400 1.4571 9091017 9095179
Test connection M20 x 1.5
Adapter piece for valves with test connection
A suitable adapter piece is available for valves with test connection

(test female G ½ / female M20 x 1.5).
Design Material Order no.
Adapter piece Ms 9091700

St 9091718
1.4571 9091726
Test female G ½ / female M20 x 1.5
Page 2 of 4 WIKA data sheet AC 09.02 ∙ 12/2011
652/658
Dimensions in mm
Form A, LH/RH union / male
DIN 16270 DIN 16271 DIN 16272
Test connection LH-RH union

LH-RH union LH-RH union
wheel per DIN 16283
per DIN 16283 per DIN 16283
Pressure gauge
wheel
Form B, nipple and union nut / male, with shaft for mounting bracket
DIN 16270 DIN 16271 DIN 16272
Test connection Sealing nipple

wheel connection
Sealing nipple Sealing nipple DIN 16284
connection connection
DIN 16284 DIN 16284
Pressure gauge
wheel
Design Dimensions in mm Weight in kg

a b ±5 Ms St 1.4571
DIN 16270
Form A 100 ±1 85 0.54 0.52 0.52
Form B 120 ±5 85 0.61 0.56 0.56
DIN 16271
Form A 100 ±1 85 0.67 0.65 0.65
Form B 120 ±5 85 0.79 0.74 0.74
DIN 16272
Form A 100 ±1 85 0.95 0.95 0.95
Form B 120 ±5 85 1.00 1.00 1.00
WIKA data sheet AC 09.02 ∙ 12/2011 Page 3 of 4
653/658
To order, the 7-digit order number is sufficient. Other options require additional specification.
Page 4 of 4 WIKA data sheet AC 09.02 ∙ 12/2011

12/2011 GB

Tel. (+49) 9372/132-0
Fax (+49) 9372/132-406
E-mail info@wika.de
www.wika.de
654/658
TEST 20 Type SMK Connection Thread M 16 x 2
Fast coupling for:

• Monitoring and control of pressure
• Venting
• Sampling in high- and low-pressure systems
Advantages:
• Coupling at system pressure level
• Leakproof connection before ball valve is open
• Simple connection to measuring,
Test hose control and switching devices
with swivel nut • Self locking metal guard cap
Working pressure:
• Max. working pressure 630 bar
For SMK style G and K the recommended working pressure
of fitting manufacturer has to be applied
• Joining under pressure up to 400 bar max.
Materials:
• Metal parts:
Steel: C6F = zinc/nickel plated
Stainless Steel on request: V2A (1.4305 / AISI 303),
V4A (1.4571 / AISI 316Ti)
• Ball: Stainless Steel
Test coupling • Seals:
P = NBR (Temperature range -20° C to +100° C)
(Internal seals made of FPM (even at the standard
NBR-type))
V = FPM (Temperature range -20° C to +200° C)
E = EPDM Ethylene Propylene (for Break Fluid,
Temperature range -40° C to +150° C)
• Hose: Polyamide (Temperature range -35° C to +100° C)
• Vibration safety O-ring made of NBR (standard)
Media:
• Suitable for hydraulic oils and other mineral oil based fluids
(Please pay attention to the sealing materials used !)
Protective cap • For use in conjunction with other liquid media please
consult STAUFF
The complete STAUFF-

T E S T- 2 0 - Ty p e - S KK
SMK
range is also available
with a hexagonal pro-
tection cap made out of
steel, or with a plastic
protection cap.
655/658
5
TEST 20 Type SMK Connection Thread M 16 x 2
Test coupling with protective cap

Working Order No.
Thread
Seal pressure h1 h2 Hex
G NBR FKM
bar
M8x1 250 38 8,5 17 SMK20-M8x1-PA-C6F SMK20-M8x1-VA-C6F
M10x1 630 38 9,8 17 SMK20-M10x1-PA-C6F SMK20-M10x1-VA-C6F

Type A
M10x1 400 37 8 17 SMK20-M10x1-PB-C6F SMK20-M10x1-VB-C6F
M12x1,5 630 37 12 17 SMK20-M12x1,5-PB-C6F SMK20-M12x1,5-VB-C6F

Type B
G1/8 400 39 8 17 SMK20-G1/8-PB-C6F SMK20-G1/8-VB-C6F
M10x1 400 39 8 17 SMK20-M10x1-PC-C6F SMK20-M10x1-VC-C6F
M12x1,5 630 37 12 17 SMK20-M12x1,5-PC-C6F SMK20-M12x1,5-VC-C6F

Type C
G1/8 400 39 8 17 SMK20-G1/8-PC-C6F SMK20-G1/8-VC-C6F
R1/8K 400 37 8 17 SMK20-R1/8K-PD-C6F SMK20-R1/8K-VD-C6F
R1/4K 630 35 12 17 SMK20-R1/4K-PD-C6F SMK20-R1/4K-VD-C6F

Type D
1/8 NPT 400 36 10 17 SMK20-1/8NPT-PD-C6F SMK20-1/8NPT-VD-C6F
1/4 NPT 630 35 15 17 SMK20-1/4NPT-PD-C6F SMK20-1/4NPT-VD-C6F
5/16-24UNF 400 38 7,5 17 SMK20-5/16UNF-PE-C6F SMK20-5/16UNF-VE-C6F

Type E
9/16-18UNF 630 37 10 19 SMK20-9/16UNF-PE-C6F SMK20-9/16UNF-VE-C6F
M10x1 630 38 9,5 17 SMK20-M10x1-PE-C6F SMK20-M10x1-VE-C6F
M12x1,5 630 37 11 17 SMK20-M12x1,5-PE-C6F SMK20-M12x1,5-VE-C6F
M14x1,5 630 38 11 19 SMK20-M14x1,5-PE-C6F SMK20-M14x1,5-VE-C6F
For ordering the hexagonal protection cap version please add “-SK” to the order number.
For ordering the plastic protection cap version please add “-KK” to the order number.
Other port connections and seals on request.
6 656/658
Teil D Absperrventile, Nadel- und Regelventile
Section D Globe valves, Needle and Control valves
Muffen-Durchgangsventile aus Rotguß, Screwed globe valves, gunmetal,

PN 16, DIN 3844-2 PN 16, DIN 3844-2
Abschlußkörper mit PTFE-Dichtung, screwed bonnet, complete with PTFE

eingeschraubtes Oberteil, valve seal, handwheel operated
beiderseits Innengewinde, with screwed female connections,
Art.-Nr. 01021.X.0000 Part No. 01021.X.0000

Standardausführung. standard type.
Art.-Nr. 01021.X.5330 Part No. 01021.X.5330

Rückschlagventil mit Kopfstücksicherung, screw down non return valve with tab
absperrbar, mit Schließfeder. washer for bonnet, with closing spring.
Verwendungsbereich: Art.-Nr. 01021.X.0000 Art.-Nr. 01021.X.5330

Geeignet für nichtbrennbare, ungiftige
Flüssigkeiten, Gase und Dämpfe. Die den d1 d1
Verwendungszweck betreffenden Gesetze, 5
5
Verordnungen und Normen sind zu beachten.
Zulässige Betriebstemperaturen und -drücke:
-10°C (263K) bis +80°C (353K) max. 16 bar,
3 3
S2 S2
+80°C (353K) bis +120°C (393K) max. 10 bar, 2
2
+120°C (393K) bis +160°C (433K) max. 6 bar.
H
H
4 4
Applications: S1 S1
1 1
Suitable for non-inflammable, non-toxic
fluids, gases and vapours.
The laws, regulations and standards
G
G
are to observe for the range of application.

Working temperatures and pressures:
-10°C (263K) up to +80°C (353K) max. 16 bar, a a
+80°C (353K) up to +120°C (393K) max. 10 bar, L L
+120°C (393K) up to +160°C (433K) max. 6 bar.
Wichtig: Bei Bestellungen und Anfragen bitten wir Werkstoffe/Materials

um Angaben über Durchflußmedium, Betriebsdruck Mat.Nr.
und Betriebstemperatur. 1-Gehäuse/body 2.1096.01 G-Cu Sn 5 Zn Pb
2-Kopfstück/head piece 2.0380.10 Cu Zn 39 Pb 2
Essential: When ordering or requesting an offer 3-Spindel/stem 2.0380.10 Cu Zn 39 Pb 2
Technische Änderungen vorbehalten c /Data subject to alternation c
please indicate flow medium, working pressure 4-Teller/disc 2.0380.10 Cu Zn 39 Pb 2

and working temperature. 5-Handrad/handwheel Zink-Druckguß/zinc diecast
Art.-Nr./Part No. 01021.X./01021.X.5330

Nenngröße/Nom.Size G 1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2 2 1/2 3 4
Größenschl./dim. code .X. 0200 0300 0400 0600 1000 1200 1400 2000 2400 3000 4000
Baulänge/face-to-face dim. L 50 50 60 70 80 95 105 130 150 165 205
Höhe/height H 75 75 85 95 105 120 130 145 175 195 285
Muffentiefe/socket depth a 9 10 13 14 17 19 19 23 22 23 30
Handrad-Ø/handwheel-Ø d1 40 40 50 60 70 80 90 110 150 160 210
Schlüsselweite/A/F S1 22 22 27 32 41 50 58 70 85 100 130
Schlüsselweite/A/F S2 4,5 4,5 5 6 7 8 9 9 11 13 16
Gewicht/weight ca.kg 0,25 0,25 0,3 0,43 0,7 1,0 1,3 2,1 4,0 5,5 12,0
Maße in mm/dimensions in mm. Gewinde/thread: ISO 228/1.
HEROSE GMBH Postfach 1561 Tel.: (+4531) 509-0 Seite/Page D 010

ARMATUREN UND METALLE D-23835 Bad Oldesloe Fax: (+4531) 509120 Ausgabe/Edition 03/98
657/658

658/658

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Beschreibung der grundlegenden Sicherheits- und Gesundheitsschutzanforderungen gemäß

Zutreffend Applicable Erfüllt Fulfilled

1.1 ALLGEMEINES | REMARKS

1.1.1 Begriffsbestimmungen | Definitions

DeclarationOfIncorporation-Annex_131M083_BoosterModule.doc Seite Page 1 / 2

ANFORDERUNGEN AN SCHUTZEINRICHTUNGEN | REQUIRED

1.6 INSTANDHALTUNG | MAINTENANCE

1.6.1 Wartung der Maschine | Machinery maintenance X X

1.7 INFORMATIONEN | INFORMATION

Informationen und Warnhinweise an der Maschine | Information and warnings on the

DeclarationOfIncorporation-Annex_131M083_BoosterModule.doc Seite Page 2 / 2

* observed as known; not included in scope of supply

* danger of electric shock when working on electrical devices / components or improper

* flammable media; fire hazard when leakage

* earthing screws exist; need to be connected

29 1.6.3 - Isolation of energy sources * observe manual / trained staff

* all components/connections have name(numbers) plates in specified languages acc. to

35 1.7.2 - Warning of residual risks * see Annex to Declaration of Incorporation

Print Date: 28.05.2014 ResidualRisks_131M083_Booster_MultLang.xls 1/1

Fuel Oil Booster Module

Q’ty Pos. Description Supplier part no. DN PN Supplier or dealer

Q’ty Pos. Description Supplier part no. DN PN Supplier or dealer

Q’ty Pos. Description Supplier part no. DN PN Supplier or dealer

Q’ty Pos. Description Supplier part no. DN PN Supplier or dealer

CL090 MIX.T.LEVEL HIGH

Heater At regular intervals visual inspection for leaks. Alfa Laval Aalborg

Viscosity system At regular intervals visual inspection to check for leaks VAF

Duplex filter Regularly check for leaks, for corrosion and other damage, Boll+Kirch

Pulsation damper The device is basically maintenance‐free. HYDAC

Cooler At regular intervals visual inspection for leaks. SONDEX

y‐strainer At regular intervals remove and clean inside screen. ARI, DRW

Ball valves At regular intervals visual check for leaks. Valtec

Globe valves At regular intervals visual inspection to check for leaks. ARI

Heater At regular intervals visual inspection for leaks. Alfa Laval Aalborg

Duplex filter Regularly check for leaks, for corrosion and other damage, Boll+Kirch

Pulsation damper The device is basically maintenance‐free. HYDAC

Cooler At regular intervals visual inspection for leaks. SONDEX

Ball valves At regular intervals visual check for leaks, replace Valtec

Globe valves At regular intervals visual inspection to check for leaks. ARI

Flowmeter The device is basically maintenance‐free. KRACHT

Heater The heater should be cleaned regularly every six months Alfa Laval Aalborg

Pulsation damper The device is basically maintenance‐free. HYDAC

Cooler At regular intervals visual inspection for leaks. SONDEX

y‐strainer At regular intervals remove and clean inside screen. ARI, DRW

Ball valves At regular intervals visual check for leaks, replace the Valtec

Globe valves At regular intervals visual inspection to check for leaks. ARI

Heater The heater should be cleaned regularly every six months Alfa Laval Aalborg

Duplex filter Regularly check for leaks, for corrosion and other damage, Boll+Kirch

Cooler Once a year as a minimum: Check general condition, look SONDEX

y‐strainer At regular intervals remove and clean inside screen. ARI, Krombach

Ball valves At regular intervals visual check for leaks, replace the Valtec

Globe valves At regular intervals visual inspection to check for leaks. ARI

maritime assembly systems GmbH PHONE: +49 (0) 3841 - 7125 - 0

CABLE DUCTS: PVC 1309 PPO ...

DOOR FIXING DEVICE: YES NO ...

INTERNAL WIRES NUMBERS: SLIDE ON WITHOUT ...

CONTROL MIN.CROSS SECTION: 0,75mm² 0,5mm² ...

F MOTOR GROUNDING: CABLE LOCAL ...

C MAX.AMBIENT TEMPERATURE: 55°C

B WORKSHOP REVISION 06/14 KK RATED SHORT-TIME WITHSTAND CURRENT I CW: 20kA

A CABLE INFORMATIONS ADDED 03/14 RH MAX.ALTITUDE: 1000m

INDEX MODIFICATION DATE NAME

CLASS APPROVAL REMARK: CUSTOMER APPROVAL REMARK: