Boiler

Iriitruction manual for boiler plant, volume 1
: 2 x MISSION™ D4ypo model 55000

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AALBORG TABLE OF CONTENTS
INDUSTRIES
IMO 9312494
DSIC T3000-8 _ . . - ' .
Table of contents
System concept (vol. 1)

Technical data 1
Flow diagrams 2
MISSION™ D-type boiler/accessories (vol. 1)

Descriptions 3
Operation and maintenance 4
Feed and boiler water 5
Water level gauge 6
Safety valves 7
Feed water system 8
Three-point feed water control 9
Steam flow measuring 10
Regulating feed water valve 11
Feed water pumps 12
Chemical dosing pump 13
Salinity, type SL 700 14
Oil detection equipment 15
Steam dump equipment 16
Steam injection system 17
Soot blower 18
Drawings 19
Datasheets 20
KBSD burner/accessories (vol. 2)

Descriptions 1
Operation and maintenance 2
Oil flow regulation valve 3
Oil flow meter 4
Differential pressure transmitter 5
Regulating valves 6
Ignition burner pump 7
Combustion air fan 8
Fuel oil supply pumps ;.. 9
Language UK Page 1/2

INDUSTRIES
Heat-exchanger 10
Smoke density equipment 11
Oxygen analyzer 12
Drawings 13
Datasheets 14
Performance curves 15
Control system/electrical equipment (vol. 3)

MISSION control system 1
Operating principles 2
Operation of the panels 3
Commissioning and service 4
Burner sequence diagram 5
Flame safeguard 6
Menu structure for the panels 7
Modbus address list 8
PC monitoring and control system 9
Electric drawings for local panel 10
Electric drawings for power panel 11
Set point diagrams 12
Data sheets 13
Spare parts (vol. 3)

Spare parts for boiler 14
Spare parts for burner 15

INDUSTRIES
Table of contents
Technical data for boiler unit

General data..: : 1
Dimensions for boiler unit 2
Water/steam process data.... 3
Combustion process data , 1 4
Data for atomising steam , 5
Data for electric systems 6
Data for pressure part 7
Data for burner 8
Data for water level operation 9
Data for steam pressure operation 10
Manuals 11

AALBORG TECHNICAL DATA FOR BOILER UNIT 737695#01.0
INDUSTRIES
Technical data for boiler unit
1 General data
• ProjectNo.: 737695, 737697, 737699, 738154, 738156, 738158
• ProjectNo.: 738160, 739388, 738390
• Hull No.: T3000-8/9/10/11/12/13/14/16/17
• Classification society: LRS
• Pressure gauge calibration: Bar g
• Thermometer calibration: °C
• Language for signs: UK
2 Dimensions for boiler unit

• Height to top of local control panel incl. burner retraction: 10,156 mm
• Length and width excl. insulation: approx. 6,065 x 5,880 mm
• Weight of boiler unit excl. water: 63,000 kg
• Weight of boiler unit incl. water: 80,000 kg
3 Water/steam process data
• Steam output: 50,000 kg/h

• Working pressure: ...20.0 Bar g
• Max. allowable working pressure: 22.0 Bar g
• Working temperature: 214°C
• Feed water operation: modulating
• Feed water temperature, operation: 85-95°C
• Feed water temperature, layout: 60°C
4 Combustion process data

• Min. calorific value of diesel oil: 42,200 kJ/kg
• Min./max. viscosity of diesel oil: 3/12 cSt
• Density of diesel oil: 890 kg/m3

INDUSTRIES
• Min. calorific value of fuel oil: 40,200 kJ/kg

• Max. viscosity of fuel oil: 700 cSt at 50°C
• Density of fuel oil: 980 kg/m3
• Fuel oil temperature before pre-heater min: 50°C
• Fuel oil viscosity at burner inlet: 15cSt
• Fuel oil temperature at burner inlet: 140°C
• Ambient air temperature: 45°C
• Air excess No. at 100% load: 1.15
• Flue gas temperature (clean boiler): 351°C
• Air consumption at 100% load: 57,636 kg/h
• Flue gas flow (approx.): : 61,315 kg/h
• Pressure loss across elements: 63 mmWC
Data for atomising steam
• Atomising steam pressure at burner, max.: 6.0 Bar g

• Atomising steam consumption, max.: 191 kg/h
• Atomising air pressure at burner, max.: 7.0 Bar g
• Atomising air consumption, max.: 337 kg/h
Data for electric systems
• Power supply: 3 x 440V, 60Hz

• Control voltage: 1 x 230V, 60Hz
• Pilot voltage: 24V
• Insulation class: B or F
• Degree of protection: IP44
• Colour of boiler control panel: RAL7032
• Colour of boiler power panel: RAL 7032
Data for pressure part
• Boiler type: Large oil fired boiler

• Model: MISSION™ D-type
• Test pressure: 33.0 Bar g
• Protection of boiler body: trapezoid plate
• Colour of insulation plates: (blue) RAL 5002

INDUSTRIES
8 Data for burner
• Burner type: Steam atomising, modulating

• Model: KBSD4150
• Burner capacity on diesel oil, min./max.: 415/3521 kg/h
• Burner capacity on fuel oil, min./max.: 415/3679 kg/h
• Colour of burner Standard
Data for water level operation
• Too high water level alarm +200 mm

• High water level warning: +150 mm
• Normal water level: 0 mm
• Start stand-by feed water pump: bar g
• Low water level warning: -150 mm
• Too low water level alarm and burner off: -200 mm
• Too low water level alarm and burner off: -200 mm
10 Data for steam pressure operation
• Safety valve: 22.0 Bar g

• High steam pressure alarm and burner off: 21.5 Bar g
• High steam pressure warning: 21.0 Bar g
• Steam dump opening pressure: 7.0 Bar g
• Burner start/stop high pressure: 16.2/16.8 Bar g
• Burner operation: 16.0 Bar g
• Low steam pressure warning: 10.0 Bar g
11 Manuals
• Language for manuals: UK

• Set of working manuals: .' 10
• Set of instruction manuals: 6/ship
• Document revision date: 28 Apr. 05

INDUSTRIES
Table of contents
Flow diagrams
Steam/water system X01:029851h
List of parts for steam/water flow diagram X01:029851h
Oil system X02:029894c
List of parts for oil system „ X02:029894c
Burner unit 92X02:038042
List of parts for burner unit flow diagram 92X02:0038042

Heating coil arr. corrected 01.032001 BJJa PVN Data sheel No. for 3K6 changed
3K13 remote temp. Indicatoradded. 3U24 connected. 15,im)04 HeBJ I PVN C6 &C164 (MOD •> AQ-2). 1M12,2M12.12M12added,2K6 changed
Feed water
pumps
lii
Steam Oato
Water
Chemicals
NOTE: Cust6mer Dalian New Shipyard 2 x MiSSIWJ Wyfe Kdd 550OO+1 x AQ-2 2000 !f# ISk 14.01.2004
- Components specified by item no. are supplied by Al Oils
Air Society LRS LRS LRS LRS LRS LRS LRS LRS LRS Steam/water system KMo 14.01.2004
- Items: see separate list of parts. T3000-8 T3000-9 T3000-10 T3000-11 T3000-12 T3000-13 T3000-14 T3000-16 T3000-17
Blow down/drain lines Newb. No. Feed water regulation modulating / on-off seal*:
External wiring - For electrical connections, see actual electrical wiring diagrams. 1:1 A1
Project No. 737695-96 737697-98 737693-700 738154-55 738156-57 738158-59 738160-61 739388-89 739390-91
Oil - * Instrument air AALBORG Row diagram AitWeJDrawtngNM
Exhaust gas BoilefNo. 14187-88 14190-91 14193-94 14784-85 14787-88 14790-91 14793-94 16231-32 16234-35
INOUSDIES
Boiler No. 14189 14192 14195 14786 14789 14792 14795 16233 16236 XO1 :029851
I
AALBORG
INDUSTRIES
List of Parts for Oil Fired Boiler Type MISSION D-type Rev: g Class.:
"Steam/Water Flow Diagram", Drawing No.: X01:029851g Date: 03.05.2005 LRS
Item Qty Dim Description Applications Data Sheet
No DN or Drawing
1C l Vertical two-drum D-type boiler 50t/h- 05Y:029875
7/20-22 bar g
Cl 2 65/100 Safety valve Boiler 261 1174
C2 1 250 Stop valve with stellited seat & cone Main steam valve 6010 000085
C3 2 100 Stop valve with stellited seat & cone Feed water valve 6010 000092
C4 2 100 Stop-check valve Feed water valve 6030 000032
with stellited seat & cone
C5 1 40 Stop-check valve Scum valve 6030 000016
C6 1 40 Stop valve Scum valve 6010 000037
C7 1 50 Stop-check valve Blow-down valve 6030 000035
C8 1 50 Stop valve Blow-down valve 6010 000130
C9 1 1/2" Stop valve Sample valve 6220 000002
CIO 1 1/2" Stop valve Air valve 6220 000002
Cll 1 1/2" Stop valve Gauge board valve 6220 000002
C14 1 250 Check valve Main steam check valve 6020 000023
C15 1 25 Stop valve By-pass steam valve 250 1088
C16 2 50 Valve Furnace drain valve 253 1005
C17 1 25 Water level gauge, left Water level indicator 7010 000136
C18 1 25 Water level gauge, right Water level indicator 7010 000135
C23 1 Heating coil
*C24 1 25 Stop valve Heating coil inlet 250 1088
*C25 1 25 Stop valve Heating coil outlet 250 1088
C26 1 15 Safety valve for heating coil 261 1358
C27 2 25 Stop valve for item W16 250 1088
C30 1 Gauge board (mounted on burner) Boiler
C179 1 1300 Smoke uptake 05K37:032015
C123 1 80 Soot blower stop valve Steam flow 250 1093
C125 2 Soot blower Manual Clyde SR/V/D
C130 1 3/4" Drain valve for soot blower Instrument stop valve 6000 000012
C184 2 Expansion for safety valve 85Y:013427
C186 2 Remote pull for safety valve K03:019136
C187- 2 Remote pull for water level gauge K03:019137
V:\Marine\Order\737xxx\737695~700\0800 Documentation\0810 Flow diagrams - steam water\737695.doc737695.doc
y
'i/8 ' . > • • ' - • '• ••••' ':
AALBORG
INDUSTRIES
No DN or Drawing
1C 1 Vertical two-drum D-type boiler 50t/h- 05Y:029875
7/20-22 bar g
C195 1 15 Steam trap 7020 000001
C211 1 Counter flanges incl. gaskets and bolts K16:004096
C212 set (not shown on the flow diagram)
C213
C213
C227 1 80 Control ball valve with micro switch 6050 000152
and solenoid valve (IGS interlock)
L2 1 Boiler control panel
W14 1 25 Water level switch 8100 000008
W16 1 25 DP unit 70Z:019540
:
' • 2 / 8 • "• ••'. * '
AALBORG
INDUSTRIES
No DN or Drawing
2C 1 Vertical two-drum D-type boiler 50t/h- 05Y:029875 "
7/20-22 bar g
C2 1 250 Stop valve with stellited seat & cone Main steam valve 6010 000085
C3 2 100 Stop valve with stellited seat & cone Feed water valve 6010 000092
C4 2 100 Stop-check valve Feed water valve 6030 000032
L with stellited seat & cone
C7 1 50 Stop-check valve Blow-down valve 6030 000035
C8 1 50 Stop valve Blow-down valve 6010 000130
C9 1 1/2" Stop valve Sample valve 6220 000002
CIO 1 1/2" Stop valve Air valve 6220 000002
Cll 1 1/2" Stop valve Gauge board valve 6220 000002
C13 1 25 Stop-check valve Atomising steam valve 6030 000001
C14 1 250 Check valve Main steam check valve 6020 000023
C15 1 25 Stop valve By-pass steam valve 250 1088
C16 2 50 Valve Furnace drain valve 253 1005
C17 1 25 Water level gauge, left Water level indicator 7010 000136
C18 1 25 Water level gauge, right Water level indicator 7010 000135
C23 1 Heating coil
*C24 1 25 Stop valve Heating coil inlet 250 1088
*C25 1 25 Stop valve Heating coil outlet 250 1088
C30 1 Gauge board (mounted on burner) Boiler
C179 1 1300 Smoke uptake 05K37:032015
C123 1 80 Soot blower stop valve Steam flow 250 1093
C125 2 Soot blower Manual Clyde SR/V/D
C130 1 W Drain valve for soot blower Instrument stop valve 6000 000012
..
C184 1 Expansion for safely valve 85Y:013427
:: ;:
3/8 •- , , ' '
AALBORG
INDUSTRIES
No DN or Drawing
2C 1 Vertical two-drum D-type boiler 50t/h- 05Y:029875
7/20-22 bar g
C187 1 . Remote pull for water level gauge K03:019137
C195 1 15 Steam trap 7020 000001
C213
C213
C227 1 80 Control ball valve with micro switch 6050 000152
and solenoid valve (IGS interlock)
W14 1 25 Water level switch 8100 000008
W16 1 25 DP unit 70Z:019540
• 4 / 8 " - ' . ; . - ••• ••• •- <- ' •

AALBORG
INDUSTRIES
List of Parts for AQ-2 Rev: g Class.:

"Steam/Water Flow Diagram", Dwg. No.:X01:029851g Date: 03.05.2005 LRS
Item Qty Dim. Description Applications Data Sheet
No DN or Drawing
3C 1 Exhaust gas boiler- 2000 kg/h- B47:031560
Boiler mountings supplied loose 7 - 9 bar g
C2 1 100 Stop valve Main steam valve 6010 000092
C3 2 32 Stop valve with stellited seat & cone Feed water valve inlet 6010 000129
C4 2 32 Stop-check valve Feed water valve inlet 6030 000011
C7 2 32 Stop-check valve Blow down valve 6030 000011
C8 2 32 Stop valve Blow down valve 6010 000030
C9 1 W Instrument stop valve Sample valve 6220 000002
CIO 1 W Instrument stop valve Air escape for boiler 6220 000002
Cll 1 W Instrument stop valve Gauge board valve 6220 000002
C17 1 25 Water level gauge, left 7010 000111
C18 1 25 Water level gauge, right 7010 000110
C23 1 Heating coil
C24 1 25 Valve for heating coil inlet Stop valve 250 1088
C25 1 25 Valve for heating coil outlet Stop valve 250 1088
C30 1 Gauge board 61Z:031816
C162 1 U-tube differential press, indicator 649 9731
C184 1 Expansion for safety valve 85Y:013421
C187 1 Remote pull for water level gauge K03:019137
C218 1 100 Stop-check valve Main steam valve 6030 000032
C213
C213
W33 1 50 Feed water control Feed water control SD9230#21
:
5/8 - - ' -• -
AALBORG
INDUSTRIES
List of Parts for MISSION D-type & AQ-2 Rev: g Class.:

"Steam/Water Flow Diagram", Drawing No.: X01 .-029851 g Date: 03.05.2005 LRS
Item No Qty Dim Description Applications Data Sheet
DN or Drawing
12H3 1 Pressure transmitter Common line 663 8233 .
12H14 l Pressure transmitter valve Common line 254 1002
12M4 1 Feed water pumps A65/5C-05.1
12M7 1 Pressure gauge suction side 663 3122
12M8 l Pressure gauge pressure side 663 3118
12M9 l Pressure switch 6310303
12M10 2 Instrument stop valve 666 6006
12M12 1 Orifice K18:035884
12M130 1 Remote start/stop box 8000 000036
12N5 1 150 Steam dump control valve with pneumatic 6050 000329
actuator for IGS
12N5.1 1 150 Orifice
12N6 1 Filter regulator with automatic drain 291 5101
1H2 1 Remote steam pressure indicator 8000 000034
1K1 1 Oxygen analyzer 8210 000013
8310 000004
1K6 1 Temperature transmitter 8060 000026
1K24 1 Smoke density equipment SM-202 OM9420#01
1M4 1 Feed water pumps A65/5C-05.1 5541 00 271
1M8 1 Pressure gauge pressure side 663 3118
1M9 1 Pressure switch 631 0303
1M12 1 Orifice K18:035884
1M24 1 Chemical dosing unit 9296 000002
1M25 1 Sample cooler 875 0005
M82 1 80 Stop valve for steam injection 64Z:027656
M83 1 80 Strainer for steam injection 64Z:027656
M84 1 80 Steam injection control valve 64Z:027656
M85 1 Control system 121 with pocket for steam 64Z:027656
M86 1 80 Check valve for steam injection 64Z:027656
6/8 .
AALBORG
INDUSTRIES

DN or Drawing
M87 1 Vz" Vacuum breaker for steam injection 64Z:027656
M88 6 VA" Steam injector 64Z:027656
1W1 1 65 Feed water control valve 6050 000220
1W3 1 Filter regulator with automatic drain 2915101
1W32 1 Remote water level indicator 8000 000034
1W49 1 250 Pitot tube for steam flow measuring
1W50 1 Diff. pressure transmitter 8020 000001
1W51 1 Pressure transmitter 8010 000008
1W51.1 1 Instrument stop valve for W51 254 1002
2H2 1 Remote steam pressure indicator 8000 000034
2K1 1 Oxygen analyzer 8210 000013
8310 000004
2K24 1 Smoke density equipment SM-202 OM9420#01
2M4 1 Feed water pumps A65/5C-05.1
2M9 1 Pressure switch 6310303
2M12 1 Orifice K18:035884
2W1 1 65 Feed water control valve 6050 000220
2W3 1 Filter regulator with automatic drain 2915101
2W32 1 Remote water level indicator 8000 000034
2W49 1 250 Pitot tube for steam flow measuring
2W50 1 Diff. pressure transmitter 8020 000001
2W51.1 1 Instrument stop valve for W51 2541002
V:\Marine\Order\737xxxY737695~700\0800 Documentation\0810 Flow diagrams - steam Water\737695.d6c737695.doc
7/8 . • , , ; *
AALBORG
INDUSTRIES

DN or Drawing
*3H2 1 Remote steam pressure indicator 8000 000034
3K8 1 Temperature gauge + Exhaust gas inlet 8080 000017
connector 8500 000085
3K9 1 Temperature gauge + Exhaust gas outlet 8080 000017
connector 8500 000085
*3K13 2 Remote temp, indicator 8000 000034
3M4- 2 Feed water pumps CR5-16 5540 000073
. 3M10 4 Instrument stop valve 666 66006
3N5 1 65 Steam dump control valve with pneumatic 6050 000158
actuator
3N6 1 Filter regulator with automatic drain 2915101
*3W32 1 Remote water level indicator 8000 000034
C191 1 Water washing hose with nozzle 8500 000016
(not shown on the flow diagram
LI 1 Boiler power panel
L3 1 Remote control PC in engine room 9320 000009
Monitor (not shown on flow diagr.) 8500 000387
Trackball (not shown on the flow diagram) 8500 000129
Converter box (not shown on the flow diagr.) 8500 000130
Printer (not shown on the flow diagram) 8500 000655
Keyboard (not shown on the flow diagram) 8500 000539
LCD Monitor, flush mounted 8500 000387
Marine kit for PC 8500 000540
Marine kit for keyboard 8500 000541
M77 1 Water test equipment 880 0001
M145 1 Oil detection equipment 8210 000025
8310 000005
M146 1 Salinity alarm equipment 8210000032
8620 000082
V:\Marine\Order\737xxxV737695~700\0800 Documentation\0810 Flow diagrams - steam water\737695.doc737695.doc
8/8
G47 data sheet changed
Revised according to order
Instrument air
max. 10 bar
min. 5 bar
JL fl G114
Heavy fuel oil Heavy fuel oil

Diesel fun oil tank
settling tank service tank
Viscosity:
Viscosity: Viscosity:
(for pumping)
(for pumping) (for pumping)
max. 12cSt
max. 380 cSt max. 380 cSt
min. 4 cSt.
min. 45 cSt. min. 45 cSL
J I
Steam
max. 16 bar
min. 6 bar
Water
- All heavy fuel oil piping to be steam traced piping and insulated
Chemicals
- Components specified by Tag No. are supplied by Al.
Dalian New Shipyard Flow diagram, oil system
Air
For 2 x steam atomising burner size 4150
Blow down/drain lln - Components: see separate list of parts.
External wiring - Electrical wiring connections shown is our standard.
Oil For actual plant we refer to electrical wiring drawings. AALBORG
Exhaust gas Article/Drawing No:
INDUSTRIES
THtS DRAWING AND DESIGN SHOWN HERON IS THE PROPERTY OF AALBORG INDUSTRIES
AND MUST HOT 8E USED BY OR REPRODUCED FOR THIRD PAHTY X02:029894
Tag No./
Item PCS. Designation Dimension Article No.
1F 1 Burner unit, chosen by project
1F.1 1 Burner front plate incl. lance 4800000029
2F 1 Burner unit, chosen by project
2F.1 1 Burner front plate incl. lance 4800000029
G19 1 Filter for steam DN50 PN40 7040000046
G20 1 Temperature control valve DN50 PN25 6050000064
1G22 1 Fuel oil heater L=1400 8640000121
2G22 1 Fuel oil heater L=1400 8640000121
1G23 1 Safety valve 1/271/2" 87S0041
2G23 1 Safety valve 1/271/2" 87S0041
1G24 1 Heater drain valve oil side 1/2" 30 bar 87D3062
2G24 1 Heater drain valve oil side 1/2" 30 bar 87D3062
G28 1 Temp, transmitter PT100 G1/2"-m 0-160 Deg.C. 8060000007
1G40 1 Air vent valve for heater 1/2" PN100 87N6003
2G40 1 Air vent valve for heater 1/2" PN100 87N6003
G41 1 Temperature gauge 88T0003
G42 1 Temp, gauge HFO heated 0-200 Deg.C. 1/2"-m 88T0003
G47 1 Pressure gauge 0-40 bar 6633122
G48 1 Instrument stop valve 87D3050
G78 1 Pressure relief valve DO 3/8" 87D3059
G97 1 Ball stop valve - FO return DN32 87D3066
G99 1 Pressure transmitter FO press. 0-40 Bar G1/2"-m 6638234
G99.1 1 Gasket for G99, not shown 018/06.51=2 2911602
G100 1 Control valve - FO press. DN32 PN40 6050000165
G101 1 Stop valve - FO press, control DN32 87D3066
G102 1 Ball stop valve - FO by-pass DN32 87D3066
G105 1 Instrument stop valve 1/2" PN400 2541002
G111 1 Three way ball valve FO return DN32 6070000029
G114 1 Air filter/regulator for G111 0-10 bar 2915101
G115 1 Three way ball valve HFO/DO DN80 6070000042
1G145 1 Ignition oil pump 0-25 kg/cm2 6638141
2G145 1 Ignition oil pump 0-25 kg/cm2 6638141
G147 1 Fuel oil supply pump
G148 1 Fuel oil pressure control unit DN32 4800000023
G224 1 Remote start/stop box 8001002002
G279 1 Counter flanges (not shown)
G354 1 Check valve 6020 000028
L1 1 Boiler power panel
1R 1 Fan unit chosen by project
Title Drawn Date
• ISk 15.01.2004
• • #
Flow diagram, oil system Appr. Date
Mk For 2 x steam atomising burner size 4150

Weight Scale Size
AALBC)RG 1:1 A2
I N D U ST R I E S Article / Drawing No: Affix
Page 1 04/01-2006
This drawing and design shown herein is the property of Aalborg Industries
and must not bs used by or reproduced for third party
X02 :029894 c
Tag No./
Item Pcs. Designation Dimension Article No.
2R Fan unit chosen by project
Title Drawn Date

ISk 15.01.2004
Flow diagram, oil system Appr. Date
For 2 x steam atomising burner size 4150
Weight Scale Size
AALBORG 1:1 A2
INDUSTRIES
Article / Drawing No: Affix
Page 2 04/01-2006
and must not be used by or reproduced for third party
X02: 029894
Description Index Date Drawn Appr.
C331 & C431 new no. b 030207 KTN STh
P a r t list u p d a t e d c 02MAJ2005 UMD
Aux. atomising steam supply from

other steam system (dry steam)
for start-up.
NOTE:
- The Indicated tag numbers are AI supply
- Components: see separate list of parts
• For electrical connections, see actual electrical wiring diagrams
- All heavy fuel oil piping to be steam traced piping and Insulated
- Steam tracing to be temperature controlled
- For connections: [g]- see burner arrangement drawing 3
ll -1
Signatures:
M E E
to .£
It
Title: Date
Steam
Water
1 x KBSD Appr.
STh 21.05.2002
Date
Chemicals Standard JMN 21.05.2002
Air
Weight Scale: Size
Blow down/drain lines
Burner unit
1:1 A3R
External wiring
AALBORG Flow diagram Article/Drawing No: Index
Oil INDUSTRIES
THIS DRAWING AND DESIGN SHOWN HEREIN IS THE PROPERTY OF AALBORG INDUSTRIES
Exhaust gas
AND MUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY 92X02:038042
Tag No./
Item Pcs. Designation Dimension Article No.
C31 1 Instrument stop valve
C33 1 Pressure gauge
C35 1 Pressure switch max. steam
C48 1 Pressure transmitter
C50 1 Drain valve
F1 1 Steam atomising burner
F17 1 Stop valve, ball - oil ign burner
F18 1 Solenoid valve - oil ign burner
F19 1 Solenoid valve - oil ign burner
F31 1 Ignition burner
F33 2 Flame scanner auto/man
F36 1 Temp, switch - fire in windbox
F41 1 Stop valve, ball atom, steam
F42 1 Stop valve, ball - atom, steam
F43 1 Water separator atom, steam
F44 1 Shut off valve - purge steam
F45 1 Non return valve - purge steam
F50 1 Instrument stop valve
F51 1 Press, transm. atom, steam
F56 1 Solenoid valve, air for F57
F57 1 Pneumatic actuator for F42
F62.1 1 Manometer
F62.2 1 Filter regulator, for F148
F63.1 1 Filter regulate for valve actuator
F63.2 1 Manometer
F64 1 Stop valve, ball FO to burner
F65 1 Solenoid valve for F66
F67 1 Ball stop valve, FO to burner
F68 1 Pressure gauge FO nozz. pr.
F69 1 Instrument stop valve
F73 1 Stop valve
F74 1 Position switch, lance in position
Title Drawn Date
• •• STh 21.05.2002
1 x KBSD Appr. Date
iiiiiilii
AALBC)RG
Standard
Burner unit
Weight Scale
1:1
Size
A3R
INDUST R 1E S Article / Drawing No: Affix
Flow diagram
Page 1 04/01-2006
This drawing and design shown herein is the property of Aaiborg Industries
92X02 :038042
Tag No./
Item PCS. Designation Dimension Article No.
F75 1 Three way valve, FO return
F76 1 D.P. transmitter, airflow
F77 1 Non return valve
F78 1 Solenoid valve
F85 1 Micro switch on F67
F86 1 Micro switch on F75
F87 1 Stop valve, ball
3
F91 1 ressure control valve
F92 1 Stop valve, globe
F93 1 Stop valve, ball
F94 1 Control valve
F95 1 I/P converter
F96.1 1 Filter regulator
F96.2 1 Manometer
F97.1 1 Filter regulator
F97.2 1 Manometer
F99 1 Three-way valve
F100.1 1 Flow meter, oil
F100.2 1 Pick-up for flow meter
F106 1 Flame scanner - ign. burner
F135 1 Pressure gauge
F148 1 Actuator
F149 1 Position switch
F152 1 Throttle valve
F157 1 Temperature indicator
F166 1 Transformer for Ignition Burner
Title Drawn Date

STh 21.05.2002
•• • •
1 x KBSD Appr. Date
iii Standard
Burner unit
Weight Scale Size
AALBC)RG 1:1 A3R
INDUST Article / Drawing No: Affix
R 1E S Flow diagram
Page 2 04/01-2006
92X02:038042
INDUSTRIES
Table of contents
Descriptions
MISSION™ boiler 1
Boiler mountings 2
Water level control 3
Gauge board _
. 4

AALBORG MISSION™ D-TYPE BOILER 737695#02.0
INDUSTRIES
N..e: MISSION™ D-type Boiler

1 Description
The MISSION™ D-type is a vertical two-dram boiler, insulated and pre assembled
with boiler mountings for easy installation and operation.
The boiler is top-fired and equipped with a steam atomising burner. Like the burner,
the local control panel and all relevant boiler mountings are mounted on top of the
boiler. The boiler is easily operated and monitored from the burner platform. Most
of the cabling for instrumentation and drain is pre-wired prior to delivery.
The control system supplied with the MISSION™ D-type boiler unit provides fully
automatic operation of the boiler and the steam atomising burner.
1.1 Boiler Pressure Part

The principal drawing of the MISSION™ D-type boiler is shown in Figure 1. The
steam drum is furnished with branch connections and necessary internal fittings
ensuring an even distribution of feed water and circulation water from a possible
exhaust boiler. Furthermore, a steam separator is installed to ensure a sufficient
dryness of steam.
Manholes are conveniently arranged in both steam and water drams and, inside the
drams, enough space is available for inspection and maintenance.
The design of the water drum is similar to that of the steam dram. The drum size
gives optimal space for the heating coil and easy access for inspection.
The boiler foundation is provided with four supports, i.e. one fixed foot and three
foots which provide the possibility of thermal expansion. Counter plates are
provided for welding to deck.
Both the furnace and the generating tube bank are located asymmetrically and are
separated by the screen wall. Besides the screen wall, the furnace consists of gas-
tight membrane walls. The furnace roof, side and floor panel walls are formed from
one all-welded membrane wall forming a "D". The furnace front and rear panel
walls are welded into the top and bottom headers, which again are welded to the
drams.
The generating tube bank consists of vertical bare tube arranged in a staggered
configuration. The tubes are expanded into the dram shells. To avoid the risk of
vibration problems, supports are arranged in the middle of the bare tube section.
The flue gas passes through the deflected tubes at the bottom of the screen wall, up
through the generating tube bank and out through the smoke outlet box.
An effective circulation in the boiler is achieved, by means of down comers.
The bottom of the furnace is covered with a minimum of refractory.
Access to the furnace is possible through the access door at the bottom of the
furnace. Inspection of the generating tubes is possible through the access door
provided on the flue gas outlet box. Further inspection of the generating tubes is
possible through the inspection door placed in the middle of the bare tube element
section.
The boiler is provided with buck stay in order to avoid the risk of the membrane
walls bulging/bursting during operation.

• ••
• •*
AALBORG MISSION™ D-TYPE BOILER 737695#02.0

INDUSTRIES
Inspection of the burner flame is possible through the two inspection holes arranged
at two different levels on the furnace panel wall.
Principal drawing of MISSION™ D-type boiler
Access door.
Smoke outlet/
Steam drum
Burner
Manhole -
Inspection door J^ Inspection hole
I ^^^- Buckstay
Manual soot blower
Inspection hole
Access door
Supports
Furnace
Generating tube bank
Membrane walls
Screen vail
Down comer
Water drum
Heating coil
Figure 1 Miss D9.cdr

AALBORG BOILER MOUNTINGS SD9220#14.2
INDUSTRIES
Boiler mountings
1 Mountings
The following is a brief description of the most important items of the boiler
mountings. The components mentioned in this section are referring to the general
arrangement drawing of the boiler.
Safety valves
Two safety valves are fitted to the pressure vessel of the boiler. They are installed
for security reasons, and designed to prevent the boiler pressure from rising above
the design value.
The safety valves must be supplied with waste steam pipes and either expansion
devices, or bellows.
Main steam valve
The main steam valve is a shut off valve. When closed, it isolates the boiler from the
main steam line. A check valve is mounted after the main steam valve which
prevents steam from flowing backwards into the boiler.
The steam piping up to the main steam valve must be flexible in order to minimise
external loads on the main steam valve and associated branch. The flexibility can be
achieved with loops build into the main steam line to take up heat expansion from
the boiler and steam piping or with an expansion joint next to or close to the main
steam valve.
By-pass valve
The by-pass valve is a shut-off valve. The purpose of the valve is to equalise the
pressure between the boiler and the steam system when the main steam valve is
closed.
Atomising steam valve
The atomising steam valve is a shut-off/non-return valve. The shut-off function is
for security and the non-return function prevents steam/water from flowing into an
empty boiler by mistake.
Feed water valve / feed water valve (sdnr)
Two groups of feed water valves are provided in the boiler. Each group comprises a
shut-off valve and a non-return valve.
The shut-off valve in the ordinary group must be open when the boiler is in
operation, or if the boiler is used as a steam drum.
The shut-off valves should be closed when the boiler is not in use.
Water level gauges
Two local water level gauges are connected to the front of the boiler, each gauge
being provided with two shut-off valves and a drain valve.
The shut-off valves, fitted at the top and bottom of the sight glass, have a quick-
closing mechanism to be used in case of broken glass.
The pipes from the drain cocks on the water level gauge must lead to an open drain,
visible for inspection.

AALBORG BOILER MOUNTINGS SD9220#14.2
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Blow-down valve
Two blow-down valves of the shut-off/non-return type are mounted at the bottom of
the boiler body.
The shut-off function is for security and the non-return function prevents
steam/water from flowing into an empty boiler by mistake.
Air valve
The air/ventilation valve located on top of the boiler is a shut-off valve. It is
normally closed except when the boiler is being filled or completely drained. The
end of the drain pipe from the air valve must be visible in order to determine when
water or steam is coming out.
Gauge board valve(s)
The gauge board valve(s) are located on the top of the boiler and is of the shut-off
type. The valve(s) must always be opened during boiler operation.
Scum valve
Two scum valves of the shut-off/non-return type are mounted of the boiler body.
The shut-off function is for security and the non-return function prevents
steam/water from flowing into an empty boiler by mistake.
In the event of scum in the boiler, this scum can be blown off from the water surface
by opening this valve.
Valves for heating coil
The boiler is provided with two shut-off valves for inlet and outlet connection of the
heating coil. The valves should only be opened when the water drum is filled with
water.
Valves for soot blower
The boiler is provided with a shut-off valve and two ball valves for the soot blower
arrangement. Furthermore, a drain valve is fitted in the system.
Sample valve
A sample valve is installed enabling connection to a sample cooler for taking test
samples to perform boiler water analyses.
Inspection hole
Two small inspection holes are provided in the furnace wall to enable inspection of
the burner flame. A proportion of the air supply is bled off from the burner fan to
cool the window of the inspection hole, and prevent soot deposits.
Inspection door
The boiler is provided with an inspection door to enable inspection of the generating
tube bank.
Manhole
Two manholes placed at the boiler top and boiler bottom allow inside inspection of
the steam/water drum.
Access door
Access to the furnace is possible through the access door placed at the bottom of the
furnace.
Drain for furnace
The furnace bottom is provided with a socket for drain of the washing water.

AALBORG WATER LEVEL CONTROL SD9230#19.1
INDUSTRIES
Water level control

1 Description
The water level control is a modulating system at this type of boiler. The system is
illustrated in Figure 1. The safety device system for too low water level shut down
and burner cut out consists of a level float switch mounted as an external unit.
Control and measurement of the water level is achieved by means of a three point
regulation where water level, steam flow, and feed water flow are used as control
inputs, and combined with two PID regulators these provide level alarms/shut downs
and control of the regulating feed water valve.
Water level control system
Instrument air
Main steam line
Regulating feed water valve
i
Dp-transmitter for / £ 3^
flow measurementV T
Reference leg
Variable leg
Valve
manifold
dp-transmitter
Figure 1 dp_l_mod_flowl.cdr
The first control element is the dp water level transmitter unit, which includes
external reference and variable legs, and a dp-transmitter. The second control
element is the steam flow measuring equipment, which consists of a measuring
probe, pressure transmitter, and flow computer.

INDUSTRIES
Finally the third control element is the feed water flow, which is measured by means
of the boiler pressure transmitter and feed water pressure transmitter. The
differential pressure of the transmitters together with the opening signal of the
regulation valve is calculated into feed water flow.
When the boiler is stopped, in starting/stopping mode, or operating at low loads only
the dp water level transmitter unit is active. At higher loads and especially if large
load variation occurs all three control elements are active. Thus the feed water
regulation becomes more rapid in this condition.

AALBORG GAUGE BOARD SD9240#09.1
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Gauge board
1 Description
The function of the gauge board is to control the burner and to give alarm and shut
down for low and high steam pressure.
• A pressure gauge is fitted for analogous reading of the actual steam pressure in
the boiler. The pressure gauge is located on the local control panel.
• A pressure switch "high steam pressure" gives shut down and cut-off the burner
when the steam pressure rises above the pre-adjusted set point (one set point in
high pressure mode). Furthermore, the pressure switch locks the burner in stop
mode. Operation of the burner is only possible when the steam pressure falls
below the differential set point of the pressure switch and the shut down
function is reset.
• A pressure transmitter connected directly on the boiler converts the actual steam
pressure of the boiler into corresponding electric signals. The signals are used to
give alarms for low/high steam pressure and shut down/burner cut-off for high
steam pressure.
• A pressure transmitter is located in the main steam line. The transmitter is
common for both boilers and converts the actual steam pressure in the common
steam line into corresponding electric signals. The signals are used to give
alarms for low/high steam pressure and shut down/burner cut-off for high steam
pressure. Furthermore, the signals are used to control start/stop and modulation
set point of the burners both in low and high pressure mode. The signals from
the transmitter are also used to control the master/slave operation.

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Table of contents
Operation and maintenance
Start/stop of the boiler
General .1
Start-up , ..2
Boiler stop ..3
Boiler maintenance
Boiler maintenance ,1
Inspection of the boiler. ,2
Boiling out
Boiling out
Water washing
Description
Soot blowing
Description .1
Cleaning procedure. ,.2
Preservation
Preservation of boiler..
Boiler repair - plugging of tubes
Plugging of tubes
Boiler repair - refractory
Refractory repair
Maintenance of repair. \i
Language UK Pag
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Lighting-up curve
Lighting-up curve.
Language UK, Page 2/2./

AALBORG START/STOP OF THE BOILER OM9210#01.2
INDUSTRIES
Start/stop of the boiler
1 General
The following chapters of the instruction manual describe the operation and
maintenance of the pressure part. As this is only a part of the complete boiler plant,
it is important to study the remaining chapters in this manual very thoroughly. It is
especially important that the operator of the boiler plant becomes familiar with the
operation instructions of the burner and the control panel.
Important: To ensure a safe and reliable operation of the boiler plant, all
operation and/or maintenance of the boiler should be carried out
only by skilled personnel.
Start-up
When the boiler is started, the lighten-up rate of the boiler must not be accelerated
too much as this might cause an unnecessary overstrain of the boiler material by
quick and uneven temperature rises. It might be necessary to perform a number of
start/stop sequences to reduce the lighten-up rate.
Attention: At the commissioning start-up of the boiler and after any repair
work of the refractory, it is very important to further reduce the
lighting-up rate. This is because the new refractory still contains a
small amount of water. When heated the water vaporises and
expands which might cause fissures and cracks in the refractory.
The burner must therefore only be operated at minimum load and
in intervals of 1-2 minutes for the first hours. Between each
operation interval the burner should remain stopped for
approximately 8-10 minutes.
Before start-up of the boiler plant, some general work and check procedures must be
considered.
Step A: Check that the main steam valve, by-pass valve and circulation valves if
provided, scum valve, and blow-down valves are closed.
Step B: Open the feed water valves and the air valve. Fill the boiler with feed water
to approximately 50 mm below normal water level. The water level rises
due to expansion when the boiler is heated. If the temperature difference
between the boiler and feed water exceeds approximately 50°C, the boiler
must be filled very slowly.

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Note: When filling a pressure less boiler, the shut-off valve after the feed water
pump must be throttled. Otherwise the pump motor will be overloaded.
Step C: Check the water level in the water level gauges. Check frequently during
the complete start-up. The water level gauges should be blown down
several times to ensure a correct indication.
Step D: Check that the water level control system is connected and operational.
Step E: Check the oil system and start the fuel oil supply pump. Pre-heat the fuel oil
if the burner should operate on heavy fuel oil.
Step F: Check the burner and the safety functions according to the separate
instruction.
2.2 Start and pressure rise
The following work procedures must be followed during start-up of the boiler.
Step A: Check that the gauge board valve and pressure gauge valves are opened.
Step B: Check that the air valve is open if the boiler pressure is below 1.0 barg.
Step C: Start the burner on manual control and on low load. Check that the water
level does not rise too high during the pressure rising period.
Step D: Drain via the blow down valves if the water level is too high.
Step E: If the air valve was opened close it when only steam blows out. A pressure
reading should be indicated on the boiler pressure gauge before the air
valve is closed.
Step F: Tighten all covers such as manholes, hand holes, inspection doors, etc.
during the pressure rising period. If required, check all flange joints on the
plant.
Step G: Change to automatic control of the burner when the boiler pressure is 0.5
barg lower than the working pressure of the boiler.
Step H: Open the by-pass valve slowly to heat-up and pressurise the steam system.
If the boiler is not provided with a by-pass valve, the main steam valve
should be used to heat-up and pressurise the steam system.
Step I: Open the main steam valve and close the by-pass valve.
Step J: Open the valves to the steam consumers carefully in order to avoid water
chocks.
Step K: When the boiler is in normal operation, check that the water level control
system and the gauge board functions are fully operational.
Language UK . Page 2/4

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Note: After 3-4 weeks in operation, mud and deposits in the piping system may
have accumulated in the boiler water. This may cause level variations
which disturb the steam generation, and it is therefore recommended to
blow down the boiler. It should then be inspected, cleaned, and refilled
with boiler water.
Boiler stop
3.1 Normal boiler shut down

If necessary, the boiler can be shut down at any load without special preparations.
Note: When the boiler is stopped, sudden temperature and pressure drops
should be avoided as they might expose mountings, pipe lines, and the
boiler plant to inadmissible temperature gradients.
Step A: When minimum load is obtained, stop the burner.
Step B: Keep the water level at normal level until the boiler stops producing steam.
Step C: Stop the feed water pump and close the feed water valves.
Step D: Close the main steam valve.
3.2 Emergency shut down
The boiler must be taken out of service immediately if:

• parts of the heating surface have been glowing or the boiler shows recognisable
deformations. The supervising authorities must be informed, and the boiler must
not be used until approval from these authorities is available
• a substantial loss of water is noted
• the feed water system is unable to provide the necessary amount of feed water,
e.g. due to failure of parts
• the safety valve cannot function
• sudden cracks or damage are noted in the refractory, and if steam or moisture is
coming out of the refractory
• oil in the feed water is detected
• too high salinity level is detected
If an emergency shut down must be carried out, the fuel supply should be stopped.
The main steam valve should be closed gradually, and the boiler must be cooled.
The safety valves must not be operated. Parallel working boilers should be
disconnected at once.

AALBORC START/STOP OF THE BOILER OM9210#01.2
INDUSTRIES
3.3 Stop for repair or inspection
The following describes the measures to be taken when the boiler is shut down for
repair or inspection.
Step A: Clean the boiler from soot with water.
Step B: Operate the burner for at least 15 minutes after the soot removal to dry out
the remaining water.
Step C: Stop the boiler as mentioned previously.
Step D: Check the furnace and the pin tubes with regard to cleanliness.
Step E: Empty the boiler from water and clean it. Check if lime stone appears.
Step F: Check and clean the outer fittings. Change gaskets where required.
Step G: Clean the feed water tank and feed water pipes.
Step H: Clean and grease the bearings of motor, pump, and fan.
Step I: Check and align the burner, if necessary.
Step J: If the boiler is shut down for a long period of time, the pin tubes must be
thoroughly cleaned.
Step K: Check that the necessary spare parts are available. Order complementary
parts in time.
Warning: It is of extreme importance that the boiler is NOT operated without

water when the oil burner is in operation, e.g. due to disconnection
of the water level safety devices. This will immediately cause
complete break down of the boiler.

AALBORG BOILER MAINTENANCE OM9210#10.1
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Boiler maintenance
1 Boiler maintenance
The boiler maintenance should always be executed with skill and in accordance with
valid rules and regulations from the authorities, and below are given some
recommendations for periodical inspections and maintenance.
1.1 Daily operation
During normal operation of the boiler some work and check procedures have to be
considered every day.
Step A: Check the boiler steam pressure and the water level.
Step B: Check that the feed water control system is operational, see separate
instructions.
Step C: Check the boiler water condition and make necessary countermeasures with
regard to the feed and boiler water treatment. If necessary blow-down the
boiler.
Step D: Check the function of the oil burner at different capacities through the
inspection holes on the boiler.
Step E: Check the flue gas temperature after and/or the draft loss across the boiler.
If either the temperature or the draft loss is too high, the pin-tube section
must be cleaned.
1.2 Weekly routine checks
Step A: Drain each water level glass for about 10-15 seconds.
In case of contaminated boiler water or insufficient water treatment, the draining of
the water level glasses must be done more often.
Step B: Check the safety water level device.
Step C: Depending on the boiler water tests blown-down the boiler. Open the blow-
down valves quickly for a few seconds, and then close and open again for
about 5-10 seconds.
Repeat this operation when required according to the boiler water tests.
Step D: Perform scum blow out by means of the scum valve when required. The
scum blow out must be carried out until the drained water is clean.

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1.3 Monthly routine checks
Step A: Test all stand-by pumps.
Step B: Check all boiler mountings for damage or leaks and repair/replace if
necessary.
Step C: Check the function of the high steam pressure switch by lowering the set
point or by raising the steam pressure, e.g. by closing the main steam valve
slowly.
The burner must stop automatically.
Inspection of the boiler
2.1 Inspection of furnace

The furnace should be inspected at least twice a year. During this inspection the
following issues should be taken into consideration:
• Check for cracks at the refractory lining and that the furnace walls are free from
excessive soot deposits.
• Examine carefully the area opposite the burner. Too much soot deposits indicate
that the burner should be adjusted.
• Check that the pin-tube elements are intact and that soot deposits are within
normal limits.
2.2 Inspection of burner throat
In case of boilers with refractory in the burner opening the throat should be
inspected at least once a year. During this inspection the following issues should be
taken into consideration:
• Check for wear and cracks at the refractory area.
• Check for wear on ceramic felts, if fitted.
• Check for wear and cracks on burner stones, if fitted.
2.3 Inspection of boiler water side
The boiler water side (interior) must be carefully inspected at least twice a year. This
inspection of great importance and without a doubt the most important of all the
maintenance measures, since it has a direct influence on the boiler longevity and on
the security.
At these inspections, hard deposits, corrosion and circulation disturbances can be
found at an early stage, and preventive measures must be taken to avoid unexpected
material damage and boiler breakdown.
Presence of hard deposits at the furnace wall and the pin-tubes reduces their heat
transfer properties and decrease the capacity of the boiler.

INDUSTRIES
Further, it is possible to make out if the feed water treatment has been satisfactory
and if the blow-down has been carried out sufficiently.
Incorrect feed water treatment is commonly causing hard deposits or corrosion.
Insufficient blow-down will cause sludge deposits in the tubes and accumulation of
sludge in the bottom of the boiler.
If hard deposits are not removed, it may lead to overheating in the boiler plate
material which is exposed to the flame in the furnace wall area. This may cause
material damages.
Incorrect feed water treatment does not always lead to hard deposits. For example, a
too low or too high a pH-value may give an electrolytic reaction, causing corrosion
in the boiler.
When the boiler interior is inspected, examine all parts carefully and be attentive to
deposits, corrosion and cracks. It is advisable to pay special attention to this
inspection. If any unusual signs are found, contact Aalborg Industries at once for
advice.
2.4 Procedure and remarks for inspection
Step A: Shut off the boiler and allow it to cool (below 100°C).
Note: The boiler should NOT be depressurised by lifting the safety valves and
then filled with cold feed water since the stress induced by too rapid
cooling may cause damage.
Step B: Empty the boiler and close all valves.

If the boiler is connected to a second boiler, check that the valves between them are
closed.
Step C: Unscrew and remove the manhole hatch(s) on the boiler and enter the boiler
when it is sufficiently cold.
Check the welding in the boiler. A careful examination should be carried out with
respect to any possible corrosion or crack formation.
Special care should be taken to the water line area in the pressure vessel where
oxygen pitting may occur.
If deposits are found to be forming in the boiler tubes, the boiler should be
chemically cleaned.
It is advisable to consult a company of cleaning specialists who will examine the
boiler deposits and treat the boiler accordingly.
Note: After chemical treatment the boiler should be blown-down at least twice
a day for approximately one week. This will ensure that excessive sludge
deposits due to chemical treatment do not collect in the bottom of
pressure vessel.

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2.5 Contamination
If the boiler is contaminated with foreign substances like oil, chemicals, corrosion
products etc., it is very important to act immediately to avoid damages to the boiler.
Layers of thin oil films, mud, etc. exposed to the heating surfaces causes a bad heat
transfer in the boiler, leading to overheating followed by burned out pressure parts.
In order to remove such contamination, a boiling out or acid cleaning have to be
performed immediately.
Note: Corrosion products from the pipe system or insufficient boiler water
treatment may result in corrosion in the boiler itself. It is therefore
important to observe that such circumstances do not occur in the system.

AALBORG BOILING OUT OM9210#11.0
INDUSTRIES
Boiling out
1 Boiling out
Before putting the boiler into operation for the first time, it should be boiled out to
remove all protecting remedies and impurities on the boiler waterside.
The boiling out procedure is recommended to be carried out as described below:
Caution: Extreme care should be taken while handling the chemicals. The
person handling the chemicals/solution should be properly
dressed/protected.
Step A: Fill the boiler with a solution consisting of 4-5 kg trisodiumphosphate

Na3PC>4 per 1000 kg water. The chemicals can be added through the
manhole.
Step B: Add feed water until the solution is visible in the water gauges above
"lower water level".
Step C: Close the feed water valve (pump stopped).
Caution: Do never fill feed water into the boiler if the temperature difference
between boiler and feed water exceeds 50°C.
Step D: Raise steam pressure slowly to working pressure, and keep the pressure for
approx. 3-4 hours with closed main steam valve.
Step E: Scum until water level is between "Normal water level" and "High water
level".
By this procedure grease and other impurities are removed from the internal surfaces
of the boiler.
Step F: Start skimming by opening the scum valve, and lower the water level to
lower edge of "Normal water level" mark.
Step G: Close the scum valve.
Step H: Refill the boiler with feed water and start skimming again in intervals of 30
minutes for a period of two hours.
Step I: Stop the boiling out procedure by switching off the burner.
Step J: Let the boiler water rest for about five minutes.

AALBORG BOILING OUT OM9210#11.0
INDUSTRIES
Step K: Carry out a final skimming.
Step L: Blow off the boiler water by opening the blow down valves.
Step M: Remember to open the air escape valve, to avoid a vacuum in the boiler
when the boiler pressure decreases to approx. depressurised/atmospheric
pressure.
Step N: Open the manhole and let the boiler cool down to approx. 100°C.
Step O: The boiler is to be flushed with clean water on the boiler waterside, when
the temperature has decreased. The flushing removes remaining impurities.
Step P: Dismantle the bottom blow down valves, for cleaning and inspection
because deposits/foreign substances will usually be accumulated in these
valves and cause leaking if not cleaned.
Step Q: Inspect the boiler and remove any remaining deposits and foreign
substances.
Step R: Finally, new gaskets to be fitted in all hand- and manholes before refilling
the boiler with water to upper edge of "Low water level".
The boiler is now ready to be taken into service.
Note: During the first two weeks in operation we recommend to carry out
frequently skimming and bottom blow down to remove impurities
entering the boiler from the pipe system.

AALBORG WATER WASHING OM9210#29.1
INDUSTRIES
Water washing
1 Description
In order to keep the heat transfer area sufficiently clean the boiler is designed with a
high flue gas velocity through the generating tube bank. Therefore fouling will be
minimised, under normal circumstances, with a correct combustion. However, after
long term operation, e.g. during combustion of poor quality oil or with reduced
combustion quality, deposits can be formed on the heating surface.
The most effective way of soot cleaning is water washing, as most of the deposits
consist mainly of non-soluble particles held together by a water soluble bonding
material. Water washing will have the following benefits:
• Dissolves the bonding material.
• Washes the loosened insoluble deposits away.
Water washing of the generating tube bank
Water washing hoseN
Smoke outlet'
r^q< LJ_

AALBORG WATER WASHING OM9210#29.1
INDUSTRIES
The MISSION™ D-type boiler is easily cleaned from the smoke outlet box with a
water hose. Water washing must be carried out when the oil burner is stopped and
the boiler has been cooled down to a temperature below 100°C. The boiler should,
however, be warm enough for the water to evaporate so that the generating tube
bank and furnace will not remain moist after washing.
Both fresh and sea water can be used. If sea water is used, the boiler must be
thoroughly washed afterwards with fresh water in order to remove all salt deposits.
Where deposits are highly corrosive or bonded, a soaking spray with a 10% soda ash
solution is advisable before washing.
At the beginning of the water washing procedure the water supply should only be
slightly opened, until it is ensured that the drain and soot collecting system are
working properly.
Warning: When the generating tube bank is water washed, there is a risk of
generating steam. It is therefore very important that all of your body
is outside the smoke outlet box in order not to get your skin burned
by the steam.
When the water washing has begun, it must be completed until the generating tube
bank is thoroughly washed and all deposits are removed. This is because some types
of coatings hardens and accordingly get very difficult to loosen when they first have
been saturated and then dry out.
After the water washing procedure is completed the refractory at the furnace bottom
must be cleaned with alkaline water because the washing water is very corrosive. It
must be observed that all the washing water and loosened deposits are removed from
the boiler.
The boiler must be dried out immediately after the water washing has been
completed in order to avoid damage on refractory and heating surfaces. The boiler
must be lightened-up and pressurised as described in the chapter "Start/stop of the
boiler".
Important: The refractory in the furnace must be heated slowly up in order to

let the water absorbed by the refractory evaporate slowly.

AALBORG SOOT BLOWING OM9210#28.1
INDUSTRIES
Soot blowing
1 Description
Generally, there will be a self cleaning effect of the generating tube bank due to the
high flue gas velocity. However, deposits are formed on the heating surfaces, e.g.
due to combustion of poor quality oil or reduced combustion quality. These deposits
will accumulate on the heating surface of the generating tube bank if not removed by
cleaning.
The MISSION™ boiler is equipped with soot blowers for cleaning of the generating
tube bank. The soot blowers are manually operated and are arranged for direct
connection to the steam system of the ship. In order to obtain an efficient soot
cleaning, the steam pressure must be at normal working pressure. Furthermore, the
boiler load should not be lower than 50%. This ensures a sufficiently high velocity
of the flue gas, which is necessary to carry loosened soot deposits out of the boiler.
Figure 1 shows a soot blowing arrangement.
Because of the varying combustion parameters, it is impossible to specify exact time
intervals between soot blowing. In general soot blowing is recommended every 24
hours.
Note: Excessive soot blowing by means of steam might cause erosion damage
on the generating tube bank.
During operation of the boiler plant, the operating personnel should determine the
necessity with regard to time intervals for soot blowing. This interval should then be
increased or decreased to fit the specified plant.
Cleaning procedure
Step A: Check that the steam pressure is at normal working pressure.
Step B: Check that the main valve for soot blower and the two manually operated
ball valves are closed.
Step C: Open the drain valve to drain water from the main tube for a few seconds
and close it again.
Step D: Open the main valve.
Step E: Open the lower manually operated ball valve and soot blow for
approximately five seconds.
Step F: Close the lower manually operated ball valve again.

AALBORG SOOT BLOWING OM9210#28.1
INDUSTRIES
Step G: Open the upper manually operated ball valve and soot blow for
approximately five seconds.
Step H: Close the upper manually operated ball valve again.
Step I: Repeat step "D" to "G" 3-4 times.
Step J: Close the main valve.
Step K: Check that both ball valves are closed.
Illustration of a soot blowing arrangement
On special request
Main valve
Manual
valve
Steam trap
Drain valve
o o o o o o o o o o o o o o o o o o o o o o o o o
Figure 1 sootblowla.cdr

AALBORG PRESERVATION OM9210#13.1
INDUSTRIES
Preservation
1 Preservation of the boiler

If the boiler is to be shut down for a period of 1-30 days, it should be top filled to
prevent corrosion. Before top filling, it should be cleaned from soot deposits.
If the boiler is to be shut down for more than one month, different methods to
prevent corrosion can be applied:
• Dry preservation.
• Wet preservation.
• Nitrogen preservation.
• VCI preservation.
The work procedures related to each of these preservation methods are described in
the following:
1.1 Dry preservation

When this method is applied the boiler should be totally emptied off water and dried
out.
Step A: Empty the water/steam contents inside the boiler by means of the bottom
blow down at a boiler pressure of 3-5 barg. Open the boiler when it is
depressurised and drain off any remaining water.
Step B: Manhole doors and hand hole covers should be opened when the boiler is
still hot. If there is water left in the bottom of the boiler it must be removed,
e.g., by using a vacuum cleaner.
Step C: If the boiler is cold, drying of the boiler can be done by either circulating
dried air from a fan or by placing bags of silicagel inside the boiler.
Step D: Before the manhole doors and hand hole covers are closed, place a tray with
burning charcoal to remove oxygen. As soon as the tray with charcoal is in
position, close the manhole doors and hand hole covers using new gaskets.
Step E: Alternatively, a small steam phase inhibitor can be added to the boiler after
cooling and careful draining. Afterwards the boiler should be closed
completely.
1.2 Wet preservation

While dry preservation is a question of draining off water to avoid corrosion, the
principle of wet preservation is to prevent oxygen from entering the boiler.
This method can be used for a short period of iay-up' (1-3 months).

AALBORG PRESERVATION OM9210#13.1
INDUSTRIES
Step A: The boiler is filled with treated boiler water and hydrazine is added until an
excess of 100-200 ppm is obtained.
Step B: The water should be circulated continuously or at least once per week to
avoid corrosion from any penetration of oxygen, and it is necessary to
check the hydrazine concentration and add the necessary amount to have an
excess of 100-200 ppm. Other oxygen binding agents can also be used.
The pH-value should be 9.5-10.5.
Note: If there is any risk of the temperature falling back below 0°C, this
method should not be used to avoid frost damages.
As this preservation method involves applying hydrazine to the water inside the
boiler, the boiler must be completely drained and refilled with fresh water before
taken into service again.
1.3 Nitrogen preservation
The boiler should be drained, dried and sealed in the same way as mentioned in
section "1.1, Dry preservation".
Step A: Make a connection point to the bottom of the boiler and open the air escape
valve on top of the boiler.
Step B: Connect cylinders with nitrogen to the bottom connection point via a
reduction valve and purge the boiler until there is no oxygen left.
Step C: Close the air escape valve.
Step D: Leave a cylinder with nitrogen connected to the boiler via a reduction valve
and keep an overpressure of approximately 0.2 bar inside the boiler.
1.4 VCI preservation
An alternative to the above mentioned preservation methods may be the use of a so-
called volatile corrosion inhibitor (VCI).
The VCI is a water soluble chemical which partly evaporates and protects both the
water and steam spaces of the boiler. It should be able to eliminate the need for
complete drainage and/or application of nitrogen, and may in particular be
interesting when a forced circulation type exhaust gas boiler is installed in the steam
system. The boiler must be effectively sealed from the atmosphere to maintain the
corrosion protection.
The VCI is offered by various chemical companies and must be used in accordance
with their recommendations.

AALBORG BOILER REPAIR - PLUGGING OF TUBES 737692
INDUSTRIES
Boiler repair - plugging of tubes

1 Plugging of tubes
In case of a leakage on a boiler tube, the burner must be stopped and the pressure
lowered to atmospheric pressure.
If the leaking tube cannot be located immediately the boiler should be set on
pressure by means of the feed water pumps so that the leakage will indicate which
tube is damaged.
Step A: When the boiler is emptied of water remove the manhole covers in the
steam drum and the water drum.
Step B: When the damaged tube is located it must be plugged with a conical or an
external tube plug. Before the tube plug is mounted clean the inside of the
tube ends with a steel brush, so that no deposits are present in the tube.
Note: Plugging of tubes results in reduced efficient heating surface and

accordingly the boiler efficiency will decrease. Temporary repairs
require more attention than a normal working boiler.
Attention: The classification society should be notified about the repair work
and a schedule must be made for exchange of the damaged tubes.
Note: Only skilled personnel with knowledge and qualifications to perform

certified welding should perform repair work.
1.2 Plugging of furnace panel wall tubes

When a furnace tube has been plugged the furnace side of the damaged tube should
be cut vertically along the connections with the fins between the tubes in the panel
wall, see Figure 1.
Inside the rest of the tube and on the fins next to the damaged tube a number of
anchors of heat resistant or stainless steel must be welded on.
Afterwards erection of refractory against the damaged tube and the neighbouring
fins must be carried out in the full height inside the furnace.

INDUSTRIES
Plugging of furnace panel wall tubes
Header
Furnace
Header
As shown in Figure 1 approximately 110 - 120 mm of the tube is left for inserting
the external plug.
It is possible to replace the furnace panel wall tubes from the outside of the boiler.
After location of the damaged tube or tubes, those must be replaced according to the
following procedure:
Step A: Adequate amount of insulation around the damaged panel wall tubes should
be removed.
Step B: The damage tubes must be cut right below and above the headers or drums.
Step C: Afterwards the tubes are removed by cutting out in the fins.
Step D: Scraps of metal or welding in the tube holes and the header/drum must be
grind off.
Step E: The new furnace panel wall tubes must be welded on or expanded into the
header/drum and afterwards gas tight welded.

INDUSTRIES
1.3 Plugging of generating tubes
Plugging of the generating tubes are shown in Figure 2.

From an operational point of view up to 10% of all generation tubes can be plugged
with a conical plug but if more tubes are damaged, an exchange of tubes are
necessary.
When the generating tubes are replaced an opening in the surrounding side panel
wall must be cut according to the same procedure as described in section 1.2.
The new generating tubes are build-up one by one by the expansion as shown in
Figure 2.
The tubes are inserted in the drum shell and afterwards welded as well as expanded
lightly. During assembling the generating tube supports are arranged and adjusted.
Finally the opening in the panel wall must be rebuild as described in section 1.2.
Plugging and replacement of the generating tubes
Steam Drum
Plugging of tube
Water Drum
Figure 2 Miss D5b.cdr

AALBORG BOILER REPAIR - REFRACTORY OM9210#25.0
INDUSTRIES
Boiler repair - refractory

Refractory repair
The furnace floor is lined with an insulating material (Verilite R6), close to the
casing covered with a layer of castable refractory (Plicast 31).
The refractory is made with expansion joints, which should under no circumstances
be blocked or filled on purpose.
Even though the refractory is made with expansion joints, it will tend to make
additional natural expansion joints, which will be seen as fissures. However, the
fissures will generally close when the boiler is put into service. Please note the
following guidelines when examining the fissures:
• white/light fissures, which are getting darker over the time and are closing when
the boiler is in service and opening in cold condition, need no further attention.
• dark/black fissures suddenly occurred, seen in cold condition and are not closing
when boiler is in service need to be repaired/filled up with refractory (Plicast
31).
All refractory subjected to wear will, eventually, need to be repaired. This can be
done as a temporary repair or on a permanent basis.
1.1 Temporary repair

Smaller areas can be temporarily repaired making use of the repair mix Plistix 14,
supplied separately with the boiler equipment.
The durability of such a repair depends on the location, but the more exposed to
heat, the shorter lifetime. Generally, it is recommended to replace a temporary repair
with a repair on a permanent basis within one year.
Temporary repairs in vertical places ought to be made "swallow tailed", see Figure
1, if possible. This secures a better attachment to the existing refractory.
Sketch indicating a "swallow tail" repair
Refractory Swallowtail
(filled in with Plistix 14)
Figure 1 swaltail.cdr

INDUSTRIES
The surface to which the temporary repair is performed, must always be clean, dry
and rugged.
Mixing instructions for the castable refractory appears from the instruction on the
plastic bucket.
Note: Plistix 14 must be applied to the site immediately when mixed.
The boiler can be lightened-up approx. 1 hour after the refractory has been applied.
The refractory needs no further time for hardening.
If the boiler is pressurized, the lighting-up should be started with the burner in "on"
position for one (1) minute and then in "off' for two (2) minutes, during the first
half Q/z) hour. Then it can be started up according to the ordinary lighting-up
procedure.
Note: Observe the safety rules regarding the refractory which can be seen on
the plastic bucket.
1.2 Permanent repair
Major repairs and renewal of temporary repairs shall always be carried out and
supervised by maker's specialists, among other things securing that correct drying-
out time and lighting-up is observed.
1.3 Boilers with membrane furnace wall

The refractory applied to a damaged membrane furnace wall must be carried out as
shown in Figure 2.
Refractory applied to a membrane furnace wall
Furnace tube.
Failed tube
Plicast 31
Figure 2 plugrefrac.cdr

INDUSTRIES
Warning: Failed Y-anchors must only be replaced by Y-anchors made from

heat resistant steel. Y-anchors made from incorrect materials will
cause damage to the refractory.
Maintenance of refractory
Note: The refractory should be inspected once a year for shape and wear. It is
recommended to carry out an inspection in due time prior to long repair
periods such as dry docking, etc. Should a repair be required castable
refractors and bricklayers can then be ordered on short notice.
If the refractory has been exposed to water, the refractory should be dried out as
soon as possible. The drying out can be done by hot air (approx. 50°C) or by
operating the oil burner.
Warning: However, if the burner is being used, the burner should be operated
with great care.
Warning: Generated steam evaporated from water absorbed into the

refractory might cause fissures and cracks when expanding, if the
heat input from the oil burner is too heavy.
2.1 Typical refractory data
Below in Table 1 is a list of typical refractory data shown.
Verilite R6 Plicast 31 Plistix 14

A12O3 32% 44% 48%
SiO 2 24% 46% 43%
Fe 2 O 2 12% 1% 1%
TiO2 1.6% 1% 1.9%
CaO 23.3% 6.5% 4.8%
MgO 6.1% 0.5% 0.2%
Alkanes 1% 1%
Na2O 0.1%
K2O 0.2%
Operating range 100-1000°C 20-1450°C 100-1420°C
Table 1

• •• •• •• •
1 • • •
AALBORG LIGHTING-UP CURVE OM9210#32.1

INDUSTRIES
Lighting-up curve
1 Lighting-up curve for MISSION™ D-type
Figure 1 shows the lighting-up curve for the MISSION™ D-type boiler. When the
burner is started the firing capacity must be adjusted to match the lighting-up curve.
Further start/stop instructions are described in the chapter "Start/stop of the boiler".
Lighting-up curve for the MISSION™ D-type boiler
Boiler pressure (barg) t: Boiler temperature at start Temperature f C)

225
-
20-
150 100 50 30 15 0
18- / / / / / / -
16- -
/ / / / ,' /
200
14
/ / /
12-
10-
/ —
//
/ / / /
/
175
7- / /
6 I / / / -
5-
4y
/ -
4- ' /
150
3-
-
2- / /
A
125
1-
/ / /
-
100
/ / / /
-
75
-
/
50
A -
25
0 15 30 45 60 75 90 105 120 135 150

Time (min.)
Figure 1 startcur2.cdr

INDUSTRIES
Table of contents
Feed and boiler water

General 1
Layout of the treatment system 2
Feed and boiler water characteristics 3
Feed and boiler water maintenance 4
Treatment systems / injection points 5

AALBORG FEED AND BOILER WATER OM9210#99.2
INDUSTRIES
Feed and boiler water

1 General
Note: The recommended feed and boiler water characteristics are only valid
for boilers with a working pressure below 20 barg.
There is a number of ways to produce good quality feed water for boiler plants.
Methods such as e.g. reverse osmosis plants or ion exchange plants produce good
quality distillate. Also evaporators generally produce good distillate. The important
thing is that the distillate used should be clean and without foreign salt
contamination.
In practice most distillates used contain minor parts of various salt combinations
which can and must be chemically treated away. Furthermore, the distillate may
contain dissolved gases like for example oxygen (O2) and carbon dioxide (CO2)
which may lead to corrosion in the boiler, steam, and condensate system.
Important: Boiler and feed water must be chemically treated in order to avoid
corrosion and scaling in the boiler.
Layout of the treatment system

The condition of the feed and boiler water is an essential part of the boiler operation
and operation philosophy. The design and construction of the treatment system
should therefore be considered carefully during layout of the plant. Aalborg
Industries gives some general requirements and recommendations regarding the
conditions of the feed and boiler water. However, there is several ways to obtain this
results, or similar, by using different treatment systems. The following should
therefore be considered already at the layout stage:
— Choose the treatment system that should be used.
— Present the condensate and feed water system to the supplier of the treatment
system and inform about the operation philosophy of the plant.
— Let the supplier indicate where the injection points should be located and also
inform if special equipment is required.
— Let the supplier inform about which test facilities is needed.
— Purchase the recommended equipment and install it in the correct way.
— Use the treatment system as soon as the boiler is taken into operation.

INDUSTRIES
Feed and boiler water characteristics

The following text regarding feed and boiler water treatment is the normal
recommendations given by Aalborg Industries. These recommendations should be
followed strictly in order to have the best working conditions for the boiler plant and
to extend the working life of the plant. The requirements/recommendations of the
various values for feed and boiler water are listed in Table 1 below.
Unit Feed water Boiler water

Appearance Clear and free of mud Clear and free of mud
Hardness ppm CaCO3 0-5
Chloride content ppm Cl' <100
"P" alkalinity ppm CaCO3 100-150
Total (T) alkalinity ppm CaCO3 <2 x "P" - Alkalinity
PH-valueat25°C 8.5 - 9.5 10.5-11.5
Hydrazine excess ppm N2H4 0.1-0.2
Phosphate excess ppm PO4 20-50
Specific density at 20°C Kg/W <1.003
Conductivity at 25°C US/cm <2000
Oil content NIL NIL
Table 1
If hydrazine (N2H4) is not used, sodium sulphate (Na2SO3) can be used instead, and
the excess should be 30 - 60 ppm.
In cases where other kinds of oxygen binding agents are used, it is recommended
that an excess of oxygen binding agents can be measured and indicates that no
oxygen has been dissolved in the boiler water.
If it is requested to measure the content of dissolved oxygen directly, it is
recommended to keep the value < 0.02 ppm.
In addition to the above values, the various water treatment companies will add
further demands, depending on the method used for treatment of feed and boiler
water.
However, the most important point is that the above values or their equivalents are
observed and that a regular (daily) test of feed and boiler water is carried out.
3.1 Units of measurement
Concentrations are usually expressed in "ppm" i.e. parts solute per million.
Concentrations for parts solution by weight are the same as "mg/litre".
3.1.1 Specific gravity
As guidance the following conversion can be used:
• 1 Be° = 10.000 mg/1 total dissolved solids (TDS)
• 1 mg/1 total dissolved solids = 2 |j.S/cm
• 1 jxS/cm = 1

INDUSTRIES
Feed and boiler water maintenance

The following are recommended water maintenance instructions. More exact details
concerning analyses and blow downs should be set up together with the supplier of
chemicals for water treatment.
4.1.1 Daily
Step A: Analyses of feed and boiler water.
4.1.2 Weekly
Step A: Skimming (surface blow down) according to analyses, but at least once per
week (2 minutes with fully open valve).
Step B: Blow down (bottom blow down) according to analyses, but at least once per
week (each blow down valve 1 minute in low load condition).
4.1.3 Monthly
Step A: Check the functions for salinity and oil detection systems.
4.1.4 Every six months
Step A: The boiler water side (interior) must be carefully inspected at least twice a
year.
4.1.5 Yearly
Step A: Check of the water side of the boiler and hotwell/deaerator for corrosion
and scaling.
Step B: Check the chemical pump unit.

INDUSTRIES
Treatment systems / injection points

In the following tables and illustrations a number of different feed and boiler water
treatment systems are shown together with the recommended location for the
injection point of the individual chemicals as stated by the manufacturer. The
general information regarding the injection point principle can be used as guidelines
for the most common systems. But should there be any doubt for a specific system
the manufacturer/supplier should be consulted in order to obtain the correct result.
Notes for tables/illustrations:
• Note No. 1: the preferred injection point of chemicals stated by the
manufacturer/supplier.
• Note No. 2: the alternate injection point of chemicals stated by the
manufacturer/supplier.
• Note No. 3: Valid for modulating feed water systems.
• Note No. 4: valid for on/off operating feed water systems. The chemical pump
starts/stops together with the feed water pump.
• Note No. 5: valid for two boiler installation. Control of the chemicals in
question work properly at an equal load condition (feed water flow) on the two
boilers.
How to use the tables:
The tables can be used in different ways but the main idea is to do following:
Step A: Discover which manufacturer and type of chemicals that should be used for
the actual boiler plant.
Step B: Use the name of the manufacturer and type of chemicals to select which
tables that can be used.
Step C: Check the flow diagrams (Figure 1, Figure 2, or Figure 3) to find a diagram
that matches the actual boiler plant.
Step D: Find in the selected tables the table which includes the matching diagram.
Step E: If more than one table is found to match the actual boiler plant in question it
is recommended to use the method/table which includes note No. 1.
Step F: If no table is found to match the actual boiler plant in question it is

recommended to seek assistance by the chemical manufacturer/supplier.

• • •••
.jjjjjjj, FEED AND BOILER WATER

AALBORG OM9210#99.2
INDUSTRIES
Table No. 1
Manufacturer / supplier: Ashland Chemical / Drew Marine Division
Product name / method: Standard with Drewplex OX

Chemical name Injection point No. Continuous Batch Note No. Valid flow diagram No.
Adjunct B 3,3a, 3b X 1
GC 3, 3a, 3b X
1,2,3
SLCC-A 3,3a, 3b X
Drewplex OX 2,2a, 2b X 1,3,4
Manufacturer / supplier: Ashland Chemical / Drew Marine Division I Table No. 2
Product name / method: Standard with Amerzine

Adjunct B 3, 3a, 3b X 1
GC 3,3a, 3b X 1
1,2,3
SLCC-A 3, 3a, 3b X 1
Amerzine 2,2a, 2b X 1,3,4

Adjunct B 3 X
GC 3 X
1
SLCC-A 3 X
Amerzine 1 X 2,3,4

Adjunct B 3a, 3b X
GC 3a, 3b X
2,3
SLCC-A 3a, 3b X
Amerzine 1 X 2, 3, 4, 5
Product name / method: Drewplex AT / OX

Drewplex AT 3, 3a, 3b X 1
Drewplex OX 2, 2a, 2b X 1,3,4
1,2,3

INDUSTRIES
iiliiiilliiw^^
Table No. 6
Product name / method: Drewplex AT / OX

Drewplex AT 2,2a, 2b X 2,3,4
Drewplex OX 2,2a, 2b X 3,4
1,2,3
I Table No. 7
Product name / method: Drewplex AT with Amerzine

Drewplex AT 3, 3a. 3b X 1,3,4
Amerzine 2,2a, 2b X 1,3,4
1,2,3
I Table No. 8

Drewplex AT 2, 2a, 2b X 2,3,4
Amerzine 2, 2a, 2b X 3,4
1,2,3

Drewplex AT 2,2a, 2b X 2,3,4
Amerzine 1 X 2, 3,4, 5
1,2,3
Product name / method: AGK-100 with Amerzine

AGK-100 2, 2a, 2b X 1,3,4
Amerzine 2, 2a, 2b X 1,3,4
1,2,3

INDUSTRIES
iiji|^j:;;;i||i!;|5:.B!i;:;j||i;|Ji
litiiiiiiittiii
Table No. 11

AGK-100 2,2a, 2b X 3,4
Amerzine 1 2,3,4,5 1,2,3
I Table No. 12

AGK-100 1 X 2, 3, 4, 5
Amerzine 1 X 2, 3,4, 5
1,2,3
Marichem I Table No. 13

Manufacturer / supplier:
Product name / method: Standard

Alkalinity control 3, 3a, 3b X 1,3,4
Phosphate 3, 3a, 3b X 1,3,4
1,2,3
Oxycontrol 2, 2a, 2b X 1,3,4
Marichem CCI 2,2a, 2b X 1,3,4

Product name / method: Standard

Alkalinity control 1 X 2,3,4
Phosphate 1 X 2,3,4
1
Oxycontrol 2 X 3,4
Marichem CCI 2 X 3,4

Product name / method: BWT new formula

B.W.T. new formula 2,2a, 2b X 1,3,4
1,2,3

INDUSTRIES
BpBiSp
I Table No. 16
Manufacturer / supplier: Marichem
Product name / method: BWT new formula

B.W.T. new formula 1 2, 3,4, 5
Marichem CCI 2, 2a, 2b 3,4
1,2,3
I Table No. 17
Product name / method: BWT

B.W.T. powder 2,2a, 2b X 1,3,4
1,2,3
I Table No. 18
Product name / method: BWT

B.W.T. powder 1 X 2,3,4,5
Marichem CCI 2, 2a, 2b X 3,4
1,2,3
I Table No. 19
Manufacturer / supplier: Unitor Chemicals
Product name / method: I

Chemical name ' Injection point No. Continuous Batch Note No. Valid flow diagram No.
Hardness control 3, 3a, 3b X 1
Alkalinity control 3, 3a, 3b X 1
1,2,3
Oxygen control 2, 2a, 2b X 1,3,4
Condensate control 2,2a, 2b X 1,3,4
Manufacturer / supplier: | Table No. 20

Unitor Chemicals

Hardness control 1 X 2
Alkalinity control 1 X 2
1
Oxygen control 2 X 3,4
Condensate control 2 X 3,4

INDUSTRIES
ifflHMW
Table No. 21
Manufacturer / supplier: Unitor Chemicals
Product name / method: II

Hardness control 3, 3a, 3b X 1
Alkalinity control 3, 3a, 3b X 1 1,2,3
Cat sulphite L (CSL) 2,2a, 2b X 1,3,4
Condensate control 2, 2a, 2b X 1,3,4
Manufacturer / supplier: Unitor Chemicals I Table No. 22

Alkalinity control 1 X 2 1
Cat sulphite L (CSL) 2 X 3,4
Product name / method: Liquitreat

Liquitreat 3, 3a, 3b X 1
1,2,3
(Oxygen control) 2, 2a, 2b X 1,3,4
Product name / method: Liquitreat

Liquitreat 1 X 2
Condensate control 2, 2a, 2b X 3,4 1
(Oxygen control) 2,2a, 2b X 3,4
Product name / method: Combitreat

Combitreat 3, 3a, 3b X 1
Condensate control 2,2a, 2b X 1,3,4 1,2,3
Oxygen control 2,2a, 2b X 1,3,4

INDUSTRIES
iliiiiiiiiiiii
Manufacturer / supplier: Unitor Chemicals Table No. 26
Product name / method: Combitreat

Combitreat 1 X
Condensate control X 3,4
Oxygen control X 3,4
Manufacturer / supplier: Uniservice Group I Table No. 27

Hardness control 3,3a, 3b X 1
Alkalinity control 3,3a, 3b X 1 1,2,3
Hydrazine 2, 2a, 2b X 1,3,4

Hydrazine 2 X 3,4

Hardness control 3,3a, 3b X 1
Alkalinity control 3,3a, 3b X 1
1,2,3
Oxygen control 2, 2a, 2b X 1,3,4

Oxygen control 2 X 3,4

INDUSTRIES
mmmmmmmmum
loints
Uniservice Group Table No. 31
Product name / method: One Shot

BWT One Shot 3,3a, 3b X 1
Alkalinity control 3, 3a, 3b X 1,3,4 1,2,3
(Hydrazine) 2, 2a, 2b X 1,3,4
Product name / method: One Shot

BWT One Shot 1 X 2
Alkalinity control 2,2a, 2b X 3,4 1
(Hydrazine) 2, 2a, 2b X 3,4
Product name / method: Organic Treatment

OBWT3 3,3a, 3b X 1
0BWT4 2,2a, 2b X 1,3,4 1,2,3

INDUSTRIES
Flow diagram No.: 1
Single boiler operation with or without

forced circulation exhaust gas boiler
Figure 1 flowdiag_l.cdr

INDUSTRIES
Flow diagram No.: 2
Condensate
Double boiler operation with separate feed water pumps

with or without forced circulation exhaust gas boiler
Figure 2 flowdiag_2.cdr

INDUSTRIES
Flow diagram No.: 3
Double boiler operation with common feed water pumps

with or without forced circulation exhaust gas boiler
Figure 3 flowdiag_3.cdr

INDUSTRIES
Table of contents
Water level gauge

Maintenance and service instructions.

AALBORG WATER LEVEL GAUGE OM7010#01.1
INDUSTRIES
Water level gauge

1 Maintenance and service instructions
This section describes the maintenance and service instructions for the water level
gauge.
Illustration of the water level gauge
1-Nut
2 - Box heads
3 - Joint rings
4 - Box heads
5 - Tubes
6 - Screws
7 - Screws
8 - Cock plug
D - Drain cocks
G - Gauge body
S - Cocks
W-Cocks
Figure 1 kli Ole.cdr
1.1 Maintenance
The item nos. mentioned in the following maintenance instructions refer to Figure 1.
When out of service with the gauge body in cool and depressurised condition the
hexagon screws (6) can be re-tightened.

•* •
•• •• •• •• ••

INDUSTRIES
Step A: Start at the centre, working to opposite sides alternately. Max torque: 26
Nm in cold and under working conditions.
1.1.2 Maintenance during service check-up
Step A: Tighten the nuts (1).
Step B: Bolts on boiler flanges.
Step C: Union nuts (4).
Step D: Bolt form screws (7) with cocks in open positions.

If a leak cannot be stopped by tightening the bottom screws (7), the sealing surface
of the cock plug (8) may be damaged or corroded. It can also be necessary to change
the packing (3).
1.2 Blowing down
The item nos. mentioned in this following blowing down procedures refer to Figure
1.
Step A: The gauge should be blown down before lighting up the boiler and just
before closing down the boiler.
1.2.2 Cleaning the water side:
Step A: Shut the cock S and open the cock W.
Step B: Open the drain cock D for a short time. This sucks the water out of the glass
without, however, totally depressurising the gauge body.
Step C: Shut the cock D and then water is forced upwards into the glass again.
Step D: Repeat this procedure several times, opening and shutting the cock D. The
water level in glass rises and falls.
1.2.3 Cleaning the steam side:
Step A: Shut the cock W.
Step B: Open the cock S.
Step C: Blow through the steam side and gauge body by opening the drain cock D
for 1-2 seconds.
Step D: A steam blowing of longer duration is not advisable considering the service
life of glass.
Step E: Turn the cocks to operating position.

INDUSTRIES
1.3 Dismantling
The following dismantling instructions refer to Figure 1 and Figure 2.
Sectional view of the water level gauge
6 - Screws
9 - Wedge piece
10-Centre piece
11 - Reflex
12 - Sealing gasket
13-Cushion gasket
14 - Cover plate
©
Figure 2 kli 05e.cdr
Step A: Shut the cocks S and W.
Step B: The drain cock D to be opened until the glass is completely emptied.
Step C: Remove nuts (1) and lift off stuffing box heads (2) together with the gauge
body from the cocks S and W.
Step D: Slacken the union nuts (4) and pull off the stuffing box head (2).
Step E: Place the gauge body (G) horizontally with the screws (6) turning upwards
and loosen the screws.
Step F: Move the wedge piece (9) length wise and lift upwards.
Step G: Lift off centre piece (10) reflex glass (11) and gaskets (12 and 13).
Step H: Clean sealing surface of cover plate (14) and centre piece (10) and examine
for through going scars.
1.4 Assembling
The following assembling instructions refer to Figure 2.
Step A: Insert following items into the centre piece (10): sealing gasket (12) reflex
glass (11) cushion gasket (13).

• • • ••
4• • • •
aiiiiiu
AALBORG
WATER LEVEL GAUGE OM7010#01.1
INDUSTRIES
Step B: Place cover plate (14) on top.
Step C: Insert wedge piece (9) and move length wise for correct position.
Step D: Tighten screws (6) evenly starting at the centre, working to opposite
alternately. Max torque: 26 Nm in cold and under working conditions.
1.5 Maintenance of the straight-through cock
1.5.1 Operation principle and maintenance

The following assembling instructions refer to Figure 3.
Detail drawing of the straight-through cock
15-Screw
16-Split ring
17-Packing sleeve
18-Plug
19-Bottom screw
Figure 3 kli 06e.cdr
The cylindrical plug (18) is sealed with a resilient packing sleeve (17).
Should leakage arise during service the packing sleeve must be further compressed
by tightening the bottom screw (19) until the leakage is stopped. This must only be
done with the cock in open position.
1.5.2 Dismantling
Step A: Remove bottom screw (19).
Step B: Remove screw (15), washer and handle.
Step C: Knock the plug (18) together with split ring (16) and packing sleeve (3) out
of the cock body by means of a soft mandrel.
Step D: Remove split ring and knock plug out of the packing sleeve.
Step E: Clean all sealing surfaces carefully and lubricate threads with a high
temperature grease before installation.

INDUSTRIES
1.5.3 Assembly
Step A: Place the split ring (16) in the recess of the plug (18).
Step B: Push new packing sleeve onto plug.
Step C: Press the complete unit into cock body.
Note: Turn the packing sleeve until the ridge fits with the groove in the cock
body. The eyelets of the packing sleeve must neither protrude nor be
tilted.
Step D: Screw in bottom screw (19).
Step E: Place the handle and washer on the plug and fit screw (15).
Step F: Tighten the bottom screw (19) and check if the plug can be turned.

INDUSTRIES
Table of contents
Safety valves
General 1
Maintenance and start-up of boiler 2
Adjustment and dismantling 3
Temporary locking of a safety valve

General 1

AALBORG SAFETY VALVES OM6040#01.1
INDUSTRIES
Safety valves
1 General
In the following the measures required to achieve a safe and reliable operation as
well as maintenance of the safety valves will be described, together with adjustment
and dismantling instructions. An installation example of the safety valve is shown in
Figure 1.
Mounting of safety valves, example
Waste steam pipe
Expansion joint
with sealing ring
Drain
Drain
Figure 1 safe Olc.cdr
Maintenance and start-up of boiler

A regular inspection of the safety valve is recommended at least once a year. Some
media and appliances require a more frequent inspections, this is according to the
experience of the supplier.

INDUSTRIES
Warning: Prior to any handling and dismantling of the safety valve ensure that
the system is depressurised.
Before lighting-up the boiler, pipe connections must be thoroughly cleaned for dirt
and foreign bodies. If the valve is not completely tight, which often is the case after
start up of the plant, this is usually caused by impurities between the seat and the
cone. In order to remove these impurities the valve must be heavily blown out by
means of the lifting device. If the valve is not tight after several blows, it may be due
to the fact that a hard foreign body has got stuck between the cone and the seat, and
it will then be necessary to dismount the valve for overhaul.
Warning: In case of a leaking safety valve the valve must be inspected and
over-hauled as soon as possible. It must be ensured that the boiler is
totally depressurised before dismounting the valve.
Note: Before dismantling the safety valve in the workshop the position of the
adjusting screw must be measured and noted which will facilitate the
adjustment later when the valve is to be adjusted when in service.
In case the facings between the cone and the seat have been damaged, they must be
grinded.
Step A: The cone can be grinded against a cast iron plate, using a fine grained
carborundom stirred in kerosene.
Step B: The seat in the valve body can be grinded in the same way by using a cast
iron punch of suitable size.
Note: Never use the cone itself when grinding the seat.
Warning: The spindle and the valve cone must always be secured against
turning as the seat and the cone may thus be damaged.
Step C: Before assembly the valve must be thoroughly cleaned, and all traces of
grinding material and impurities must be removed.
Step D: When the valve has been mounted and the boiler is commissioned, the
valve must be checked for leakage and adjusted to the set pressure.
Step E: The adjustment screw is secured by means of its lock nut, and the valve is
sealed.

INDUSTRIES
2.2 Routine check

The following should be regarded as recommendations of routine checks on the
safety valves, in order to secure a correct function:
Monthly
Step A: Examine the safety valves for any leaking, such as:
— Is water seeping from the drain plug at the valve body?
— Is the escape pipe hot due to seeping steam from the valve seat?
Step B: Examine the drain and expansion device at the escape pipe.
Step C: Examine the lifting gear device, i.e. clean up and grease all sliding parts.
Yearly
Step A: The safety valve should be tested in operation by raising the boiler pressure.
Step B: Expansion and exhaust pipe should be examined at the same time.
Adjustment and dismantling

Safety valves are delivered with the required spring setting and sealed against
unauthorised adjustment. Adjustments are only allowed in the spring margins.
Outside the margin a new spring is required. The pressure in a system should not
exceed 90% of the set pressure.
All item numbers mentioned in the following sections refer to Figure 2.
3.1 Dismantling of lifting device

Safety valve with open cap:
Step A: Remove bolt (39) and remove lift lever (41)
3.2 Set pressure change without spring change
Note: Pay attention to spring range.
Step A: Spindle (14) must be held fast by all alterations.
Step B: Loosen lock nut (21).
Step C: Turn the adjusting screw (17) clockwise for higher and anticlockwise for
low set pressures.
Step D: Secure the new setting with the lock nut (21) and reassemble lifting device.

INDUSTRIES
3.3 Spring change
Step A: Spindle (14) must be held fast by all alterations.
Step B: Loosen lock nut (21) and turn adjusting screw (17) anticlockwise, then the
spring (37) is not under tension.
Step C: Loosen the nuts (8) and remove the bonnet (42).
Step D: Remove the upper spring plate (26), spring (37), spindle (14) with disc (12),
guide plate (4), and lower spring plate (26).
Step E: Clean the seat (2) and disc (12).
Step F: Remount the spindle unit with the new spring and upper spring plate.
Assemble bonnet (42) and adjust to the spring range.
Step G: Secure the spring setting through the lock nut (21) and remount lifting
device.
Assembling drawing of safety valve
47 Ball
42 Bonnet
41 Lifting lever
40 Split pin
39 Bolt
38 Screw
37 Spring
29 Cap
27 Gasket
26 Spn'ngplate
23 Lead seal
22 Drain screw
21 Lock nut
18 Ball
17 Adjusting screw
16 Slotted pin
15 Gasket
14 Spindle
13 Lift aid
12 Disc
10/25 Split cotters
9 Lift limitation ring
8 Hex, nut
7 Gasket
4 Spindle guide
3 Stud
2 Seat
1 Body
Figure 2 safe 03a.cdr
Language UK. Page 4/4

AALBORG TEMPORARY LOCKING OF A SAFETY VALVE OM6040#02.0
INDUSTRIES

1 General
During commissioning work or later tests of the opening pressure for the safety
valves, only one safety valve should be checked at a time. This means that the other
safety valve must be locked. The following instruction describes the temporary
locking of a safety valve.
1.1 Procedure for locking of a safety valve
Step A: Remove the bolt (39) and split pin (40), see Figure 1.
Step B: Remove the lifting lever (41).
Step C: Unscrew the screw (38) and break the lead seal (23), if provided.
Step D: Unscrew the cap (29).
Step E: Place one or two bolts (48) on top of the spindle. The height of the bolts
should be approximately 1-2 mm higher than the normal distance between
the top of the spindle and the inside top of the cap (29).
Step F: Carefully screw on the cap until the spindle and bolts are locked. The safety
valve will be completely locked when the bolts cannot be moved anymore.
Step G: The other safety valve can now be tested without any interference from the
locked safety valve.
1.2 Procedure for unlocking of a safety valve
Warning: As soon as the test procedure for the safety valve has been carried
out the locked safety valve must be unlocked.
Step A: Unscrew the cap (29) and remove the bolts (48).
Step B: Mount the cap (29) again and screw in the screw (38).
Step C: Mount the lifting lever (41), bolt (39), and split pin (40).
Step D: Provide the safety valve with a lead seal (23), if necessary. This depends on
the local rules of the classification society.

AALBORG TEMPORARY LOCKING OF A SAFETY VALVE OM6040#02.0
INDUSTRIES
Figure 1 safe 06.cdr

INDUSTRIES
Table of contents
Feed water system

Water level control 1
Safety device 2
Water level control system 3

INDUSTRIES
Water level control

Description
The water level control is a modulating system at this type of boiler. The system is
illustrated in Figure 1. The safety device system for too low water level shut down
and burner cut out consists of a level float switch mounted as an external unit.
Control and measurement of the water level is achieved by means of a three point
regulation where water level, steam flow, and feed water flow are used as control
inputs, and combined with two PID regulators these provide level alarms/shut downs
and control of the regulating feed water valve.
Water level control system
Instrument air
Main steam line
Dp-transmitter for Jf. 3=.

flow measurements ~
Reference leg
Variable leg
Valve
manifold
dp-transmitter
Figure 1 dp_l_mod_flowl.cdr
probe, pressure transmitter, and flow computer.

INDUSTRIES
of the boiler pressure transmitter and feed water pressure transmitter. The
differential pressure of the transmitters together with the opening signal of the
regulation valve is calculated into feed water flow.
When the boiler is stopped, in starting/stopping mode, or operating at low loads only
the dp water level transmitter unit is active. At higher loads and especially if large
load variation occurs all three control elements are active. Thus the feed water
regulation becomes more rapid in this condition.

AALBORG LEVEL FLOAT SWITCH OM8210#15.1
INDUSTRIES
Level float switch

1 General
The level float switch of type RBA 24 supervises the water level in the boiler. It is
installed in a vertical position and connected to the boiler sockets, provided for this
purpose, by means of shut-off valves.
A float and float rod carry a transmitting magnet which runs in a stainless steel
transmitting tube. The transmitting magnet operates the externally installed magnet
switches. When the magnet switches have been triggered, they remain in that
position until trigged again. Figure 1 illustrates the level float switch.
Illustration of the level float switch
Shut-off valves
Boiler
Steam drum
Drain valve
Figure 1 rba24.cdr
Commissioning
2.1 Electrical connection
When installing the level float switch use acetic acid-free silicon cable in the
internal part of the switch housing.
Step A: Unscrew the switch housing and check for correct assembly and wiring.

INDUSTRIES
2.2 Adjusting the switch point

The switch point of the level float switch should be pre-adjusted before the boiler is
pressurised and started for the first time.
Step A: Open both shut-off valves and close the drain valve.
Step B: Open the feed water valves and the air valve. Fill the boiler with evaporated
water until the "Too low water level" mark has been reached and adjust the
magnet switch to the switch point. It should be moved in upwards direction
until the switch is trigged and secured in this position. The magnet switch
must rest against the transmitting tube.
Note: If the temperature difference between the boiler and feed water exceeds
approximately 50°C, the boiler must be filled very slowly. When filling a
pressure less boiler, the shut-off valve after the feed water pump must be
throttled. Otherwise the pump motor will be overloaded.
2.3 Function test

During commissioning a live test of the level float switch must be carried out before
the boiler is put into normal operation. The purpose of the live test is to check that
the shut down for too low water level and cut out function of the burner is
operational. When the boiler is pressurised and the burner is in operation carry out
the following work steps:
Step A: Slowly decrease the water level in the boiler by means of the blow down
valves until the water level has fallen to the "Too low water level" mark.
Ensure that the boiler is not refilled with water by closing the feed water
valves.
Step B: Note that both the shut down and cut out function is delayed via a timer in
the control panel.
Step C: Adjust the switch point, if necessary.
Step D: After completion of the function test open the feed water valves fully and
raise the water level to the normal level.
Attention: Both shut-off valves must always be fully open during normal
operation of the boiler.
To ensure a safe and reliable operation of the boiler plant check the level float
switch whenever an opportunity occurs by comparing the magnetic switch function
with the level indicated in the water level gauges.

INDUSTRIES
A great difference in the water levels may indicate either blocked connections to the
float chamber or a water filled level float. Therefore it is recommended to blow-
through the level float switch and connection pipes frequently (see below). The
blow-through procedures can be performed, e.g. in connection with stopping the
boiler plant, in order to get rid of dissolved particles that could settle during the stop
periods. In case of prolonged standstill the level float switch should be checked for
the correct function before the boiler plant is restarted.
3.1 Blow-through procedure
The blow-through procedure with cleaning of the float chamber should be

performed as describe below when the boiler plant is in operation. The procedure
should be carried out at least once each week.
Step A: Slowly open the drain valve to fully open position, and allow the chamber
to blow-through for a few seconds.
Step B: Close the drain valve again.

In case of contaminated boiler water, e.g. sludge, mud, etc., the blow-through
procedure of the level float switch must be done more often.
3.2 Blow-through and test procedure

The blow-through procedure with test of the shut down and burner cut out function
should be performed as describe below when the boiler plant is in operation. The
procedure should be carried out at least once each month.
Step A: Fully close the upper shut-off valve.
Step B: Slowly open the drain valve to fully open position, and allow the chamber
to blow-through for a few seconds.
Step C: Then close the drain valve and open the upper shut-off valve again.
Step D: Fully close the lower shut-off valve.
Step E: Slowly open the drain valve to fully open position, and allow the chamber
to blow-through for a few seconds. As the water level falls inside the float
chamber check that the shut down function is activated and the burner cuts
out. Please note that both the shut down and cut out function is delayed via
a timer in the control panel.
Step F: After performing the blow-through and test procedure close the drain valve
and open the lower shut-off valve again.
procedure of the level float switch must be done more often.
3.3 Cleaning
The float chamber, transmitting tube, and transmitting magnet must be opened,
checked, and cleaned from dirt at least once a year. Carry out the following work
procedures:

INDUSTRIES
Step A: Perform a blowing-through procedure as described above.
Step B: Close the two shut-off valves and slowly open the drain valve.
Step C: Remove the top flange of the chamber.
Step D: Loosen the float and float rod with transmitting magnet from the top flange.
Step E: Clean the transmitter tube and transmitting magnet.
Step F: Clean the float chamber for any fossilised mud.
Step G: Check the condition of the float and that it is not water filled.
Step H: Check the condition of the electrical wiring. Exchange damaged wires if
necessary.
When the cleaning procedure is completed the level float switch must be assembled
as follows:
Step I: Assemble the transmitting magnet in the top flange.
Step J: Assemble the top flange on the float chamber.

Step K: Perform a function test as described previously when the boiler is
pressurised.

AALBORG DP WATER LEVEL TRANSMITTER UNIT OM8210#16.1
INDUSTRIES
dp water level transmitter unit

1 General
The dp water level transmitter unit controls and supervises the water level in the
boiler. The complete unit is installed in a vertical position and connected to the
boiler sockets, provided for this purpose, by means of shut-off valves (see Figure 1).
The dp water level transmitter unit includes reference leg, variable leg, transmitter
connection valves mounted on a manifold, and a differential pressure transmitter.
The differential pressure transmitter converts the detected water level into an
analogue signal (4-20 mA) which is transmitted to the control system. The signal
can also be used for remote level indication in the engine control room.
Illustration of the dp water level transmitter unit

Shut-off valves
Filling plug
Reference leg
Drain valve
Boiler
Equalising valve
dp-transmitter—
Figure 1 dpunit.cdr
The differential pressure transmitter is installed with the process connections upward
to prevent trapping of air. The pipes are mounted with continuous fall (at least 5°)
from the boiler connections to the transmitter also to prevent trapping of air.
The reference impulse leg (upper connection point) is connected to the high pressure
connection (+), and the variable impulse leg (lower connection point) to the low
pressure connection (-).
Note: The dp water level transmitter unit or any part of it must not be
insulated to ensure the correct function.

INDUSTRIES
Commissioning
2.1 Initial commissioning
Before the boiler is pressurised and started for the first time some initial
commissioning procedures can be performed with regard to the valves of the dp
water level transmitter unit. The shut-off valves, transmitter connection valves, and
equalising valve should be operated in the following sequence during the initial
commissioning:
Step A: Initial setting; all valves of the dp water level transmitter unit closed (see
Figure 1).
Step B: Open the equalising valve located on the valve manifold.
Step C: Unscrew the filling plugs for the reference leg and variable leg. Fill the legs
with feed water.
Step D: Open the transmitter connection valve and venting facility on the reference
leg side of the transmitter.
Step E: Close the venting facility on the reference leg side of the transmitter when
no more air escapes.
Step F: Open the venting facility on the variable leg side of the transmitter.
Step G: Close the transmitter connection valve on the reference leg side of the
transmitter when no more air escapes.
Step H: Open the transmitter connection valve on the variable leg side of the
transmitter.
Step I: Close the venting facility on the variable leg side of the transmitter when no
more air escapes.
Step J: Close the transmitter connection valve on the variable leg side of the
transmitter.
Step K: Close the equalising valve.
Step L: Refill the legs with feed water and screw on the filling plugs for the
reference leg and variable leg.
Step M: Open both transmitter connection valves fully.
2.2 Commissioning of the differential pressure transmitter

The differential pressure transmitter can be commissioned either through "blind
calibration" or "live calibration". In the following sections both methods are
described.

INDUSTRIES
2.2.1 Blind calibration

Blind calibration of the differential pressure transmitter can be performed if no
pressure source is available. This means when the boiler cannot be operated at
normal working pressure and the water level cannot be increased/decreased. The
"start of scale" and "full scale" differential pressures are calibrated on the basis of
calculated values. The start of scale value should be calibrated to obtain a 4 mA
output signal from the transmitter when the water level is at the lower connection
point and the full scale value to obtain a 20 mA output signal when the water level is
at the upper connection point. To ensure an accurate calibration it is necessary to
take the density difference between the water in the reference leg and in the boiler
into consideration when calculating the differential pressure values.
4 mA output signal from the differential pressure transmitter:
— When the water level in the boiler is at the lower connection point the pressure
difference over the transmitter is equal to the height between the connection
points (column of water) corrected with the density of the water in the reference
leg. The value must be specified and entered in engineering unit, e.g. in mm
H2O.
20 mA output signal from the differential pressure transmitter:
— When the water level in the boiler is at the upper connection point the pressure
difference over the transmitter is equal to the height between the connection
points corrected with the density difference between the water in the reference
leg and in the boiler. The value must be specified and entered in engineering
unit, e.g. in mm H2O.
Figure 2 indicates the calculation procedures of the differential pressures. As
standard it is assumed that the temperature in the reference leg (condensate receiver)
is 40°C. Table 1 shows the calculated values for some standard heights between the
connection points. If the actual boiler plant does not fit any of the standard
calculations the specified calculated values can be entered in the table for calibration
record purpose.
If the boiler plant is intended to operate at different set points (high/low pressure
mode) the differential pressure transmitter must be calibrated so that the minimum
indicated "Too low water level" on the control system not is lower than the actual
"Too low water level" mark. Because of the density difference in the boiler water at
different working pressures/temperatures the indicated water levels will not be
identical. This means that the differential pressures for start of scale and full scale
should be calculated using the parameters from operation in high pressure mode.
When the differential pressures corresponding to the "start of scale" and "full scale"
have been calculated carry out the following work steps (please also see the specific
instruction for the differential pressure transmitter):
Step A: Unscrew the screws that hold the protective cover of the differential
pressure transmitter for access to the push buttons.
Step B: Use the "M" key to select modes on the differential pressure transmitter.
When a mode is selected, the keys T and 4 are used to change the mode
value.

INDUSTRIES
Step C: Set the values in mode 4 (electrical damping), 9 (output in error situation),
10 (pushbuttons functions), 11 (characteristic), 13 (value displayed), and 14
(engineering units). In mode 14 select e.g. "mm H2O" as engineering units.
Step D: Select mode 5 using the "M" key.
Step E: Use the t or •!• key to set the start of scale in the selected engineering unit. If
mm H2O is selected as engineering units, then set the start of scale to the
calculated value in mm H2O (differential pressure at 4 mA).
Step F: Press both the t and 4- keys simultaneously for about 2 seconds, and the
start of scale is set to zero (in the selected engineering unit).
Step G: Select mode 6 using the "M" key.
Step H: Use the t or i key to set the full scale in the selected engineering unit. If
mm H2O is selected as engineering units, then set the full scale to the
calculated value in mm H2O (differential pressure at 20 mA).
Step I: Press both the t and I keys simultaneously for about 2 seconds, and the full
scale is set to the upper limit (in the selected engineering unit).
Step J: Mount the protective cover of the differential pressure transmitter again.
Height between Working pressure Transmitter output, Differential pressure

Connection point
connection [mm] [barg - kg/cm2l [mAl calibration [mm H2O]
Calculations for standard heights, working pressures, and ambient temperature (40°C)
Lower connection 4 521
7.0
Upper connection 20 50
525
16.0
Upper connection 20 70.
7.0
700
16.0
7.0
800
16.0
Calculation records for other heights, working pressures, and/or ambient temperatures
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Lower connection 4
Upper connection 20
Table 1

INDUSTRIES
Calculation of the differential pressures
t, = 40°C, density: 992.2 kg/m3
t, = not existing
Differential pressure
between connections:
Height between
525 X 0.9922 =
connections, e.g.:
525 mm
521 mmH2O(at4mA)
, Water level
\
= 170°Cat7barg,
204°Cat16barg
* = 40°C, density: 992.2 kg/m3 t, = not existing
Water level
between connections
(at 7 barg):
525 X (0.9922 - 0.8970) =
Height between
50.0 mm H2O (at 20 mA) connections, e.g.:
525 mm
between connections
(at 16 barg):
525 X (0.9922 - 0.8596) =
69.6 mm H2O (at 20 mA)
\
= 170°Cat7barg,
density 897.0 kg/m3
204°Cat16barg,
density 859.6 kg/m3
Figure 2 dpunit_calil.cdr
2.2.2 Live calibration

Live calibration of the differential pressure transmitter can be performed when a
pressure source is available. This means when the boiler can be operated at normal
working pressure and the water level can be increased/decreased. The "start of scale"
and "full scale" output signals of the differential pressure transmitter are set during
actual operating conditions. It is therefore not necessary to take the density
difference between the water in the reference leg and in the boiler into consideration.
However, if the boiler plant is intended to operate at different set points (high/low
pressure mode) the differential pressure transmitter must be calibrated so that the

INDUSTRIES
minimum indicated "Too low water level" on the control system not is lower than
the actual "Too low water level" mark. Because of the density difference in the
boiler water at different working pressures/temperatures the indicated water levels
will not be identical. This means that the differential pressure transmitter should be
calibrated when the boiler plant operates in high pressure mode.
When the boiler operates at normal working pressure carry out the following work
steps (please also see the specific instruction for the differential pressure
transmitter):
Step A: Unscrew the screws that hold the protective cover of the differential
pressure transmitter for access to the push buttons.
Step B: Use the "M" key to select modes on the differential pressure transmitter.
When a mode is selected, the keys t and •I are used to change the mode
value.
Step C: Set the values in mode 4 (electrical damping), 9 (output in error situation),
10 (pushbuttons functions), 11 (characteristic), 13 (value displayed), and 14
(engineering units). In mode 14 select "raA" as engineering units.
Step D: Ensure that the boiler cannot be filled with feed water by closing the feed
water valves or stopping the feed water pumps.
Step E: Slowly decrease the water level in the boiler until the lower connection
point is reached (socket centre line of the variable leg). The water level can
be decreased by means of the blow down valves.
Step F: The upper and lower connection points will normally be beyond the visual
indication area of the water level gauges. It is therefore impossible to see
when the water level is at these points. However, the rising/falling rate of
the water level can be controlled, by throttling the feed water valves/blow
down valves. By clocking the rate it can be calculated when the water level
has reached the connection points.
Step G: Select mode 2 using the "M" key.
Step H: Set the output current corresponding to the start of scale using the T and -I
keys. Or set the output current to 4 mA by pressing the t and -I keys
simultaneously for about 2 seconds.
Step I: Slowly increase the water level in the boiler until the upper connection point
is reached (socket centre line of the reference leg). The water level can be
increased by means of the feed water pumps.
Step J: When the water level is increased operate the burner so that the boiler
pressure is kept at normal working pressure.
Step K: Select mode 3 using the "M" key.
Step L: Set the output current corresponding to the full scale using the t and 4-
keys. Or set the output current to 20 mA by pressing the T and 4- keys

INDUSTRIES
Step M: Mount the protective cover of the differential pressure transmitter again.
2.3 Final commissioning
During final commissioning a function test of the dp water level transmitter unit
must be performed before the boiler plant is put into normal operation. The purpose
of the function test is to check that the output signals from the differential pressure
transmitter are correct. Furthermore, it should be checked that the connected
alarms/shut downs and control functions are operational. The boiler should be
operated at normal working pressure during the test to provide for correct
indications. When the boiler is at normal water level and the burner is in operation,
carry out the following work steps:
Step A: Slowly increase the water level in the boiler by forcing operation of the feed
water pump until the water level has risen to the "High water level" level.
The control system should indicate an alarm, (if provided).
Note: Note that shut downs, alarms, and cut out functions can be delayed via
timers in the control system.
Step B: Increase the water level somewhat until the "Too high water level" mark is
reached. The burner should stop, and a shut down should be indicated on
the control system, (if provided).
Step C: Increase the water level somewhat until the upper connection point is
reached (socket centre line of the reference leg). Check that the output
signal from the differential pressure transmitter is at 20 mA or the full scale
value in the selected engineering units.
Step D: The upper and lower connection points will normally be beyond the visual
indication area of the water level gauges. It is therefore impossible to see
when the water level is at these points. However, the rising/falling rate of
the water level can be controlled, by throttling the feed water valves/blow
down valves. By clocking the rate it can be calculated when the water level
has reached the connection points.
Step E: Ensure that the boiler cannot be filled with feed water by closing the feed
Step F: Decrease the water level in the boiler by means of the blow down valves
until the water level has fallen to the " Low water level " level. The control
system should indicate an alarm.
Step G: Decrease the water level somewhat until the "Too low water level" mark is
the control system.
Step H: Decrease the water level somewhat until the lower connection point is
reached (socket centre line of the variable leg). Check that the output signal

'
* ••
• • • I
I • • • •

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from the differential pressure transmitter is at 4 mA or the start of scale

value in the selected engineering units.
Step I: After completion of the function test open the feed water valves or start the
feed water pumps.
Attention: Both shut-off valves between the boiler and impulse legs must
always be fully open and the reference leg must be totally filled with
water during normal operation of the boiler.
To ensure a safe and reliable operation of the boiler plant check the dp water level
transmitter unit whenever an opportunity occurs by comparing the water level
indicated by the control system with the level indicated in the water level gauges.
A great difference in the water levels may indicate blocked connections to the
differential pressure transmitter. Therefore it is recommended to blow-through the
impulse legs and connection pipes frequently. The blow-through procedures can be
performed, e.g. in connection with stopping the boiler plant, in order to get rid of
dissolved particles that could settle during the stop periods. In case of prolonged
standstill the dp water level transmitter unit should be checked for the correct
function before the boiler plant is restarted.
3.1.1 Blow-through procedure of the impulse legs

The blow-through procedure should be performed as describe below when the boiler
plant is in operation and in steady load condition. The procedure should be carried
out at least once each month. When the blow-through procedure is carried out, it is
very important that the water level in the boiler is carefully and continuously
supervised by the ship engineering personnel. The feed water control valve must be
operated manually, if necessary.
Step A: Isolate the differential pressure transmitter by closing the two transmitter
connection valves in the manifold. The equalising valve must remain closed
during the blow-through procedure and normal operation.
Step B: Slowly open the drain valves of the impulse legs, and allow the legs to
blow-through for a few seconds.
Step C: Close the shut-off valve for the reference leg.
Step D: Close the drain valves again when the reference leg is completely
depressurised.
Step E: Unscrew the filling plug of the reference leg and fill the leg with feed water.
Step F: Screw on the filling plug and slowly open the shut-off valve for the
reference leg.
Step G: Open the two transmitter connection valves in the manifold.

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Step H: After performing the blow-through check that the dp water level transmitter
unit and feed water control valve are fully operational.
procedure of the impulse legs must be done more often.
3.1.2 Blow-through procedure of the connection pipes
The blow-through procedure should be performed as describe below when the boiler
plant is stopped, but still pressurised. The procedure should be carried out at least
once each year.
Step A: Open the venting facilities located on the valve manifold for the impulse
legs. The transmitter connection valves must remain open and the
equalising valve closed during the blow-through procedure.
Step B: Close the venting facilities on the valve manifold when only clean water
escapes.
Step C: Close the shut-off valve for the reference leg.
Step D: Slowly open the drain valve of the reference leg.
Step E: Close the drain valve again when the reference leg is completely
depressurised.
Step F: Unscrew the filling plug of the reference leg and fill the leg with feed water.
Step G: Screw on the filling plug and slowly open the shut-off valve for the
reference leg.
procedure of the connection pipes must be done more often.
3.1.3 Function test of the dp water level transmitter unit
During normal operation of the boiler plant a function test of dp water level
transmitter unit should be carried out at least once each month. The purpose of the
function test is to check that the connected alarms/shut downs and control functions
are operational. The boiler should be operated at normal working pressure during the
test to provide for correct indications. When the boiler is at normal water level and
the burner is in operation, carry out the following work steps:
Step A: Slowly increase the water level in the boiler by forcing operation of the feed
water pump until the water level has risen to the "High water level" level.
The control system should indicate an alarm, (if provided).
Note: Note that shut downs, alarms, and cut out functions can be delayed via
timers in the control system.
Step B: Increase the water level somewhat until the "Too high water level" mark is
the control system, (if provided).

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Step C: Ensure that the boiler cannot be filled with feed water by closing the feed
Step D: Decrease the water level in the boiler by means of the blow down valves
until the water level has fallen to the "Low water level" level. The control
system should indicate an alarm.
Step E: Decrease the water level somewhat until the "Too low water level" mark is
the control system.
Step F: After completion of the function test open the feed water valves or start the
feed water pumps.

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Table of contents
Three-point feed water control

Drum level control theories 1
Drum water level by nature 2
Drum level during burner start/stop .3
The York three-point feed water control 4

AALBORG THREE-POINT FEED WATER CONTROL OM9230#01.0
INDUSTRIES
Three-point feed water control
Drum level control theories

Preferably drum level control should be designed as simple as possible regarding
costs. However, physical circumstances such as small drums may require more
sophisticated control systems in order to make sure the water level in the drum is
kept within pre-desired levels at all boiler loads. Two drum boilers like the
MISSION D-type boiler with small drums are very sensitive to the shrink and swell
phenomena inside the drum.
1.1 Single element control

Single element control is based on the well known principle with a level transmitter
delivering a signal to the measured value input on the controller. The set point is set
internally in the controller. PI parameters are normally adjusted to values able to
cope with the task. The D-parameter is normally not used.
Only small boilers and boilers in systems with limited load change gradients can be
operated satisfactorily with this type of level control.
1.2 Two element control

As the boilers become bigger or the load change gradients increase the demands to
level control increases. A solution to meet such demands may be adding more
elements to the level control as is the case in two element and three element level
control systems.
In two element control a derivative action circuitry is added. Whenever the steam-
load on the boiler changes it is detected by this circuitry that is fed from the output
signal of a steam flow transmitter. The output of the circuitry supplies a correct
signed signal to the measured value or to the output of the controller depending on
the action wanted. The derived signal is present only in a timed period depending on
the settings of the derivative action circuitry.
The larger the steam load changes the larger the output of the derivative action unit.
1.3 Three element control
A three element level control system consists of three control elements being steam
flow, feed water flow, and level. Ideally the steam flow out of the drum and the feed
flow into the drum should be equal and both varying simultaneously with boiler
steam load variations. Only the best water level control systems would take such
variations into consideration and act accordingly.
Continuously adjusting the feed water flow to the same value as the steam flow
leaves a relatively simple job to the level controller. All it has to do is to compensate
when the level is drifting away from the desired value. Such drifting with the flows
outbalanced should be compensated for in a controlled and slow way as there is no
need for quicker actions.
l
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Drum water level by nature

The main reason why it may be difficult to control the water level with a single
element type in a MISSION D-type boiler is because of the small physical space
inside the drum. The shrink and swell phenomena in the drum will give inverted
signal values, i.e. if the boiler load is increased the water level seems to increase due
to swell.
2.1 Shrink and swell
When the boiler load is increased the pressure inside the drum decreases. This has a
huge effect on the physical behaviour in the zone between the steam in top of the
drum and the water in the bottom of the drum. With decreasing steam pressure many
of the bubbles in the steam layer will expand resulting in rapidly rising water level -
the swell phenomena.
However, it is well known that the level will start dropping soon after a load
increase. Hence the use of an inverted D-factor in the controlling equipment in order
to cope with this inverted signal may become necessary; inverted because of the
rising level with the rising steam load, and a D-factor because it should only last for
a limited period of time. The I-part and P-part of the controller will act according to
the inverted signal, i.e. wrong way operation from start.
Bearing the above in mind the P- and I-parameters must be considered carefully. A
short I-time will try to remove the deviation as quick as possible, i.e. with increasing
load it will try to close the feed valve. At the same time a high gain (P-factor) will
ultimately shut the valve momentarily even though the need for an open valve
shortly hereafter is obvious.
It means that the signs of P- and I-parameters cannot just be inverted in order to
cope with this fault signal. A true sign on the parameters is needed in order to
control the level as soon as the swell has gone.
In order to cheat the faulty signal from the level transmitter it is possible to utilize
the D-parameter as it operates in a relative short time, namely during changes in
measured value (or set point). However, the sign must be inverted to work correctly.
The result of a load increase will then be as follows:
— it seems like the water level rises
— the P- and I-parameters will start to close the feed valve
— the D-parameter with inverted sign will try to open the feed valve
— over time the level stabilises and the P- and I-parameters will work alone
The theory described requires carefully adjusted P-, I- and D-parameters. They are
different by nature and in various units. The result is very often that it is possible to
choose a set of parameters that will make level control possible within certain load
or level changes. Of course there will be situations where the level will be unstable
for a while due to these circumstances. But normally several hundred millimetres
water level space is available inside the drum before the alarm limits are hit.
Language UK, Page 2/13

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Drum level during burner start/stop

The heat input is totally removed during burner stop periods. Stopping the burner
will create a total collapse of the steam bubbles in the zone between pure steam and
pure water inside the drum. This means that the detected water level will drop
drastically when the burner stops. Normally the level control would cope with this
by filling up the drum to normal level with relatively cold water.
However, this would be fatal when starting the burner again as the opposite situation
takes place. When the heat input starts the mentioned zone will now expand, and the
result will be a rising level without feeding - and even unwanted high alarm level
may be reached in this period. To avoid this situation a second water level set point
is introduced. When the burner stops the level controller set point is reduced by 50-
100 millimetres to avoid that. The swell phenomena will compensate for those
millimetres when steam production in the drum starts again.
The York three-point feed water control

Control and measurement of the water level is achieved by means of three-point
feed water control where water level, steam flow, and feed water flow are used as
control inputs, and combined with two PID controllers these provide level
alarms/shut downs and control of the feed water valves. Figure 1 illustrates the
system diagram and Figure 2 the function diagram.
probe, dp-transmitter, pressure transmitter, and flow computer.
of the boiler pressure transmitter and feed water line pressure transmitter. The
differential pressure of the transmitters together with the input signal to the control
valve is calculated into feed water flow.
4.1 First control element, water level

As indicated in Figure 2 the water level controller is divided into two parts. This
feature has been implemented in order to have two sets of controller parameters
which can be adjusted individually. Set 1 will be active when only the ordinary PID
water level controller is operational and set 2 when the water level controller is part
of the three-point feed water control. The switch point position (A or B) determines
the active parameter set (set 1 or set 2).
The water level controller includes two different set points; stop mode set point
(setp.) and operation mode set point (setp.high). When "setp." is active the water
level is controlled only by the ordinary PID controller and when "setp.high" is active
the water level controller is part of the three-point feed water control. The active set
point (SP) and hereby the switch point position is dependent on a number of factors.
The switch point will be in position A (ordinary PID water level control) if:
• the water level controller is in manual mode or
• the burner sequence step is between "steam purge 2" to "ignition" or

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• the steam or oil flow is below the setting in the "flow error" menu or
• the feed water flow is zero
The switch point will be in position B (part of three-point water level control) if:
• the water level controller is not in manual mode and
• the burner sequence step is between "safety time" to "steam purge 1" and
• the steam or oil flow is above the setting in the "flow error" menu and
• the feed water flow is higher than zero
Normally the switching of set points is activated from the burner sequence step. It is,
however, possible to achieve a faster action, so that switching back to the stop mode
set point will take place sooner. This feature can be set in the "follow oil valve"
menu.
4.1.1 Controller function
The water level controller receives a 4-20 mA signal from the water level dp-
transmitter as measured value input (MV) and a set point input (SP) from either the
"setp." value or the "setp.high" value.
When the "setp." value is active this input together with the measured value are
handled in the controller. The output value from the water level controller is
continuously adjusted and set to a value dependent on the result of the comparison
part, settings of the set 1 PID parameters as well as settings of the P-part limitation
and I-part limitations. The controller output is then fed directly to the I/P positioner
of the feed water valve.
When the "setp.high" value is active the water level controller works in a similar
way, just with the set 2 PID parameters. However, before the "setp.high" signal
enters the controller it passes a ramp function (w.reg.ramp). The ramp function is in
mm/sec, and is only active for a limited period of time when the set point changes
from "setp." to "setp.high". The "setp.offset" menu displays the actual ramp
function set point as a positive value.
Furthermore, the output signal passes both a minimum output limitation part
(wl.reg.min) and a maximum output limitation part (wl.reg.max) before it is send to
the calculation part for the first and second control elements. The purpose of the
limitation parts is to limit the effect of the output signal from the water level
controller on the steam and water flow balance.
4.2 Second control element, steam or oil flow

4-20 mA signals from the steam flow measuring equipment and oil flow regulation
valve are received by the flow input part via the calibration menus. In the flow input
part selection between steam flow or oil flow as feed forward signal can be made.
As standard steam flow is used.
The selected signal then enters the flow error part where a cut off limit for the steam
flow or oil flow signal can be set. If the signal is lower than the value set, the three-
point feed water control is cut off and the control system uses the ordinary PID
water level controller for regulation. In order to prevent the control system from
switching between three-point control and ordinary PID control at only one specific
point a hysteresis range can be set in the "flow offset" menu.
If the signal is within the permitted limits it enters the calculation part for the first
and second control elements

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4.3 Calculation part for first and second control elements
The calculation part summaries the input signals from the water level controller and
steam/oil flow part. The output signal is then used as set point (SP) for the water
flow controller.
4.4 Third control element, feed water flow
In order to have a measurement for the feed water flow a calculation part is
implemented in the flow circuit. The feed water flow is calculated by means of the
following formula:
Q = V open xVdp
— Q: calculated feed water flow

— Vopen: opening position of the feed water valve
— dp: differential pressure between the feed water line pressure and boiler pressure
As opening signal for the feed water valve the actual input signal to the I/P
positioner is used. The signal is first handled by a loop back filter which is used to
lower the influence of a jumpy output signal and hence reduce the possibility of
oscillations in the flow circuit. Then the opening signal is processed in the valve
correction part. In here the input signal to the I/P positioner is linearised, in steps of
10%, to fit the characteristic of the feed water control valve before it finally reaches
the feed water flow calculation part.
The 4-20 mA signals from the feed water line pressure transmitter and boiler
pressure transmitter are received by the calculation part via the calibration menus.
The two signals are then added, one positive value and one negative value, hereby
becoming a differential pressure.
The calculated feed water flow is then received by the water flow controller where it
is employed as measured value (MV).
It is possible to make a selection between display or no display of the feed water
flow in the "calc.flow" menu. By selecting "yes" the value will be available in the
SCADA trend system.
4.5 Water flow controller
The water flow controller receives, as described above, a measured value input
(MV) from the feed water flow calculation part and a set point input (SP) from the
calculation part for water level and steam/oil flow. These two inputs are handled in
the controller. The output value from the water flow controller is continuously
adjusted and set to a value dependent on the result of the comparison part and the
settings of the PID parameters.
The controller output is the same as the input signal to the I/P positioner of the feed
water valve. However, before the signal is received by the I/P positioner it passes a
ramp function (w.out.ramp). The ramp function is in %/sec. and is only active for a
limited period of time when the set point changes from the stop mode set point to
operation mode set point. This means when the control system changes from the
ordinary PID control to three-point control.

• • •
• • •
• • • • •

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4.6 Menu settings in the control system

Figure 3 to Figure 8 illustrate the menu setting areas in the control panel.
• Figure 3: BOILER / WATER LEVEL menu
• Figure 4: BOILER / WATER FLOW menu
• Figure 5: CMN / FEED WATER / VALVE CORRECTION menu
• Figure 6: CMN / FEED WATER / CONSTANT menu
• Figure 7: CMN / FEED WATER / PID PARAMETERS menu
• Figure 8: SETUP / CALIBRATE menu
System diagram for York three-point feed water control

Steam flow pressure Main steam line
transmitter
Feed water
sj control valves
Feed water line

pressure transmitter
Figure 1 3-point-reg_2.cdr

• •• •• •••
• • • r

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Function diagram for York three-point feed water control

f From bolter f Fromfeedwater » From steam flow J From oil flow f From dp-water
pressure transmitter line transmitter I probe via flowcom I regulation valve level transmitter
4-20 mA 4-20 mA I 4.20mA 4-20mA 4-20 mA
The switch will be in position A

(stop mode PID regulation) if:
• Not running or
- Water level controller in manual or
- Steam flow < FLOW ERROR setting or
- Oil flow < FLOW ERROR setting or
-Water flow < 0
Feed water valve
Figure 2 3-point-reg_l.cdr

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Settings in the "BOILER / WATER LEVEL" menu

f From etp-water
I level transmitter
4-20 mA
The highlighted menu items should be setup in:

BOILER / WATER LEVEL MENU
Feed water valve
Figure 3 3-pt_a.cdr

• • • • •
• • • • •

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Settings in the "BOILER / WATER FLOW" menu

From boiler f From feed water ¥ From dp-water
I
f From steam flow T From oil flow
I probeviafiowcom regulation valve level transmrtter
4-20 mA 4-20 mA 4-20 mA
pressure transmitter line transmitter
4-20 mA 4-20 mA

BOILER / WATER FLOW MENU
Feed water valve
Figure 4 3-pt_b.cdr

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Settings in the "CMN / FEED WATER / VALVE CORRECTION" menu
I I
From bailer f From feed water From dp-water
level transmitter
4-20 mA
4-20 mA 4-20 mA

CMN / FEED WATER/ VALVE CORRECTION MENU
Feed water valve
Figure 5 3-pt_c.cdr

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Settings in the "CMN / FEED WATER / CONSTANT" menu

J From boiler f From feed water f From dp-water
I pressure transmitter I line transmitter level transm'rtter
4-20 mA 4-20 mA 4-20 mA

CMN / FEED WATER / CONSTANT MENU
Feed water valve
Figure 6 3-pt_d.cdr

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Settings in the "CMN / FEED WATER / PID PARAMETERS" menu

f From boiler T From feed water * From steam flow 9 From oil flow f From dp-water
pressure transmitter
4-20 mA I
Una transmitter
4.20 mA
I probe via flowcom I regulation valve
4-20 mA 4-20 mA
level transmitter
4-20 mA
Calibration Calibration Calibration Calibration Caltoration
BO11£RPRES FW.PRJFL STEAM FLOW OIL FLOW WATER LEVEL
îSwitch point
Follow oil valve Burner

Calculation, Selection between steam or
flow = opening x Vtfiff. pressure (select) sequence
FLOW INPUT FOU.CWaLUAi.VS s p

CMN / FEED WATER / PID PARAMETERS MENU
Feed water valve
Figure 7 3-pt_e.cdr

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Settings in the "SETUP / CALIBRATE" menu

From boiler ? From feed water
4-20 mA 4-20 mA

SETUP / CALIBRATE MENU
Feed water valve
Figure 8 3-pt_f.cdr

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Table of contents
Steam flow measurement

Technical data for steam flow equipment ;..l
Steam flow measuring probe 2
Flow computer 3
Dp-transmitter, type 7MF4433 4

AALBORG STEAM FLOW MEASURING PROBE OM8620#03.1
INDUSTRIES
Steam flow measuring probe

1 General
The Deltaflow is an integrated pitot-tube designed to measure the steam flow in
pipes using the differential pressure principle. It is equipped with condensate pots
and primary shut off without surcharge, see Figure 1. The steam condenses in the
steam pots and the differential pressure arising in the water columns below the pots
is measured by means of the dp- transmitter.
Illustration of the Deltaflow probe
-E
Probe
-Support flange Condensate pots
JB
N /
Connections to
Shut off valves' dp-transmitter
Figure 1 deltaflowl.cdr
Installation
Note: Careful handling and correct installation are necessary to guarantee an

optimal function.
2.1 Straight pipe runs
To achieve the optimal accuracy the Deltaflow probe must be positioned in a fully
turbulent flow profile. After bends or other flow disturbances a straight pipe run is

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recommended. See Figure 2 for optimal straight pipe runs. If it is not possible to
keep these recommendations the straight inlet runs must be doubled.
Illustration of straight pipe runs (seen from above)
7xlD ' 3xlD
9xlD ' 2xlD
17xlD ' 4xlD
7xlD ' 3xlD
7xlD ' 3xlD
=£1 1
24xlD ' 4xlD
Figure 2 deltaflow2.cdr
2.1.1 Suitable mounting position after bends

After bends, the head of the probe should be positioned on the outside bend, see
Figure 3. Asymmetric profiles will be optimal compensated there.

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Illustration of mounting position after bends (seen from above)
Correct installation position
2.2 Mounting the welding support
The Deltaflow probe is manufactured exactly for the inner diameter of the steam
pipe, so that it fits either to the end precisely at the opposite wall of the pipe or it is
exposed to a slight tension. By this, the probe is protected against vibrations. The
welding support of the Deltaflow probe is available with flange. The correct
positions of the flange and Deltaflow probe are shown in Figure 4, Figure 5, and
Figure 6. When mounting carry out the following work procedures:
Step A: Clean the surface of the steam pipe.
Step B: Drill a hole of 28 mm at the horizontal or vertical centre line of the steam
Pipe-
Step C: Use the probe to help to position and orientate the support flange correctly
considering the fitting position and inclination.
Important: The probe including condensate pots must be mounted exactly

horizontal (use water level). An incorrect installation of the probe
can alter the hydrostatic pressure and cause measuring errors.
Step D: Fix the support flange with a few welding points.
Step E: Remove the Deltaflow probe before welding.
Step F: Weld the support flange. Please take into account that the weld may shrink
after it cools. Therefore it may be necessary to leave a small gap between
the support flange and the steam pipe. The probe is exactly adapted to the
geometry of the steam pipe and can be too long or too short, if it is not
mounted correctly.
Step G: Mount the Deltaflow probe.
Note: The condensate pots and internal pipe connections should not be
insulated.

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Illustration of the flange position
Correct
Vertical steam pipe Horizontal steam pipe
Illustration of the condensate pots position
Illustration of the probe position
2.3 Process connections
The differential pressure transmitter should be located approximately 1 metre below

the condensate pots. The pressure connection tubes must have the same length.
Ensure that the process connections are not exchanged by mistake at the dp-
transmitter or at the pressure conducts. There is a "+" and a "-" on the process
connections and an arrow on the probe. The arrow shows the correct flow direction.
The "+" is the process connection with the higher pressure.

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Commissioning and operation

After installation and a few times after start up of the boiler plant, it is imperatively
necessary to calibrate the zero point of the dp-transmitter. Afterwards it is
recommended to calibrate approximately once a year. Commissioning notes for the
dp-transmitter can be found in the specific instruction.
4 Maintenance
The Deltafolw probe is maintenance free apart from cleaning. The probe is very
insensitive to dirt. It is nevertheless possible, in particular during commissioning of
the boiler plant, that extreme amounts of particles can block the channels of the
probe. In that case a washing with compressed air or other mediums can be carried
out in regular intervals. Please make sure, that the dp-transmitter is disconnected
before cleaning. With regard to maintenance of the dp-transmitter please refer to the
specific instruction.
Faults and rectifying faults

Please note that the trouble shooting list is a general list for the Deltaflow and has
not been made for any particular plant or setup. Therefore, the cause of your specific
problem may not be mentioned and vice versa. You are always welcome, however,
to contact our Service Department for advice and service assistance.
Problem Possible cause

The Deltaflow probe does Is the grommet of the correct size?
not fit into the pipe Does the dimension of the steam pipe correspond exactly to the
information plate on the Deltaflow?
Is the assembly support correctly mounted and does it have the right
position?
The measurement is not Is the initial shut off valves open?
shown on the Flowcom Is the electric connection of the dp-transmitter installed correctly?
display Are the process connections (+/-) installed correctly, so that the side
exposed to the flow shows the higher differential pressure?
If the transmitter supplies > 4 mA, please check the electric evaluation.
The values supplied by Is the position of the Deltaflow probe correct?
the measurement are too Is the recommended position for bends and flow disturbances kept?
high or too low Is the dp-transmitter correctly calibrated?
Does the dimension of the steam pipe correspond exactly to the
information plate on the Deltaflow?
Does the characteristic curve of the dp-transmitter correspond to the
calculation in the Flowcom (square rooting)?
Are there any other installations in front of the Deltaflow probe in the
steam pipe?
Is the assembly support correctly mounted and does it have the right
position?
Is deaeration of the internal channels carried out?
Is the calculation of differential pressure and absolute pressure correct?
Table 1

AALBORG FLOW COMPUTER OM8210#33.0
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Flow computer
1 General
The Flowcom is a device used to handle and calculate the steam flow from the
measurement equipment. It corrects pressure dependent errors made by the flow
measurement devices. The Flowcom is provided with two separate channels for
possible connection of separate flow measurement devices, e.g. in case of a double
boiler plant. Figure 1 illustrates the Flowcom.
The front panel is equipped with five keys and the display. By means of these the
Flowcom can be configured, parameters can be set, and operation data can be
viewed.
Front and back view of the Flowcom
Error LED Push buttons
Terminal rows Power connection

\
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1-IHi; { # = r i 'F - I H - I 1 -1 1 l=:

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m Mr •: ' . • ; • • •
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Figure 1 flowcoml.cdr
Menu structure
The Flowcom has four basis menus which are the main menu, programming menu,
error record menu, and expanded menu. Inside each menu there are a number of
submenus. In normal operation the main menu is automatically displayed. Figure 2
illustrates the basis menus and how to reach them.

INDUSTRIES
Illustration of the basic menus
Main menu Main menu Main menu Main menu

(Various readings) (Various readings) (Various readings) (Various readings)
^ Common Channel 1 Channel 2

^ Parameters Setup Setup
Error No. 1 Error No. 2 Error No....

(Date - Time) (Dale-Time) (Date-Time)
2 sec
Expanded menu Expanded menu Expanded menu

(Various readings) (Various readings) (Various readings)
Figure 2 flowcom2.cdr
2.1 Main menu

From the main menu various readings for operation data are displayed. The
programming menu, error record menu, and expanded menu can also be reached
from the main menu.
2.2 Programming menu
All parameters and settings necessary to configure the Flowcom for the measuring
application are located in the programming menu. The programming menu has three
submenus (common parameters, setup channel 1, and setup channel 2). In the
common parameters submenu the parameters and quantities common to both
measuring channels are set. In the setup channel 1 and setup channel 2 menus,
values for the respective channels are set. Please note that the setup channel 2
submenu only appears when there are analogue entries it does not share with
channel 1.
2.2.1 Common parameters menu
All generally applicable options and functions are set in the common parameters
submenu. These are e.g. the display option setup, analogue outputs setup, system
setup, etc. Figure 3 illustrates a detailed overview of the common parameters
submenu.

INDUSTRIES
Illustration of the common parameters menu

Main menu Common
(Various readings) Parameters
Display Options
Setup
Datalogger
Setup
Relay 1
Setup
Relay 2
Setup
Analoi
DP Output 1
Analog Output 2
Setup
Analog Output 3
Setup
Analog Output 4
alog Out|
Setup
System
Setup
Password
Options Setup
Baudrate
Setup
Totalizer
Setup

INDUSTRIES
2.2.2 Setup channel 1 menu

The setup channel 1 submenu contains all parameters and settings which Flowcom
needs to correctly calculate values for the channel 1 measurement. These are the
definitions of measurement inputs and outputs for channel 1. Correctly defining the
inputs is crucial for subsequent flow calculations. Figure 4 illustrates a detailed
overview of the setup channel 1 submenu.
Illustration of the setup channel 1 menu

Main menu Common
{Various readings) Parameters
Medium C1
Define
Temperature C1
Define
Pressure C1
Define
Flow C1
Define
Pulse Output C1
Define
Totalizer C1
Zero Now
2.2.3 Setup channel 2 menu

The setup channel 2 submenu is only available when the analogue inputs of
measurement channel 2 are not the same as those used by measurement channel 1
(e.g. channel 2 is used in case of a double boiler plant). This submenu is similar to
the setup channel 1 submenu, see Figure 4, but contains the values for measurement
channel 2. If channel 2 is not being used (e.g. like in a single boiler plant), it is
advisable to deactivate the analogue inputs or set constant values in the submenu.

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2.3 Error record menu

On the front panel of the Flowcom is an error LED which displays errors and
alarms. The error record can only be accessed once the Flowcom has detected an
error in the system. Figure 5 illustrates the error record menu. A steady light
indicates that there is currently a failure, e.g. such as a disconnected cable between
the Flowcom and a transmitter. A blinking LED indicates that all errors have been
corrected, although there are still undeleted errors in the error record.
Press and hold the "error" key to go to the error record. Then press the "scroll" key
to view the errors one by one. Current (undeleted) errors are marked with a * sign to
the left of them and cannot be deleted. Corrected errors do not have a * sign next to
them and can be deleted by pressing and holding the "OK" key. If it is desired to
delete all corrected errors in one operation, then press and hold both the "error" key
and "OK" key for approximately five seconds.
Illustration of the error record menu

Main menu
(Various readings)
1st Alarm name OK

Date/Time
3th Alarm name OK

Date / Time
Essa
* Xth Alarm name Errors marked with'

Date / Time cannot be deleted
Xth Alarm name

Date / Time
Main menu
(Various readings) Mr
2 sec.
Alarm name OK
Date/Time
Simultaneously
for 5 sec.
—•«—

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2.4 Expanded menu

The expanded menu gives further information about the status of inputs, outputs,
measurements, etc.
Wiring
The Flowcom terminals are located on the back of the device. There are three 15-
pole data terminals and one 3-pole supply terminal. The Flowcom must be wired
according to Figure 6. Please note that terminal B is only wired in case of a double
boiler plant where both measuring channels are used. Finally the power cables
should be plugged in.
Illustration of the Flowcom wiring
Terminal row A 1 2 3 4 5 f3 7 8 9 10 11 12 13 14 15
Pressure Flow Analog Analog

input input output 1 output 2
Channel 1 Channel 1 4-20 mA 4-20 mA
4-20 mA 4-20 mA Control e.g.
Pressure dp-transmitter system remote
transmitter indication
Terminal row B 1 2 3 4 5 (3 7 8 9 10 11 12 13 14 15
Pressure Flow Analog Analog

input input output 3 output 4
Channel 2 Channel 2 4-20 mA 4-20 mA
4-20 mA 4-20 mA Control e.g.
Pressure dp-transmitter system remote
transmitter indication
Terminal row C 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Commissioning and operation

The five keys on the front panel are used to configure and set-up the Flowcom. A
number of submenus inside the programming menu must be entered. From here
parameters and settings must be set or checked. The following descriptions give an
overview of how to configure the Flowcom for steam flow measurement. The
figures illustrate the different submenus and how to reach, set, and/or check them.

INDUSTRIES
4.1 Common parameters
4.1.1 Display options setup

The display options setup menu consists of two further submenus, the preferred
display data setup menu and the unit setup menu. Figure 7 illustrates the display
options setup menu.
Preferred display data setup menu
Enter this menu and set "Scroll, Mass flow Cl, Mass flow C2, or Em sum C1+C2".
If "Scroll" is selected the display changes reading continuously, "Mass flow Cl" or
"Mass flow C2" indicate the steam flow for each channel, "Sm sum C1+C2"
displays the total mass flow for both channels.
Unit setup menu
Enter this menu and set physical units to "SI".
Illustration of the display options setup menu
4.1.2 Datalogger setup

The datalogger function is not used for this application and can therefore be skipped
and it is not necessary to perform any check.

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4.1.3 Relay 1 setup

The relay 1 alarm is only used for function alert in this application. It should be set
to "Relay 1 function alert". Figure 8 illustrates the menu.
Illustration of the relay 1 setup menu
Relay 1 1—MJJJ
Parameters
* Sffll Funct. Alert accepted
« B ) 1 Relay 1 Various L J 3 J Parameters I

•«H| Temperature C settings I Wmr] accepted I
To change alarm typo.
p
asss ssssssr \-
4.1.4 Relay 2 setup

The relay 2 alarm is only used for function alert in this application. It should be set
to "Relay 2 function alert". Figure 9 illustrates the menu.
Illustration of the relay 2 setup menu

Main menu Common
(Vartout readings) Parameters
Relay 2
Setup
ym—i
Parameters
—T RinSM* accepted
Relay 2 LggSLJ" Various Parameters I

Temperature C1 I t B W n settings accepted I
Parameters
accepted |

INDUSTRIES
4.1.5 Analogue output 1 setup

Analogue output 1 gives a 4-20 mA output for channel 1 which is connected to the
control system. Enter this menu and set the analogue output 1 to "Mass flow Cl",
see Figure 10.
Next step is to set the "4 mA analog output 1" value. It should be set to
"+0.0000E+0 kg/h". Then set the "20 mA analog output 1" value. It must be set to
the design mass flow which is also found in the channel I/flow Cl setting, see
section 4.2.4. The value corresponds to maximum boiler load, e.g. if the maximum
load is 25,000 kg/h enter the value "+2.5000E+4 kg/h".
Finally set the "error current analog output 1". The error current should lie either
between 1.0-3.6 mA, or between 21.0 (22.8) - 23.0 mA. In case of a fault on an
input device the Flowcom will clearly recognize it.
Illustration of the analogue output 1 setup menu
Common
Parameters -m-
I Display Options | fc
1 setup ri
* E 3 IAna"s ° U| P U| 1 1
Analog Output 1 Various Parameters I

Temperature C1 settings Various f~ accepted |
settings I
Analog Output 1 Various arameters

(other outputs) settings "TJI Various >" accepted I
Hj settings I
It
3
S AI Analog Output
__. 1. ^ ^ . L l 4mAAna.Out. 1 |_tSSLJ20mAAna.Out. 1 LJgJSLJ Error Ana.Out. 1 I B 8 , Parameters \
~ Mass"- - ~ ngB*1+P.0000E+0kg/hnHBH+Q.OOOuE-H)kg/hnMn+2.5000E+0mAlalri
flowCI accepted I
i
2see. iffifitol I' »»:--i Zeac lTil«iiH Mafrs&i 2sec W$M \z£sM 2sec.
I Analog Output 1 I Various Parameters

1 (other outputs) | settings !| Various V" accepted I
• .• HJ settings I
Figure 10 flowcoml0.cdr

Analogue output 2 gives a 4-20 mA output for channel 1 which can be connected to
a remote steam flow indicator, if provided. If applicable enter this menu and set the
analogue output 2 to "Mass flow Cl". Hereafter, carry out the same settings as
described in section 4.1.5. Figure 10 illustrates the procedure.
Analogue output 3 gives a 4-20 mA output for channel 2 which is connected to the
control system. If applicable enter this menu and set the analogue output 3 to "Mass
flow C2". Hereafter, carry out the same settings as described in section 4.1.5. Figure
10 illustrates the procedure.

INDUSTRIES

Analogue output 4 gives a 4-20 mA output for channel 2 which can be connected to
a remote steam flow indicator, if provided. If applicable enter this menu and set the
analogue output 4 to "Mass flow C2". Hereafter, carry out the same settings as
described in section 4.1.5. Figure 10 illustrates the procedure.
4.1.9 System setup

Figure 11 illustrates the system setup menu. Enter this menu and set the system to
"Separate sites".
Illustration of the system setup menu
bggy I System
" ~WBB~I Setup
Parameters I
accepted I
Mem ~~L3SmsLJ Splitting Range Parameters I

a Range ] ~ T 1 2 dp-Transducer accepted I
humidity corr. Parameters

+Q.00O0E-0 accepted
im
itge To cftango
Figure 11 flowcomll.cdr
4.1.10 Password option setup

The password function is not used for this application. It should be set to "No".
Figure 12 illustrates the menu.
Illustration of the password option setup menu
rameters
xepted |
Password tegm I Confirm

2 sec

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4.1.11 Date / time setup

Figure 13 illustrates the data / time setup menu. Enter this menu and set the date and
time. It might be advantageous to set date/time for GMT in order to have a fixed
time during sailing.
Illustration of the data / time setup menu
Main menu Common

(Various readings) Parameters
Date /Time
Setup >B 1
hJJH "GUEST H
4.1.12 Baud rate setup

The baud rate function is not used for this application and can therefore be skipped
4.1.13 Totalizer setup
The totalizer function is not used for this application and can therefore be skipped
4.2 Setup channel 1
4.2.1 Medium Cl define

Information about the measured medium, in this case saturated steam, are stored in
the Flowcom. Enter this menu and set the medium for channel 1 to "Saturated
steam". Then set the "Tolerance temperature" value. It should be set to
"+0.0000E+0 K". Figure 14 illustrates the medium Cl define menu.

INDUSTRIES
Illustration of the medium Cl define menu
Parameters ,
accepted I
4.2.2 Temperature Cl define

Figure 15 illustrates the temperature Cl define menu. Enter this menu and set the
temperature for channel 1 to "Constant value". Then set the "Constant temperature
C l " value. It should be set to "+0.0OOOE+0 °C". In this case Flowcom ignores the
temperature function.
Illustration of the temperature Cl define menu
Channel 1
Setup
Parameters
accepted |~~"
tjgjjgi
•
To charge

INDUSTRIES
4.2.3 Pressure Cl define

Figure 16 illustrates the pressure Cl define menu. Enter this menu and set the
pressure for channel 1 to "Gauge pressure". Next step is to set the "Atmospheric
pressure" value. It should be set to "+1.0133E+2 kPa". Then set the "Gauge pressure
at 4 raA" value to "+0.0000E+0 kPa". When asked to set the "Gauge pressure at 20
mA" value it should be the maximum pressure transmitter range which should be
set. E.g. if the transmitter range is 0 - 25 bar enter the value "+2.5000E+3 kPa" (25
bar equals 2500 kPa).
Finally set the "Analog input pressure Cl". Here it will be required to select whether
the pressure input for channel 1 is applicable for that channel only, or whether it
applies to channel 2 as well. Select the option "only for C l " in this application.
Illustration of the pressure Cl define menu
4.2.4 Flow Cl define

Information about the flow type is set in this menu. Figure 17 illustrates the flow Cl
define menu. Enter this menu and set the flow for channel 1 to "dp squarerooted".
Attention: When "dp squarerooted" is selected in the Flowcom setup the same
must also be selected for the dp-transmitter setup.
Set the "Design differential pressure". The value can be found in the "Technical data
for steam flow equipment"' section. E.g. if the design differential pressure is 100
mbar the setting will be "+1.0000E+1 kPa". Next step is to set the "Design mass
flow" value. It should be set to the maximum boiler load, e.g. if the maximum load
is 25,000 kg/h enter the value "+2.5000E+4 kg/h".
Then set the "Design temperature" value from the "Technical data for steam flow
equipment" section. E.g. if the design temperature is 170°C the setting will be
"+1.7000E+2°C".

••• ••
uiiiiii* FLOW COMPUTER OM8210#33.0

AALBORG
INDUSTRIES
When asked to set the "Design pressure" value it should be the working pressure
when the boiler operates in low pressure mode. The value must be entered as
absolute pressure and is also found in the "Technical data for steam flow
equipment" section. E.g. if the working pressure is 7 barg the setting will be 7 + 1 =
8 bar, "+8.0000E+2 kPa".
Set the "Expansion factor" to the value found in the "Technical data for steam flow
equipment" section. Finally set the "Dead band". Due to the fact that dp-transmitters
can have a zero point drift, a reasonable value should be entered. It could e.g. be 2%
of the design differential pressure. E.g. if the design differential pressure is 100 mbar
the setting will be 2 mbar equal to a setting of "+2.0000E-1 kPa".
Illustration of the flow Cl define menu
4.2.5 Constant feed Cl define

The constant feed Cl setting function is not used for this application and can
therefore be skipped and it is not necessary to perform any check.
4.2.6 Pulse output Cl define
The pulse output Cl function is not used for this application. It should be set to "not
activated". Figure 18 illustrates the menu.

INDUSTRIES
Illustration of the pulse output Cl define menu
Medium C1 Li
Define r1
ulse Output C1L_lre3J Various LfiSLj Parameters

thermal heal F l B i r i settings r H r l accepted
J Pulse Output C11 .

mass | M"MH settings
2 MO.
4.2.7 Totalizer Cl zero now

The totalizer Cl zero function is not used for this application and can therefore be
skipped and it is not necessary to perform any check.
4.3 Setup channel 2
4.3.1 Medium C2 define

Parameters defining the measured medium for channel 2 are set in this menu. If
applicable enter this menu and set the medium for channel 2 to "Saturated steam".
Hereafter, carry out the same settings as described in section 4.2.1. Figure 14
illustrates the procedure.
4.3.2 Temperature C2 define
If applicable enter this menu and set the temperature for channel 2 to "Constant
value". Hereafter, carry out the same settings as described in section 4.2.2. Figure 15
4.3.3 Pressure C2 define
If applicable enter this menu and set the pressure for channel 2 to "Gauge pressure".
4.3.4 Flow C2 define

If applicable enter this menu and set the flow for channel 2 to "dp squarerooted".
. illustrates the procedure.
If not applicable the flow for channel 2 must be set to "not activated".

INDUSTRIES
4.3.5 Constant feed C2 define

The constant feed C2 setting function is not used for this application and can
therefore be skipped and it is not necessary to perform any check.
4.3.6 Pulse output C2 define
The pulse output C2 function is not used for this application. It should be set to "not
activated". Figure 18 illustrates the menu.
4.3.7 Totalizer C2 zero now
The totalizer C2 zero function is not used for this application and can therefore be
skipped and it is not necessary to perform any check.
Repair
The Flowcom is equipped with two fuses located on the digital plate inside the
cabinet. In case of replacement of the fuses carry out the following work procedures:
Step A: Disconnect all electrical plugs.
Step B: Unscrew the six screws on the top side of the casing. The lid can then be
lifted off. Beneath it the analogue plate is located and under it the digital
plate which holds the fuses.
Step C: Carefully remove the front plate (display) from the unit by lifting it upward.
Please use care when handling the connecting cables between the front plate
and digital plate.
Step D: Open the brackets on the light grey plugs of the analogue plate outwards.
Step E: The analogue plate can now be lifted forward out of the casing.
Step F: Replace the fuses on the digital plate.
Step G: Assembly in reverse order.
Faults and rectifying faults

Please note that the trouble shooting list is a general list for the Flowcom and has not
been made for any particular plant or setup. Therefore, the cause of your specific
problem may not be mentioned and vice versa. You are always welcome, however,
to contact our Service Department for advice and service assistance.
Warning: When operating electrical equipment, various parts are inevitably

carrying dangerous voltages. If the warnings are ignored, serious
physical injury or property damage may occur. Therefore it is
essential to disconnect all plugs before opening the unit.

INDUSTRIES
Fault finding chart

Problem Possible cause Possible solution
Following a power failure, the "AD- The analogue plate or digital plate are Check that the plates are correctly inserted
CHECK ERROR" display appears and the incorrectly inserted and secure with the hook
Flowcom fails to start measuring A fuse is faulty Check and replace the fuse
Press the "ERROR" key for approx. two
The Flowcom has identified a fault at an
The red LED is flashing or permanently lit seconds. The fault will be displayed.
input or has triggered an alarm
Correct and reset the fault
Check the supply voltage and the installed
Supply voltage interrupted
fuses
The display does not work
Check that the plug connections between
The display is not connected
the display and digital plate
Check whether the desired alarm is
The alarm is not correctly parameterised
parameterised as expected
Use suitable instrument to check whether
No alarm was given The checks carried out up to now have
there is a short circuit or any other
been positive. Nevertheless, downstream
interruption between the terminals in the
peripherals do not recognise the alarm
event of an alarm.
Press the "MORE" key for approx. two
seconds to go to the extended menu. Use
The input is not correctly parameterised the "SCROLL" key to find the desired
At one input the corresponding signal is input. Check whether the input is activated
not measured, or the measured value does and parameterised as expected
not change as expected Use a suitable measuring instrument to
All hardware checks up to now have
check whether a current is flowing at the
proved positive, nevertheless, the signal
input. There may be a cable break/short
cannot be measured
circuit
Press the "MORE" key for approx. two
seconds to go to the extended menu. Use
The output is not correctly parameterised the "SCROLL" key to find the desired
output. Check whether the output is
activated and parameterised as expected
No signal is emitted at an output or the
Check that the positive/negative terminals
value does not change as expected The connection cables are reversed
are correctly assigned
Use a suitable measuring instrument to
All hardware checks up to now have been check whether a current is flowing at the
positive, nevertheless, no signal is emitted output. There may be a cable break/short
circuit
Table 1

AALBORG DP-TRANSMITTER, TYPE 7MF4433 OM8020#04.0
INDUSTRIES
Dp-transmitter, type 7MF4433

1 General
The following description is valid for a differential pressure transmitter SITRANS P,
type7MF4433.
Warning: This device may only be assembled and operated after qualified
personnel has ensured, by providing suitable power supplies, that no
hazardous voltages can get into the device in normal operation or in
the event of a failure of the system or parts thereof.
Warning: The device may be operated with high pressure and corrosive media.
Therefore serious injuries and/or considerable material damage
cannot be ruled out in the event of improper handling of the device.
The perfect and safe operation of this equipment is conditional upon proper
handling, installation, and assembly as well as on careful operation and
commissioning.
Technical description
2.1 Application
The SITRANS P transmitter can be used to measure:

• the differential pressure, e.g. the active pressure,
• a small positive or negative excess pressure,
• flow q ~ p 0 5 (together with a flow control valve)
of non-corrosive and corrosive gases, vapours, and liquids.
Measuring spans are possible between 1 mbar and 30 bar depending on the type.
The output signal is a load-independent direct current of 4 to 20 mA. A linear
(proportional to the differential pressure) or square rooting characteristic
(proportional to the rate of flow) can be selected.
Transmitters conforming to the type of protection "Intrinsic safety" and "Explosion-
proof may be installed within potentially explosive atmospheres zone 1 or zone 0.
The transmitter is provided with an EU prototype test certificate and comply with
the corresponding harmonised European standards of the CENELEC.

INDUSTRIES
2.2 Mode of operation
Figure 1 shows a function diagram of the SITRANS P differential pressure and flow
transmitter. The item numbers referred to in the following description are those
mentioned in the in the figure.
The differential pressure is applied via the diaphragms (4) and the filling liquid (3)
to the silicon pressure sensor (7). If the measuring limits are exceeded, the overload
diaphragm (6) is flexed until one of the diaphragms (4) rests on the measuring cell
body (2), thus protecting the silicon pressure sensor (7) from overloading.
The measuring diaphragm of the silicon pressure sensor is flexed by the applied
differential pressure. The resistance of four piezo-resistors fitted in the diaphragm in
a bridge circuit th+us changes. This change in resistance results in a voltage output
from the bridge proportional to the differential pressure. This voltage is amplified
and converted into a frequency by means of a voltage-to-frequency converter (9).
This signal is evaluated by a micro controller (10), and its linearity and temperature
effect corrected.
The processed signal is converted by a digital-to-analogue converter (11) into an
output signal of 4 - 20 mA.
The data specific to the measuring cell as well as the parameters of the transmitter
are stored in a non-volatile memory (EEPROM).
The cable termination point and the electronics are arranged opposite one another.
Parameterisation of the transmitter is performed using a laptop, PC, HART®
Communicator, or the input keys. Normally the input keys are used to set-up the
transmitter.
Function diagram
12 13
Differential pressure 5 O-Ring

as input variable 6 Overload diaphragm
/A Output signal 7 Silicon pressure sensor
UH Power supply 8 Instrument amplifier
9 Voltage-to-frequency converter
1 Process flange 10 Microcontroller
2 Measuring cell body 11 Digital-to-analog converter
3 Filling liquid 12 LCD (option)
4 Diaphragm 13 Analog indicator (option)
Figure 1 7mf33 Ol.tif

INDUSTRIES
The following parameters can be set or their current interrogated:

• measuring range
• measured value in mA, %, and unit of pressure
• unit of pressure
• linear or square rooting characteristic
• application point of the square rooting characteristic
• electric damping
• current transmitter
• output current in the event of an error
• disabling input keys and/or functions
2.3 Dimensions
SITRANS P, differential pressure and flow transmitter, dimensions
161 for seriMDS with PROFIBUS-RA

• 45 for Pg 13,5 with adapter
1 Process connection 54-18 NPT 5 Connection side

for absolute pressure (+) side 6 Electronics side, digital display
2 Mounting thread M10, M12 or 7 / 1 6 - 20 UNF (greater length for cover with window)
3 Dummy plug 7 Protective cover over keys
4 Electrical Connection: 8 Sealing screw
Screwed gland Pg 13.5 (adapter) 9 Side vent for measuring liquid
M20x1.5or%-14NPTor 10 Side vent for measuring gas (supplement H02)
Han 7D/Han 8 U plug 11 Mounting bracket (optional)
Figure 2 7mO3 02.tif

INDUSTRIES
Installation
3.1 Place of installation

The transmitter can be installed above or below the pressure tapping point. When
measuring gases, it is recommended to install the transmitter above the pressure
tapping point and the pressure pipe to be laid so it runs down to the pressure tap.
This will permit any condensation in the pipe to drain off and not affect the
measurement. When measuring liquids, the transmitter should be installed below the
pressure taping point and the pipe laid so it rises up to the pressure tap, thus enabling
any gas in the pipe to dispersed.
The point of installation should be easily accessible, preferably close to the
measuring point and free from vibration. The permitted ambient temperature limits
must not be violated. Protect the transmitter from direct heat sources. Before
installing the transmitter, compare the process data against the data on the rating
plate. Keep the transmitter closed during the installation process.
The transmitter can be fitted directly to the valve manifold or secured with a
mounting bracket.
3.2 Fixing with a mounting bracket
The mounting bracket is fixed to either

• a wall or mounting frame using 2 screws,
or to
• a vertical or horizontal mounting pipe (50 to 60 mm in diameter) using a U-bolt
(see Figure 3).
The transmitter is fastened to the mounting bracket using the four screws supplied.
Fixing the transmitter using a mounting bracket
Figure 3 7mf33 03.tif

INDUSTRIES
3.3 Rotating the measuring cell in relation to the housing
If necessary, the measuring cell of the transmitter can be rotated in relation to the
electronics housing, so that the digital display is visible and/or access the input keys
and the current connection for an external measuring instrument is possible.
Only a limited rotation is permitted. The range of rotation (7), see Figure 4, is
marked at the base of the electronics housing. At the neck of the electronics housing
there is an orientation mark (6) which always must be within the marked range when
rotated.
Step A: Loosen the locking screw (8).
Step B: Rotate the electronics housing in relation to the measuring cell (only within
the marked area.
Step C: Tighten locking screw (torque 3.5 +tu Nm).
Rotating the measuring cell in relation to the housing
3.4 Electrical connection
Warning: Observe the relevant regulations during the electrical installation. In

hazardous areas, pay particular attention to:
• the regulations governing electrical systems in hazardous areas (Elex V),

• the specifications regarding the installation of electrical systems in hazardous
areas (VDE 0165), and,
• the EC type examination certificate

INDUSTRIES
Warning: Check that the auxiliary power supply matches that specified on the
rating plate.
The transmitter should be powered from a SELV (safety extra-low voltage) source.
If other power sources are used, it is recommended to earth the transmitter housing
and PE connection. The earth terminal in the connection box must be connected
internally to the PE connection.
Please note that:
• The sealing caps in the cable entries have to be replaced by relevant cable
glands or blanking plugs, which must be certified when using transmitters
conforming to protection type "Flame-proof enclosure".
• The following general guidelines apply when laying terminal (maximum cross
section 2.5 mm2)/signal cables:
— lay the signal cable separately from cables carrying voltages > 60 V
— use twisted-pair cables
— do not lay cables close to large electrical systems, or use screened cable
3.4.1 Connection to screw terminals
Electrical connection
Step A: Unscrew the cover of the connection box (marked "FIELD TERMINALS"
on the housing).
Step B: Insert the connecting cable through the cable gland.
Step C: Connect the wires the "+" (2) and "-" (3) to the terminals, see Figure 5 and
observe the polarity. Position (4) is a test plug for an external DC amp-
meter.
Step D: Connect the screen (1) to the screen screw, if necessary.
Step E: Screw on the housing cover.

INDUSTRIES
Note: In explosion-proof transmitters the housing cover must be screwed on

tightly and secured with the cover catch.
3.4.2 Connect with plug

The contact parts for the coupling socket are enclosed packed in a bag. Please note
that these must not be used for explosion-proof transmitters.
Step A: Push the sleeve and screwed gland onto the cable.
Step B: Insulate the cable ends approximately 8 mm.
Step C: Crimp or solder the contact parts to the cable ends.
Step D: Assemble the coupling socket.
Connection with plug
output current
auxiliary power
3.5 Turning the digital display
If the device cannot be operated in a vertical position the digital display can be
turned to make it easier to read. To do this, proceed as follows:
Step A: Unscrew the cover .from the electronics housing.
Step B: Unscrew the digital display. Depending on the position of the transmitter it
can be screwed back in four different positions (rotation by +90° or ±180°
are possible).
Step C: Screw on the housing cover.

INDUSTRIES
Commissioning
The process data must correspond to that on the rating plate. The transmitter
functions as soon as the power is turned on.
Warning: Serious injury or considerable material damage may result if:
• the venting valve and/or the sealing screw are missing or not tight enough
and/or
• the valves are operated wrongly or improperly
Warning: When working with a hot medium, the individual steps described
below must be performed in quick successions, otherwise the valves
and transmitter may overheat and be damaged.
4.1 Measuring gases
The isolating valves should be operated in the following sequence, see Figure 7:
Measuring gases
1 Transmitter
2 Equalizing valve
3 Pressure Inlet valves
4 Impulse lines
5 Isolating valves
7 Outlet valves
9 Condensate traps
10 Pressure source
Transmitter above Transmitter below

pressure source pressure source
(normal configuration) (non-standard)

INDUSTRIES
Step A: Initial setting: all valves closed.
Step B: Open both isolating valves (5) at the pressure tapping points.
Step C: Open the equalising valve (2).
Step D: Open the pressure inlet valve (3A or 3B).
Step E: Check the zero point (4 mA) at start of scale (0) and correct if necessary.
Step F: Close the equalising valve (2).
Step G: Open the other pressure inlet valve (3A or 3B).
4.2 Measuring liquids
Measuring liquids
1 Transmitter
2 Equalizing valve
3 Pressure inlet valves
4 Impulse lines
5 Isolating valves
7 Outlet valves
8 Venting valves
10 Pressure source
12 Gas trap
Transmitter below Transmitter above

pressure source pressure source
(normal configuration) (non-standard)
Figure 8 7mf33 O8.tif
Step C: Open the equalising valve (2).

INDUSTRIES
Step D: If the transmitter is below the pressure source: open both outlet valves (7)
slightly, one after the other, until no more air escapes.
Step E: If the transmitter is above the pressure source: open both venting valves (8)
slightly, one after the other, until no more air escapes.
Step F: Close both outlets (7) or venting valves (8).
Step G: Open the pressure inlet valve (3A) and venting on the positive leg of the
transmitter (1) slightly until no more air escapes.
Step H: Close the venting valve.
Step I: Open the venting valve on the negative leg of the transmitter slightly until no
more air escapes.
Step J: Close pressure inlet valve (3 A).
Step K: Open the pressure inlet valve (3B) slightly until no more air escapes, close
after.
Step L: Close the venting valve on the negative leg of the transmitter (1).
Step M: Open the pressure inlet valve (3 A) lA a rotation.
Step N: Check the zero point (4 mA) against start of scale (0) and correct if
necessary.
Step O: Close the equalising valve (2).
Step P: Open the pressure inlet valves (3 A and 3B) fully.
4.3 Measuring steam
Caution: The result will only be correct when the impulse lines (4) contain an
identical head of condensate at identical temperatures. Zero point
calibration should be repeated, if necessary, when this condition is
satisfied.
Caution: The flow of steam may damage the transmitter if the equalising valve
(2) is opened when both the isolating valves (5) and pressure inlet
valves (3) are open!

INDUSTRIES
Measuring steam
1 Transmitter
2 Equalizing valve
3 Pressure inlet valves
4 Impulse lines
5 Isolating valves
7 Outlet valves
10 Pressure source
13 Condensate reservoir
14 Jacket
Figure 9 7mC3_09.tif
Step C: Open the equalising valve (2)
Step D: Wait until the steam in the impulse line (4) and in the condensate reservoirs
(13) has condensed.
Step E: Open the pressure inlet valve (3A) and venting valve on the positive leg of
the transmitter slightly until no more air escapes.
Step F: Close the venting valve.
Step G: Open the venting valve on the negative leg of the transmitter slightly until
no more air escapes.
Step H: Close pressure inlet valve (3 A).
Step I: Open the pressure inlet valve (3B) slightly until no more air escapes.
Step J: Close the venting valve on the negative leg of the transmitter.
Step K: Open the pressure inlet valve (3 A) lA a rotation.
Step L: Check the zero point (4 mA) against start of scale (0) and correct if
necessary.
Step M: Close the equalising valve (2).
Step N: Open the pressure inlet valves (3A and 3B) fully.

INDUSTRIES
Operation of the transmitter
5.1 General
The differential pressure and flow transmitter is adjusted in the field by three input
keys, located on the outside of the instrument, with which the start of scale and full
scale values are set or adjusted. By means of the digital indicator (optional)
additional parameters can be adjusted. The input keys can be accessed, by undoing
the two screws holding the protective cover in place, which can then be moved out
of the way.
Transmitter controls and displays

3 4 5
—SPAN—r
IS J
g
1)
! M t I
' ZERO—' j
Symbols for
input keys
1 Digital display
2 Connecting plug
for digital display
3 Mode key
4 Increment key
5 Decrement key
Figure 10 7mfi33 10.tif
The functions listed in Table 1 can be selected using the "M" key. When pressing
the "M" key (Mode) 2 appears in the bottom left corner on the LCD display. Every
additional key press increases the mode by one. The parameters, the current value,
or the unit of pressure can be modified using the f and i keys. In case of error
situations "Error" is displayed on the display, (see section 5.2.7). It generally
applies that:
• The transmitter changes to function "Measured value", if mode 14 is passed by
pressing the "M" key or if 2 minutes elapse without a key being pressed. In case
of the 2 minutes being passed the setting is automatically saved.
• The key lock must be released for keyboard operation.
• Numerical values are always set from the least significant digit still displayed. In
the case of an overflow in the key repetition mode it switches to the next
significant digit and only this continues to be counted. This procedure serves for
fast rough setting over a wide numeric range. For fine setting the desired key ( t

•
• ••
• • • t

INDUSTRIES
or \) have to be released and pressed again. Exceeding of the upper and lower
measured value limits are shown on the display with the signs T or X.
If the input pressure is displayed, selected in mode 13 (see section 5.2.10), and
the square rooting characteristic in mode 11 (see section 5.2.9) the differential
pressure corresponding to the flow and additionally the sign "V" is displayed on
the display.
Functions of the dp-transmitter,ty|ie SI^RANS JP 7l«IF4433 ; rl :;

Key function
Function Mode » Display, explanation Section
t tand>P
Output current in mA or % or input pressure in unit
Measured value 5.2.10
of pressure
"Error", if the transmitter is disturbed. Moving text
Error display 5.2.7
indicating reason for disturbance
Current Current Set to
Start of scale 2 Output current in mA 5.2.2
greater smaller 4mA
Current Current Set to
Full scale 3 Output current in mA 5.2.2
greater smaller 20 mA
Damping Damping Time constant T63 in seconds
Electrical damping 4 5.2.3
greater smaller Parameter range: 0.0 to 100.0
Start of scale Pressure Pressure Set to start
5 Start of scale in selected unit of pressure 5.2.4
"blind setting" greater smaller of scale 0
Set to upper
Full scale Pressure Pressure
6 measuring Full scale in selected unit of pressure 5.2.4
"blind setting" greater smaller
limit
Zero adjustment
Vent transmitter (start of scale remains unaffected).
(position 7 -- -- Execute 5.2.5
Measuring value in unit of pressure
correction)^
Constant output current in mA
Current Current
Current transmitter 8 Switch on 3.6 - 4.0 -12.0 - 20.0 - 22.8 5.2.6
greater smaller
Switch off by "M" key
Output current in Change between the Selected output current
9 -- 5.2.7
the event of an error two values Possible: fault current limits set by user
"O" = none
"LA" = all disabled
"LO" = all disabled except start of scale
Keys and/or Change between the
10 -- "LS" = all disabled except start of scale and full 5.2.8
function disable five functions
scale
"L" = write protection, operation by HART® not
possible
"Lin" = liniar
"SrLin" = square rooting
Change between the
Characteristic 11 -- (linear up to application point) 5.2.9
three functions
"SroFF" = square rooting
(switched off up to application point)
Application point of
the square rooting 12 Greater Smaller -- Parameter range 5 to 15% flow 5.2.9
characteristic
Measured value Select from three Unit of pressure (input value) or output current in
13 5.2.10
display possibilities mAor%
Unit of pressure 14 Change Technical units of pressure 5.2.11
0
Change mode by pressing the "M" key.
2)
The start of scale is in a vacuum in absolute pressure transmitters. The zero adjustment in ventilated transmitters leads to mis-adjustments.
Table 1

INDUSTRIES
5.2 Operation with LCD display
5.2.1 General
• Please note that the input keys might be disabled. To cancel a set keyboard
disable press the "M" key for 5 seconds.
Step A: Undo the two screws holding the protective cover in place, which can then
be moved out of the way.
Step B: On completion of calibration replace the protective cover and tighten both
screws.
5.2.2 Set/adjust start of scale and full scale

The start of scale and full scale can be set or adjusted with the input keys. Modes 2
and 3 (see Table 1) are available for this. This allows implementation of rising or
falling characteristics.
Setting (theoretical relationship)
In setting, a desired start of scale and/or a desired full scale are assigned to the
standard current values (4 mA/20 mA). Pre-requirements: two reference pressures
(pri, Ptf) provided by the process or generated by a pressure transmitter.
Note: The measuring span is not changed when setting the start of scale. By
setting the full scale the start of scale remains unchanged. Therefore the
start of scale should be set first and then the full scale.
The relationship between the measured pressure and the generated output current is
linear. Please note that this does not apply if square rooting characteristic is selected.
In case of linear relationship the output current can be calculated with the following
equation shown in Figure 11:
Equation for calculation of current output .
I = output current
p = pressure
MA=start of scale
ME = full scale
Example
Given a transmitter with a measuring span of 0 to 16 bar. Set to a measuring span of
2 to 14 bar.
Step A: Apply 2 bar process pressure. Set the device to mode 2 with the "M" key.
The display shows the set mode at the bottom left. Set the start of scale by
pressing the t and -I keys on the value for about 2 seconds. An output
current of 4 mA is then generated at 2 bar input pressure.

INDUSTRIES
Step B: Apply 14 bar process pressure. Set the device to mode 3 with the "M" key.
The full scale is set by pressing the t and I keys on the value for about 2
seconds. An output current of 20 mA is then generated at 14 bar input
pressure.
Step C: The output current for any input pressure can be calculated with the
specified equation shown in Figure 11.
Adjusting (theoretical relationship)
When adjusting, the start of scale and/or the full scale can be assigned to any desired
current value using one reference pressure. This function is particularly suitable if
the pressures necessary for start of scale and full scale are unavailable.
Requirements: applied pressure (reference pressure) and the set start of scale and full
scale are known. Please note that after adjusting, the measuring range specified on
the measuring point plate may no longer match Ihe setting.
Using the following equation shown in Figure 12 the current that should be adjusted
for the desired start of scale and full scale can be calculated.
Equation for calculation of current (set the start of scale and full scale)
currant to be
set at MA „ „
current to be
Bet at M E ™ •i6mA+4rnA
ME MA
n«if nom
I = output currant
p ^ = applied reference pressure ^ = oW start of scale
ME n o m - new fill seals
MA new start of scale
11
To calculate the output currents when setlng start of w a l e and full scale, the reference pressure must
be selected so that a value between 4 and 2 0 mA Is obtained for the current.
Figure 12 7mf33_13.tif
Example
Given a transmitter with a measuring span of 0 to 16 bar. Adjust to a measuring span
of 2 to 14 bar. A reference pressure of 11 bar is available.
Step A: Set the device to mode 2 with the "M" key. Using the equation from Figure
12 first calculate the current that should be adjusted for the desired start of
scale (2 bar) at the applied reference pressure and then adjust it with the t
and I keys (13 mA in this example).
Step B: Set the device to mode 3 with the "M" key. Using the equation from Figure
12 calculate the current that should be adjusted for the desired full scale (14
bar) at the applied reference pressure and then adjust it with the T and -I
keys (16 mA in this example).

INDUSTRIES
Set start of scale and full scale (practical application with actual pressures
available)
The device sets the output current for the start of scale to 4 mA and the full scale to
20 mA when the input keys are pressed according to the following instructions.
The start of scale is set by:
Step A: Apply the corresponding pressure.
Step B: Select mode 2 using the "M" key.
Step C: Set the start of scale to 4 mA with the t and -I keys.
Step D: Save with "M".

The full scale is set by:
Step E: Apply the corresponding pressure.
Step F: Select mode 3 using the "M" key.
Step G: Set the full scale to 20 mA with the t and -i keys.
Step H: Save with "M".
Set start of scale and full scale (practical application with reference pressure
available)
If the output current is not set but adjusted continuously, the currents must be
calculated so they can be adjusted mathematically. It is possible to make an
adjustment for the start of scale, the full scale, or both values one after the other.
The start of scale is adjusted by:
Step A: Apply the reference pressure.
Step C: Adjust the output current for the start of scale with the T and 4- keys.

The full scale is adjusted by:
Step E: Apply the reference pressure.
Step F: Select mode 3 using the "M" key.
Step G: Adjust the output current for the full scale with the t and 4- keys.
Step H: Save with "M".
5.2.3 Electric damping

The time constant of the electric damping can be set in steps of 0.1 second between
0 and 100 seconds with the input keyboard. This damping acts additionally to the
device-internal basic damping.
The electric damping is set by:

••• ••

INDUSTRIES
Step A: Select mode 4 using the "M" key.
Step B: Set the desired damping with the T and 4- keys.
Step C: Save with "M".
5.2.4 Blind setting of start of scale and full scale

In modes 5 and 6 the start of scale and full scale can be set/adjusted with the input
keys and without applying pressure. It is also possible to change between rising and
falling characteristics.
Theoretical relationship
First select the desired physical unit. The two pressure values can then be
set/adjusted with the f and -I keys and saved in the device. These theoretical
pressure values are assigned to the standard current values 4 mA and 20 mA.
The relationship between the measured pressure and the generated output current is
linear. Please note that this does not apply if square rooting characteristic is selected.
Example
Given a transmitter with a measuring span of 0 to 16 bar. Adjust it to a measuring
span of 2 to 14 bar without applying pressure.
Step A: Set the device to mode 5 with the "M" key. Set the start of scale to 2 bar by
pressing the t or i key. If 2 bar input pressure are applied later, an output
current of 4 mA is generated.
Step B: Set the device to mode 6 with the "M" key. Set the full scale to 14 bar by
pressing the t or -I- key. If 14 bar input pressure are applied later, an output
current of 20 mA is generated.
Set start of scale and full scale, blind (practical application)
The device sets the start of scale to the lower and the full scale to the upper sensor
limit when the keys are operated as follows:
The start of scale (blind) is set by:
Step B: Press the t and 4- keys simultaneously and hold for 2 seconds. The start of
scale is set to the lower sensor limit.
The full scale (blind) is set by:
Step C: Select mode 6 using the "M" key.
Step D: Press the t and -I keys simultaneously and hold for 2 seconds. The full
scale is set to the upper sensor limit.
Adjust start of scale and full scale, blind (practical application)
If the pressures for the start of scale and full scale are not to be set but adjusted
continuously, the keys should be operated as follows:
The start of scale (blind) is adjusted by:

INDUSTRIES
Step B: Adjust the pressure value of the start of scale with the t or 4- keys.

The full scale (blind) is adjusted by:
Step E: Adjust the pressure value of the full scale with the t or I keys.
Step F: Save with "M".
5.2.5 Zero adjustment (position correction)

The zero error resulting from the installation position can be corrected with a zero
adjustment. To do this, the device must be ventilated to correct the existing offset so
that the value 0 bar (or other unit of pressure) appears in the display. The setting of
the start of scale and full scale remain the same.
The zero adjustment is set by:
Step A: Vent the transmitter.
Step C: Set zero with the t and -I keys.
5.2.6 Current transmitter

The transmitter can be switched to constant current mode with the "M" key. In this
case the current no longer corresponds to the process variable. The following output
currents can be set independently of the input pressure:
— 3.6 mA - 4.0 mA - 12.0 mA - 20.0 mA - 22.8 mA
The current transmitter function can be cancelled again with the "M" key.
The constant current is set by:
Step B: Activate the constant current mode by pressing the t and ^ keys
Step C: Activate the constant current level by pressing the T or -I key.
Step D: Turn off the constant current mode with the "M" key.
Step E: Exit the constant current mode with the "M" key.
5.2.7 Failure current

In mode 9 it is possible to select whether the upper or lower fault current should be
the output in the event of a fault or an alarm. The current can be set to 3.6 mA or
22.8 mA. The default is the lower fault current.
The fault current is set by:

INDUSTRIES
Step B: Select the fault current with the t or 4 key.
5.2.8 Key and/or function disable

In mode 10 it is possible to disable several functions which are generally possible
with keyboard operation. In addition a write protection to protect the saved
parameters can be activated. The following settings are possible:
"0" no disabling.
"LA" input keys disabled, operation via HART® possible.
"LO" input keys disabled, only start of scale can be set. Operation via HART®
possible.
"LS" input keys partly disabled, only start of scale and full scale can be set.
Operation via HART® possible.
"L" write protection, operation via HART® not possible.
A set keyboard disable (LA, LO, LS) or a write protection for HART® (L) can be
cancelled with the input keys. To do this, press the "M" key for 5 seconds.
Note: If the "LO" or "LS" disable is selected, it is recommended to select the

measured value display "Current" in mA or % first in mode 13.
Otherwise a change in the output variable is not detected when pressing
the T and 4- keys.
The key/function disable is set by:
Step B: Select the disable mode with the t or -I key.
Step C: Save the disable mode with the "M" key.
Note: When delivered with a blanking cover, the disable mode "LS" is active,
i.e. only zero and span can be changed. If the device permanently is
operated with a blanking cover, make sure that the disable mode "LS"
remains set.
5.2.9 Flow measurement

The characteristic of the output current can be selected as:
• Linear (proportional to the differential pressure), or
• Square rooting (proportional to the flow)
Below the application point of the square rooting characteristic the output current
can either be output linearly or switched off. When "SrLin" is selected the output

INDUSTRIES
current is linear up to the application point (see Figure 13 a) and when "SroFF" is
selected the output current is switched off up to the application point. The
application point can be set between 5% to 15% of the flow.
The characteristic is set by:
Step B: Select the characteristic type with the t or I key.

The root application point is set by:
Step E: Select the application point between 5% and 15% with the t or X key.
Step F: Save with "M".
Note: Mode 12 cannot be selected when the "linear" measuring mode 11 is set.
If the input pressure is selected as a display in mode 13 and square
rooting characteristic in mode 11, the differential pressure
corresponding to the flow and root sign are displayed.
Transition point of square rooting characteristic
0 1 2 3 4
a: linear below transition point
; 20 40 60 SO 100
pressure [%]
0 1 2 3 4
b: cut-off below transition point
Figure 13 7mf33 ll.tif

INDUSTRIES
5.2.10 Measured value display

In mode 13 one of three display types can be set with the input keys.
• Display in mA.
• Display in % (of the set measuring range).
• Display in a unit of pressure (selectable in mode 14).
The unit type is set by:
Step B: Select the type unit with the t or 4- keys.
5.2.11 Selection of unit of pressure

In mode 14 it is possible to select a desired unit of pressure for the display from a
list with the input keys. The following unit of pressure can be chosen:
Bar, mbar, mm H2CP, in HÔ^, ft H2O*), mm Hg, in Hg, psi, Pa, kPa, Mpa, g/cm2,
kg/cm2, Torr, ATM, in WC, mm WC.
^ Reference temperature 20°C.
The unit of pressure is set by:
Step B: Select the unit of pressure with the t or I key.

If the display capacity of the digital display is exceeded, "9.9.9.9.9" appears in the
display. Please note that in the measuring mode the selected unit is only visible in
the display if a unit of pressure display is selected in mode 13. Otherwise "mA" or
"%" is displayed.
5.3 Operation without LCD display
5.3.1 Setting start of scale and full scale without LCD display
• Please note that the input keys might be disabled. To cancel a set keyboard
disable press the "M" key for 5 seconds.
Step A: Undo the two screws holding the protective cover in place, which can then
be moved out of the way.
Set start of scale (4 mA) and full scale (20 mA)
Assuming the input keys are pressed as described below, the transmitter sets the start
of scale to 4 mA and the full scale to 20 mA. An ammeter is not required.
Start of scale
Step A: Apply a differential pressure corresponding to the start of scale to the
transmitter.

INDUSTRIES
Step B: Press the T and •!• keys simultaneously for about 2 seconds.
Full scale
Step A: Apply a differential pressure corresponding to the full scale to the
transmitter.
Step B: Press all three input keys, making sure that the "M" key is pressed first,
hold it, and press both the other keys ( t and -i).
Calibrate start of scale and full scale
If the output current is not to be set but freely adjusted continuously, the currents
must be calculated for mathematical adjustment. It is possible to make an adjustment
for the start of scale, the full scale, or both values one after the other.
Warning: It is forbidden to screw off the transmitter cover when working in

hazardous locations and using transmitters conforming to protection
type "Flame-proof enclosure" (Explosion-proof).
Step A: Clean the transmitter to prevent the ingress of dirt.
Step B: Unscrew the cover from the electrical connection box.
Step C: Connect a DC meter to the test plug (see Figure 5).
Warning: For intrinsic safe current circuits only certified current meters are
permitted.
Start of scale
Step A: Apply a differential pressure corresponding to the start of scale to the
transmitter.
Step B: Set the output current for start of scale using the T and 4- keys.
Step C: The set output current is saved automatically when the key is released.
Full scale
Step A: Apply a differential pressure corresponding to the full scale to the
transmitter.
Step B: Set the output current for full scale using the "M" key and the t key or the
"M" key and the 4- key. Always press the "M" key first, hold it, and press
either the 1* or the -i key.
Step C: The set output current is saved automatically when the key is released.

INDUSTRIES
Maintenance
The transmitter requires no maintenance. However, the start of scale value should be
checked occasionally.
If an error occurs:
• the output current is set to 22.8 mA or 3.6 mA, depending on the selection (see
section 5.2.7)
• using SIPROM P an appropriate message is displayed in the "Measured values"
field
• "Error" is displayed on the LCD display

INDUSTRIES
Table of contents
Control valves, type 470/471
General 1
Operation 2
Maintenance 3
Pneumatic actuator, type DP
General 1
Reversal of the actuator action 2
Manual operation device 3
Maintenance 4
Positioner, SIPART PS2 6DR5000
General 1
Mechanic connection of the positioner 2
Electric connection of the positioner 3
Pneumatic connection 4
Commissioning 5
Diagnosis 6
Service and maintenance 7

AALBORG CONTROL VALVES, TYPE 470/471 OM6010#02.0
INDUSTRIES

General
This type of control valve is suited to regulate fluids, gases and steams. The valve
plug is normally a parabolic plug, but can also be supplied in a perforated design.
Both types of plugs can have either linear or equal percentage flow characteristic.
The flow direction for parabolic plugs is always against the closing direction.
However, with perforated plugs for steam and gases, it is in the closing direction. If
a valve with a perforated plug is operated by means of a pneumatic actuator with the
flow in the closing direction, the pneumatic actuator should have a stronger thrust
force. This is necessary to prevent thumping near to the closing position.
All control valves can be fitted alternately with manual-, pneumatic-, electric- or
hydraulic operation devices.
Illustration of control valves type 470 and 471
Control valve, type 470 Control valve, type 471
Figure 1 vaI47x.cdr

INDUSTRIES
Part Designation Part Designation Part Designation

Body Gland flange 15.1 Studs
Seat ring 7.1 Screw joint 17 Hexagon nuts
Mounting bonnet Spindle guiding 17.1 Hexagon nuts
3.1 Mounting bonnet 10 Stuffing box 19 Spring-type straight pin
Guiding bush 10.1 Stuffing-box packing 21 Set-pin
Plug 14 Gasket 25 Bellow housing
Spindle 14.1 Gasket 26 Bellow unit
6.1 Spindle 15 Studs
Table 1
Operation
2.1 Fitting instructions

The valve should be inserted so that the spindle has a vertical position together with
the actuator. The valve can also be tilted to a maximum horizontal position if the
installation point does not allow any better condition.
To guarantee a disturbance free function of the control valve, the inlet and outlet
stretches of the piping should be of straight piping length (min. two times the pipe
diameter by inlet and six times by outlet). The piping should be rinsed to clear out
any pollution, welding beads, rust, etc. before inserting the control valves. A strainer
should be fitted in front of the control valve to catch the remaining particles. Bolts
should be tightened after taking into operation.
The flow direction is signalled by an arrow on the valve body. The valves should be
insulated against high temperatures to guard the actuator.
2.2 Actuator assembly
The control valves are normally delivered with actuators already fitted. For
alternations or maintenance of actuator, the assembly should occur in accordance
with the operation instructions for the actuator.
2.3 Setting into operation

When the piping system is filled, the spindle sealing should be checked for leakage
and, if necessary, tightened. A PTFE-V-ring unit does not require any tightening as
the spring tension maintains the necessary force.
The bolts must be tightened gradually in steps, diametrically in pairs, but not tighter
than it is necessary for the sealing. Flange connection bolts should never be loosened
or tightened when the valve is under temperature or pressure even if a leakage may
arise.
For actuators please see to the appropriate actuator operation instructions.
, Language UK Page 2/5

INDUSTRIES
Maintenance
Before any maintenance of the control valve is carried out, the piping system must
be shut off and pressure free.
3.1 Exchange of the stuffing-box packing
A leak stuffing-box packing should initially be carefully tightened to stop the

leakage. If this does not help, a new layer should be inserted, or the complete
packing should be replaced.
3.1.1 Additional packing layer
Step A: Open the valve fully and unscrew the hexagon nuts (17).
Step B: Lift the gland flange (7) and the spindle guiding (8) upwards.
Step C: Insert adequate quantity of packing rings (split ring-displacement, splitting

at 180° to avoid overlapping).
Step D: Fix the hexagon nuts (17) properly.
3.1.2 Exchange
Step A: Drive the actuator into middle position and dismantle the actuator.
Step B: Unscrew the hexagon nuts (17) from the studs (15).
Step C: Remove the gland flange (7), the spindle guiding (8) and the old stuffing
box (10) and clean the packing compartment.
Step D: Clean the valve spindle and check for damage and if necessary replace. If
the damaged spindle is not replaced, the new packing will leak after a short
period.
StepE: Insert the new packing rings (split ring-displacement, splitting at 180° to
avoid overlapping).
Step F: Fix the hexagon nuts (17) properly.
Note: Strenuous tightening will prevent leakage, but will also have a brake
effect on the spindle which aggravates the movement of the spindle.
3.2 Exchange of a PTFE-V-ring sealing unit
A PTFE-V-ring unit is spring loaded and has enough set pressure to ensure a good
seal even by low operation pressures. It is replaced as mentioned above.
The PTFE-V-ring sealing unit should be lubricated before it is inserted. The sealing
lips must face against the pressure direction.

INDUSTRIES
Note: Special care should be given to the spindle surface. Rough surfaces wear
the sealing lips enormously and can be due to failure of the packing unit.
3.3 Exchange of the bellow unit
Step B: Unscrew the screw joint (7.1).
Step C: Unscrew the hexagon nuts (17) and remove the bellow housing (25).
Dismantle the plug as described in the next section.
Step D: Unscrew the hexagon nuts (17.1) and dismantle the mounting bonnet (3.1).
Step E: The bellow unit (26) is removed from the bellow housing (25).
Step F: Replace the two gaskets (14.1) and the gasket (14).
Step G: When the bellow unit (26) is replaced, the proper position of the anti-
twisting device must be observed.
Step H: The set pins (21) have to drive within the slots of the anti-twisting device.
Check for friction-free movement.
Step I: Replace mounting bonnet (3.1) and screw down the hexagon nuts (17.1)
crosswise.
3.4 Exchange of the plug-spindle unit
Step B: Unscrew the gland flange (7).
3.4.2 Control valve type 470
Step A: Unscrew the hexagon nuts (17) and dismantle the mounting bonnet (3).
Step B: Pull out the plug with the spindle and exchange this unit.
Step C: Remove the spring-type straight pin (19) and unscrew the spindle (6).
Step D: Replace the old parts and assemble it.
Step E: Drill a hole through the plug shaft and insert a new pin.
Step F: Replace the gasket (14) and assemble the mounting bonnet (3).
Step G: Tighten the nuts (17) evenly, crosswise.

INDUSTRIES
Step A: Unscrew the hexagon nuts (17) and dismantle the bellow housing (25) with
plug (5).
Step B: Drive the spindle in the bottom position and remove the spring-type straight
pin (19).
Step C: Unscrew the plug.
Step D: Screw a new plug at the spindle and drill through the shaft. Drive the
spring-type straight pin (19) into the hole.
Step E: Replace the gasket (14).
Step F: Assemble the bellow housing (25) with plug (5) together with the body (1)
and fix it by screwing the hexagon nuts (17) crosswise.
The spindle can only be completely replaced together with the bellow.
3.5 Changing the seat ring

The seat ring is screwed into the valve body. The seat ring can be obtained after
removing the bonnet and can then be refinished or replaced as required.
Step A: Clean and lubricate the thread and conical sealing surface before insertion.

»* • • I
*• • • I
AALBORG PNEUMATIC ACTUATOR, TYPE DP OM5520#01.0

INDUSTRIES
Pneumatic actuator, type dp

1 General
The pneumatic linear actuator is designed to be mounted directly on a control valve.
The pneumatic actuator converts positioning command signals into stem thrust
forces. The required back setting force is produced by the spring arrangement inside
the actuator. The rolling-diaphragm produces linear spindle movements over the
complete stroke.
The preferred mounting position is with the actuator and valve spindle in vertical
position.
The mode of operation for the actuator depends on how the springs are inserted
when the actuator is assembled. Even when the actuator is fitted in a piping system,
the mode of operation can be changed.
The pneumatic actuator can be operated as:
• Spring opens valve/air closes valve operation mode
• Air opens valve/spring closes valve operation mode
Illustration of a pneumatic actuator
Operation mode:
Spring opens - Air closes Air opens - Spring closes
Figure 1 dpactuat.tif

INDUSTRIES
Table 1 below shows a list of the position numbers in Figure 1 and Figure 2.
SNti
Part Denomination Part Denomination
Rolling diaphragm 15 Stroke indicator
Diaphragm housing 16 Hexagon nut
Diaphragm lid 17 Mounting rod
Diaphragm plate 18 Bellow
Spindle 19 Collar nut
Spring 21 O-ring (spindle)
10 Coupling flange 22 O-ring (bushing)
11 Guide flange 26 Slotted guide bearing
12 Rotation guard 27 Spindle guide
13 Socket screw 30 Hexagon nut
14 Threaded bushing 31 Hexagon nut
Table 1
1.1 Pneumatic connection
The air supply should be dry and at a low service temperature. A heat-guard should
be installed to prevent high service temperature.
The pneumatic supply tube must be connected to the diaphragm housing (2) by
operation mode "spring closes" and to the diaphragm lid (3) by operation mode
"spring opens".
By air failure the stem automatically returns into the original position caused by the
inserted springs.
Warning: The actuator diaphragm may only be pressure loaded on the side
opposite of the springs. The vent hole in the other connection must
remain open.
1.2 Assembly of the actuator on the valve
The assembling of the actuator on the valve is shown in Figure 2. For both "spring
closes" and "spring opens" operation modes the following assembling procedure
should be followed:
Step A: If the actuator and the valve are separated, press the plug and spindle unit
(5) into the closed position for operation mode "spring closes" or into the
open position for operation mode "spring opens".
Warning: Make sure that the plug does not turn while pressing on the seat
during assembly.
Step B: Loosen the socket screws (13), remove the rotation guard (12) and the guide
flange (11). The threaded bushing (14) is now free.

INDUSTRIES
Step C: Turn the locking hexagon nut (30) onto the valve spindle. Place the rotation
guard (12) and the guide flange (11) over the valve spindle and then turn
the threaded bushing (14) onto the valve spindle.
Step D: Check the actuator for proper operation mode and connect the pneumatic
supply to the connection piece in the diaphragm housing (2) for operation
mode "spring closes" or in the diaphragm lid (3) for operation mode "spring
opens".
Step E: Drive the actuator into approximately mid-stroke position over the air
supply and mount it onto the valve (read the value from the pressure gauge
- middle of the spring range).
Step F: Tighten the hexagon nuts (31).
Assembly of the actuator on the valve
Operation mode: Spring closes valve - Air opens valve Operation mode: Spring opens valve - Air closes valve
Pneumatic connection
Figure 2 dpactspr.tif

INDUSTRIES
1.3 Adjustment of the starting pressure signal
Step A: Drive the actuator to the required spring-starting point over the air supply.
Step B: Turn the threaded bushing (14) up against the coupling flange (10) so that
the collar enters into the flange and presses against it. Make sure that the
plug is lying on the valve seat.
Attention: Note that sufficient thread of the valve spindle is inside the threaded
bushing (14). If not, turn the coupling flange (10) downwards from
the actuator spindle and pull the threaded bushing (14) against it.
Step C: For operation mode: "spring closes":
— Attach the guide flange (11) and the rotation guard (12) with the socket screws
(13) to the coupling flange (10).
— Check that the plug lifts off the seat at the required spring starting point.
Step D: For operation mode: "spring opens":
— Check that the plug leaves the end position at the required spring starting point,
and finishes the valve stroke at the spring-range end value.
— The plug must then also press on the valve seat.
Step E: After the test operation set the stroke indicators (15) into the end positions.
Step F: Lock the hexagon nuts (16 + 30) at the valve mid-stroke.
Step G: Do not turn the plug on the seat when it is under force.
Reversal of the actuator action

The actuator action can be reversed even when the valve is installed in a piping
system. The position numbers mentioned in this section refer to Figure 1 and Figure
2.
Step A: Drive the actuator into approximately mid-stroke position with the air
supply.
StepB: Loosen and remove the socket screws (13) from the coupling flange (10)
and drop the rotation guard (12) over the valve spindle.
Step C: Remove the hexagon nuts (31) from the actuator and lift off the valve.
Step D: Reduce the air supply until the chamber is pressure free.

INDUSTRIES
Step E: Loosen and remove the diaphragm lid screws.
Step F: Remove the diaphragm lid (3).
Warning: The actuators DP 32 and DP 33 have two longer screws when fitted
with stronger spring ranges. The actuator DP 34 has four. These
screws should be the last screws to be loosened, and must be
loosened evenly to reduce the high spring tension.
Step G: For reversal from "spring closes" into "spring opens":
— Remove the springs (7) and the diaphragm plate (4) with the diaphragm (1) and
the spindle (5).
— Loosen and remove the seal lock nut (19) and remove the spindle (5). Turn over
the diaphragm plate (4) with the diaphragm (1) and the diaphragm clamping
flange, and place it over the spindle (5).
— Tighten with the seal lock nut (19). Make sure that the spindle surface is not
damaged.
— Grease the spindle surface and the 0-ring.
— Place the diaphragm plate (4) with the diaphragm (1) into the diaphragm lid (3).
— Arrange the springs (7) onto the moulds pressed into the diaphragm plate (4).
— Place the diaphragm housing with the spindle sealing unit over the spindle, and
screw it together. Make sure that the springs stay properly arranged.
— Turn the hexagon nut (16) and the coupling flange (10) onto the spindle (5).
— Mount the actuator as described previously, and connect the air supply tube to
the diaphragm lid (3).
Step H: For reversal from "spring opens" into "spring closes":
— Remove the diaphragm (1) and the diaphragm plate (4) with the spindle (5) and
the springs (7).
— Loosen and remove the seal lock nut (19) from the spindle (5). Turn over the
diaphragm plate (4) with the diaphragm (1) and the diaphragm clamping flange,
and place it on the spindle (5).
damaged.
— Stick the diaphragm plate (4) with the diaphragm (1) and the spindle (5) into the
diaphragm housing (2).

INDUSTRIES
Place the diaphragm lid (3) on the top, and screw it together. Make sure that the
springs (7) stay properly arranged.
the diaphragm housing (2).
Manual operation device

Some actuators are fitted with a manual operation device. The device is connected to
the actuator by means of a new diaphragm lid, a spindle extension with a USIT-ring
and a spindle sealing unit.
The manual operation device is equipped with stroke indicators. The stroke
indicators of both the actuator and the manual operation device must be in the same
end positions when the actuator is pressure free.
The manual operation device must be set into neutral position when the actuator is
running automatically.
The locking device of the manual operation device must be unlocked before
operating.
The locking device prevents an unwanted disarrangement of the setting during
operation, e.g. due to vibration, etc.
Maintenance
The pneumatic actuator is maintenance free. To maintain a disturbance free
operation, the air should be supplied by an air-supply station.
The diaphragm, spindle sealing unit and springs are wear parts and should be
replaced when necessary.
4.1 Exchange of spindle sealing
When the spindle sealing is changed, the slotted PTFE-guide bearing and the 0-ring
should be replaced. The spindle surface must be clean and undamaged. Before the
actuator is assembled, the spindle unit and the spindle must be greased.

AALBORG POSITIONER, SIPART PS2 6DR5000 OM5510#05.1
INDUSTRIES

General
The following instruction is a general description of SIPART positioners and covers
the complete range in the PS2 6DR5000 series.
The electronic pneumatic positioner is used as the final control element of a
pneumatic linear actuator or a part-turn actuator (rotary movements). The positioner
converts a current output signal (4 to 20 mA) from a process controller or control
system to a set point value and into a corresponding movement. The positioner
changes the pressure in a pneumatic actuator chamber or cylinder until the position
corresponds to the set point value.
The positioner can be set up either as a single-action positioner or a double-action
positioner. The single-action positioner is mainly used together with a control valve.
The opposite movement for the control valve is supplied by means of springs. The
double-action positioner is mainly used to control an air damper via a pneumatic
cylinder (actuator). All movements of the pneumatic cylinder are supplied by the
positioner. An illustration of the function diagram for the positioner is shown in
Figure 1. The function diagram is shown with option modules.
Comparison of the set point and the actual value takes place electronically in a micro
controller. If the micro controller detects a deviation, it uses a 5-way switch
procedure to control the piezoelectric valves, which in turn regulate the flow of air
into the actuating chambers. When connected in a two-wire system, the SIPART
PS2 draws its power exclusively from the 4 to 20 mA set point signal.
The piezoelectric valve converts the command into a pneumatic positional
increment. The positioner outputs a continuous signal in the area where there is a
large control deviation (high-speed zone). In areas of moderate control deviation
(slow-speed zone) it outputs a sequence of pulses. No positioning signals are output
in the case of a small control deviation (adaptive or variable dead zone).
Commissioning (initialisation) is carried out automatically to a large extend. During
initialisation, the micro controller automatically determines the zero, full-scale
value, direction of action, and positioning speed of the actuator. It uses these to
determine the minimum pulse time and dead zone, thus optimising the control.
The positioner can also be operated manually by the pushbuttons and the LCD of the
SIPART PS2.
The installation of the positioner must be carried out in the following order:
• Mechanic connection
• Electric connection
• Pneumatic connection
• Commissioning

INDUSTRIES
Illustration of a function diagram
Supply air
J__J
1 Motherboard with microcontroller and input circuit

2 Control panel with LC-disptay and momentary action switch
3 Plezo-vatve unit, always built-in
4 Vaiue unit with double action positioner always built-in
5 ly-module for positioner SIPART PS2
6 Alarm module for three alarm outputs and one digital input
7 SIA-modute(Slotlnitiator-Alarm-module)
8 Spring-loaded pneumatic actuator (single action)
9 Spring-loaded pneumatic actuator (double action)
Figure 1 sips2_5a.tif
Mechanic connection of the positioner

Normally the positioner is pre-mounted on the actuator or cylinder. If not, follow the
installation guide lines below.
2.1 Mechanic connection to an actuator
Figure 2 shows the mechanic connection of the positioner to an actuator for a control
valve.
Step A: Mount clamping assembly (3) with hexagon socket cap screws (17) and
lock washers (16) on the actuator spindle.
Step B: Insert the pick-up bracket (2) into the recesses of the clamping assembly.
Set the necessary length and tighten the screws so that the pick-up bracket
can still be shifted.

AALBORG POSITIONER, S1PART PS2 6DR5000 OM5510#05.1
INDUSTRIES
Step C: Push the roll (5), spring (13), and guide washer (22) onto the pin (4).
StepD: Insert the pin in the lever (6) and assemble with nut (18), spring washer
(14), and U-washer (12).
Step E: The value of the stroke range specified on the actuator should be set or if
this does not exist as a scaling value, the next greatest scaling value should
be set. The centre of the pin must be in line with the scaling value. The
same value can be set later under parameter "3.YWAY" in commissioning
to display the way in [mm] after initialisation.
StepF: Assemble the hexagon socket cap screw (17), spring washer (16), washer
(12), and square nut (19) on the lever.
Step G: Push the pre-mounted lever onto the positioner axis up to the stop and fix
with the hexagon socket cap screw (17).
Step H: Fit the mounting bracket (1) with two hexagon head screws (9), lock
washer (10), and flat washer (11) on the rear of the positioner.
Step I: Selection of the row of holes depends on the width of the actuator yoke. The
roll (5) should engage in the pick-up bracket (2) as close as possible to the
spindle but may not touch the clamping assembly.
Step J: Hold the positioner with the mounting bracket on the actuator so that the pin
(4) is guided within the pick-up bracket (2).
Step K: Tighten the pick-up bracket.
Step L: Position the mounting parts according to the type of actuator.
— Actuator with ledge: hexagon head screw (8), flat washer (11), and lock washer
(10).
— Actuator with plane surface: four hexagon head screws (8), flat washer (11), and
lock washer (10).
— Actuator with columns: two U-bolts (7), four hexagon nuts (21) with flat washer
(11), and lock washer (10).
Step M: Secure the positioner onto the yoke using the previously positioned
mounting parts.
Note: Set the height of the positioner so that the horizontal lever position is
reached as close to the stroke centre as possible. The lever scale can be
used as orientation. It must be guaranteed that the horizontal lever
position is passed through within the stroke range.

INDUSTRIES
Mechanic connection of the positioner (linear actuator)
22
1) 2) 4
11
10
3)
Mounting on yoke
Mounting on yoke
•)•] with ledge with plane surface
Mounting on yoke
with columns
As required
Figure 2 sips2_5b.tif

INDUSTRIES
2.2 Mechanic connection to a pneumatic cylinder

The positioner is connected to a pneumatic cylinder by means of fixing bracket,
lever arm with Allen screw, extension arm, and roller.
The pneumatic piston is connected to a guide rail with an oblique angle via a
linkage. The guide rail moves together with the piston, and the roller/lever
connection senses the position of the piston. By operating both sides of the
pneumatic cylinder, the set point is reached. A spring inserted between the fixing
bracket and the lever arm secures that the roller is pressed down against the guide
rail.
2.3 Mechanic connection to a rotary actuator

Figure 3 shows the mechanic connection of the positioner to a rotary actuator.
Step A: Attach the mounting console (9, actuator specific) onto the rear of the
positioner and secure using the hexagon head screws (14) and lock washers
(15).
Step B: Adhere pointer (4.2) onto the mounting console in the centre of the centring
hole.
Step C: Push coupling wheel (2) onto the positioner axis, pull back by about 1 mm
and tighten the hexagon socket head screw (18) with the Allen key
provided.
Step D: Place the carrier (3) onto the end of the actuator and secure using Fillister
head screw (16) and washer (17).
Step E: Carefully place the positioner with mounting console onto the actuator such
that the pin of the coupling wheel engages in the driver.
Step F: Align the positioner/mounting console assembly in the centre of the actuator
and screw tight (screws are not included in the delivery, they are part of the
actuator mounting console).
Step G: Follow the start-up sequence as described later. Drive the actuator to the
end position and adhere the scale (4.1) onto the coupling wheel (2)
according to the direction of rotation and rotary actuator. The scale is self-
adhesive.

• • • • • • •

INDUSTRIES
Mechanic connection of the positioner (rotary actuator)
Figure 3 sips2_5c.tif

INDUSTRIES
Electric connection of the positioner

When the positioner is connected in a two-wire system, the positioner draws its
power exclusively from the 4 to 20 mA set point signal. Figure 4 indicates the input
circuits for the positioner.
View of the controls and connections
11 10 9
f Input: Supply air 7 SSIencer

2 Output: Actuating pressure Y1 8 Transmission ratio selector
3 Display 9 Adjusting wheel silp clutch
4 Output: Actuating pressure Y2 *S 10 Terminals options modules'
5 Operating keys 12 Dummy plug
S Resttlbtbr 13 •Semw-typfe cable gland:.
6.1 RestrJetorYl 14 TernilnaTptete on cover
6.2 ResWctorY2*) 15 ' Porglng-air swjtefi
Figure 4 sips2_5d.tif
Ensure that the air quality is suitable. Grease-free instrumental air with a solid
content < 30 urn and a pressure dew point 20 K below the lowest ambient
temperature must be supplied.
Warning: For reasons of safety, pneumatic power may only be supplied after
assembly when the positioner is switched to operating level "P
manual" operation with electrical signal applied.
4.1.1 Selection of P manual mode

Before pneumatic power is connected, the positioner must be in P manual mode.
The display must show "NOINIT" in the bottom line.

INDUSTRIES
4.1.2 Pneumatic connections

Figure 4 shows a view of the positioner controls and connections.
Step A: If required, connect a manometer block for supply air and actuating
pressure.
Step B: The silencer in the exhaust output can be removed if necessary.
Step C: Connect actuating pressure Yl and/or Y2 (Y2*5 is only used with double-
acting actuators) according to the desired safety position.
Step D: Connect the supply air (1). The pressure should be between 1.4 to 7 bar.
Note: In order for spring-loaded pneumatic actuators to be able to reliably

exploit the maximum possible actuating path, the supply pressure must
be sufficiently greater than the maximum required final pressure of the
actuator.
4.1.3 Safety position when the electric power supply fails

For a single-action actuator is Yl deaerated. For a double-action actuator is Yl
equal to the supply air pressure and Y2 is deaerated.
4.1.4 Restrictors
To increase the positioning times for fast actuators when necessary, the air flow can
be reduced with the restrictors Yl and Y2 (only for double-action valves). Turning
the restrictors in the clockwise direction reduces the air flow until it is shut off. To
set the restrictors it is recommended to first close them and then open them again
slowly (see initialisation process RUN 3).
4.1.5 Purging air switchover

The purging air changeover switch located above the pneumatic terminal block on
the valve manifold can be accessed when the housing is open. When the switch is in
position "IN" the interior of the housing is purged with very small quantities of
clean and dry instrument air. In position "OUT" the purging air is led directly out of
the instrument.
Commissioning
initialisation, the micro controller automatically determines the zero value, full-scale
value, direction of action and positioning speed of the actuator. It uses these to
determine the minimum pulse time and dead zone, hereby optimising the control.
SIPART PS2.
The commissioning of the positioner can be divided into the following steps:
• Preparation for initialisation
• Start the automatic initialisation procedure

*•••••*

INDUSTRIES
• Set additional parameters if required

• Select automatic mode
Figure 5 shows the possible operation modes for the positioner and gives an
overview of how to change between them. The levels are P-manual mode,
configuration and initialisation, manual mode, automatic mode, and diagnostic
display. From these modes it is possible to select operation mode, set operation
parameters, restore to factory setting, run an automatic initialisation, etc.
Operation levels
Mode Display
Figure 5 sips2_5e.tif
5.1 Preparation for initialisation
Step A: Check and set the gear transmission switch to the correct position. Figure 4
(position 8) indicates the location of the switch. For linear actuators the gear
transmission switch is set according to the stroke range as described in
Table 1 for the parameter "3.YWAY". For part-turn actuators 90° must be
selected.
Step B: Check that the pneumatic supply power (inlet air) is present. The operating
pressure should be at least one bar greater than is necessary for
closing/opening the valve during initialisation.

INDUSTRIES
Step C: Without initialisation the positioner is in "P manual mode" and "NOINIT"
flashes in the display. This level can also be reached by using "55.PRST"
function (see Table 1).
Step D: Check the free running of the mechanics in the whole actuating range by
moving the actuator with the keys "f" and " j " and driving to the respective
end position.
Step E: With linear actuators drive the actuator to horizontal lever position. The
display must indicate 48% to 52%. If necessary, correct the value by
adjusting the sliding clutch. After the check is completed, the actuator must
be approximately half way along its stroke. This is due to establishment of
the action direction during automatic initialisation.
5.2 Automatic initialisation
Figure 6 shows the configuration mode including the operation in this mode and
Table 1 shows the parameter/configuration list. Figure 7 shows the initialisation
process of the positioner. The initialisation process is stored in the microprocessor.
This means that an additional initialisation only is necessary if any parts of the unit
have been changed.
Note: The numerical values used in Figure 5, Figure 6, and Figure 7 are
examples.
Step A: Call the configuration mode by pressing the hand symbol key for longer
than 5 seconds.
Step B: Set the actuator type, linear or part-turn, in the menu item line "l.YFCT".
Step C: Switch to the second parameter by pressing the hand symbol key briefly.
Step D: Set the rated angle of rotation for feedback in the menu item line
"2.YAGL". It is vital that this value corresponds to the setting of the gear
transmission ratio selector (Figure 4, position 8), 33° or 90°.
Step E: Switch to the next parameter by pressing the hand symbol key briefly.
Step F: This parameter ("3.YWAY") is only set for linear actuators and if the total
stroke in mm should be displayed at the end of the initialisation phase. To
do this, select the same value in the display to which the carrier pin to the
scale on the lever is set to.
Step G: Switch to the following parameter by pressing the hand symbol key briefly.
Step H: Start the initialisation ("4.INITA") by pressing the " f key for longer than 5
seconds.

INDUSTRIES
Step I: During the initialisation phase "RUN1" to "RUN5" appear one after another
in the bottom of the display. Please note that the initialisation process may
last up to 15 minutes depending on the actuator.
Note: The ongoing initialisation can be aborted at any time by pressing the
hand symbol key. The previous settings are retained. All the parameters
are reset to the factory setting only after performing a preset
"55.PRST".
Step J: If problems occur, carry out the measures as described in the table "Possible
messages" shown in Figure 7.
Step K: The initialisation is completed when "FINSH" appears in the bottom of the
display.
Step L: When pressing the hand symbol key briefly the menu item line "4.INITA"
is displayed.
Step M: To exit the configuration operating mode, press the hand symbol key for
longer than 5 seconds. The software version is displayed after about 5
seconds. The instrument is in manual operation after releasing the key.
Step N: The positioner can be changed to automatic mode by pressing the " j " key
once as indicated in Figure 5.
Step O: The automatic mode is the normal mode. In this mode the positioner
compares the set point current with the current position and moves the
actuator until the control deviation reaches the dead zone.
Operation in the configuration mode
at the same time
at the same time
Figure 6 sips2_5f.tif

INDUSTRIES
Initialisation process
Automatic Initial start-up (starting with factory setting) Possible messages
Step Meaning Display Meaning Measures
Acknowledge message
Part-turn turn 90° using the hand syrrbol key
actuator 1 YFCT 2 YAGL P 324 Actuatordoes
RUN 1 not move Check restrictor (§ and open
linear WAY 33° Strt if necessary
actuator 1 YFCT 2 YAGL 3 YWAY P 32.4 Drive actuator to working range
ERROR using the up and down keys
Press tte up keyfor> S sec.
Strt Restart initialisation
Remaining steps are carried out automatical;/
Cra nge gearing (7)
Continue ushg up key

P 324 Directien of action is deteimired
D RUN 1 Or adjust sliding clutch up
P 884 Down tolerance
todsplay
4 dm IU band violated P 6.4
4.) P 924 Checking of travel and adjustment of
zero andstroke (from stop to stop) h diOlU
|O RUN 2
Deterrriretion and display of positioning time Then only
a, IP 824 down(dxx.x), up(uxx.x).Stopwiththedownkey Centime ushg the down key
|l~l RUN 3 Pressing t he up key ini'ates leakage measurement Ljnearactuator. set pick-up
Once the slipping lever hto ro rizontal position
P 32.4 SB dutch has been using thB up and down keys
Deternina Bon of mhimum r o e ment length MIDDL adjusted
D RUN 4 Continueushg hand symbol key
„p Optimisation of transient response
Initialisaion teimlnated success fuly

P 98.3
UP >
Up tolerance band
violated
Acknowled ge massage
using the hand symbol key
Set the next highest travel
ID RUN s
(travel Inmmfor linear actuatcrs) valueonthelaer
324
(angle ofrotation for part-turn actuators)
Restart initialise ion
ConBnueu shg hand symbol key
Additionally possible with rotary
actuators:
Adjust using ip and down keys
up to display:
P 92.8
S 90_95
Continue using hand symbol key
Acknowledge message
using the hand symbol key
P 19.8 Up/down span
Setthe na<t lowest travel
violated
valueontre lever
Restart initialisation
Adjust positioning time ushg

1.3 Actuatordoes resHctor(s)
NOZZL not move.
Positioning Continueushg the
time is possibl e up ordown key
1.8 to adjust
NOZZU
Figure 7 sips2_5g.cdr
5.3 Parameters
Table 1 shows the parameter list for the positioner. The parameter name is written in
plain text in the "menu line" column. The function of the parameter is described
briefly in the "Function column". In addition, the possible parameter values, the
physical unit and the factory setting of the parameters are shown.
After the initialisation process, the positioner can be configured to meet the
requirements of a specified task. The factory settings correspond to the requirements
for a typical application. This means that normally only a few parameters will need
to be changed.
The positioner can be installed and configured to fit linear and part-turn actuators
with reverse action. E.g. linear actuators with the set point in the falling direction or

INDUSTRIES
part-turn actuators for counter clockwise operation direction. In this case the
parameters "7.SDIR" and 38."YDIR" should be set to "FALL".
Parameter list
Function Parameter values Unit Factory setting Customer
Menu line
setting
turn (part-turn actuator)
WAY (linear actuator)
LWAY (linear actuator
without sine correction)
l.YFCT Type of actuator ncSt (part-turn actuator WAY
withNCS)
-ncSt (part-turn actuator
with NCS, inverted)
Rated angle of rotation for feedback 90°
2.YAGL0 (must correspond to gear ratio) Degrees 33°
33°
Stroke range (optional setting) OFF
5 , 1 0 , 15 ,20
When used, the value must correspond with (short lever 33°)
the set of the leverage ratio on ihe actuator
3.YWAY2) 25 , 30,35 mm OFF
Driver pin must be set to the value of the (short lever 90°)
actuator travel or, if this value is not scaled, 40,50,60,70,
to the next lager scale value 90,110,130
(long lever 90°)
4.INITA Initialisation (automatically) noini/no/###.#/Strt no
5.INITM Initialisation (manually) noini/###J/Strt no
0MA
6.SCUR Current range of set point JJÔrnA 4MA
4MA
g riSE
7.SDIR Set point direction f "î" riSE
FALL
8.SPRA Set point for start of split range 0.0 to 100.0 % 0.0
9.SPRE Set point for end of split range 0.0 to 100.0 % 0.0
Auto
10.TSUP Set point ramp up s 0
0 to 400
ll.TSDO Set point ramp down 0 to 400 s 0
Set point function
Linear Lin
12.SFCT Equal-percentage 1:25,1:33,1:50 1-25 ,1-33 ,1-50 Lin
Inverse equal-percentage 1:25,1:33,1:50 nl-25, nl-33 , nl-50
Freely adjustable FrEE
13.SL03) Set point turning point at 0% 0.0
14.SL1 5% 5.0
to to 0.0 to 100.0 % to
32.SL19 95% 95.0
33.SL20 100% 100.0
Auto
34.DEBA Dead zone of controller % Auto
0.1 to 10.0
35.YA Start of manipulated variable limiting 0.0 to 100.0 % 0.0
36.YE End of manipulated variable limiting 0.0 to 100.0 % 100.0
Standardisation of To mech. travel MPOS
37.YNRM MPOS
manipulated variable To flow FLOW
Direction of manipulated Rising riSE
38.YDIR variable for display Falling FALL riSE
Without no
Tight closing with Top only UP
39.YCLS manipulated variable Bottom only do no
Top and bottom uPdo

INDUSTRIES
Customer
Menu line Function Parameter values Unit Factory setting
setting
40.YCDO Value for tight closing, bottom 0.0 to 100.0 % 0.5
41.YCUP Value for tight closing, top 0.0 to 100.0 % 99.5
Function of B I 1 :
None OFF
Only message (NO/NC contact) on / -on
Block configuring (NO contact) bLocl
42.BIN14' Block configuring and manual (NO contact) bLoc2
OFF
Drive valve to pos. up (NO/NC contact) uP/-uP
Drive valve to pos. down (NO/NC contact) doWn/-doWn
Block movement (NO/NC contact) StoP / - StoP
Function of BI 2:
None OFF
4) Only message (NO/NC contact) on / -on
43.BIN2 OFF
Block movement (NO/NC contact) StoP / -StoP
Without oFF
., „ .. Al=min. A2=max. N,NA
44.AFCT5) Alarm function .. . . . OFF
Al=min. A2=min. N,N
Al=max. A2=max. NA.NA
45.A1 Response threshold of alarm 1 0.0 to 100.0 % 10.0
Function of alarm output
On fault 4
47.L1FCT6) Fault + not automatic 4nA 4
Fault + not automatic + BI 4nAb
("+" means logical OR operation)
Monitoring time for fault message Auto
48. h TIM s Auto
"control deviation" 0 to 100
Response threshold for fault message Auto
49.4LIM % Auto
"control deviation" 0.0 to 100.0
OFF
50.SSTRK Limit for stroke integral OFF
1 to 1.00E9
OFF
51.4DCHG Limit for direction change OFF
1 to 1.00E9
OFF
52.4 ZERO Limit for end stop monitoring, bottom % OFF
0.0 to 100.0
OFF
53. h OPEN Limit for end stop monitoring, top % OFF
0.0 to 100.0
OFF
54.hDEBA Limit for dead zone monitoring % OFF
0.0 to 100.0
Preset (factory setting)
"no" nothing activated no
"Strt" start of factory setting after pressing
55.PRST key for 5 sec. Strt
"oCAY" display following successful
factory setting oCAY
CAUTION: preset results in "NO INIT"
1}
If turn is selected it is not possible to set 33°.
2)
Parameter does not appear if 1.YFCT = turn has been selected.
3)
Turning points only appear with selection 12.SFCT = FrEE.
4
^ Alternatively "no" if initialisation has not yet been carried out
5)
NC contact means; action with opened switch or low level. NO contact means; action with closed switch or high level.
6)
Normal means: high level without fault. Inverted means: low level without fault.
Table 1

INDUSTRIES
Diagnosis
In the diagnostic mode the current operating data (such as number of strokes,
number of changes in direction, number of fault messages, etc.) can be displayed.
From the automatic or manual modes the diagnostic mode can be reached by
simultaneously pressing all three keys for at least 2 seconds.
Table 2 shows an overview of the displayable values. The diagnostic display has a
similar structure as the parameter menu displays. The respective next diagnostic
value can be selected with the hand symbol key. Certain values can be set to zero by
pressing the "f" key for at least 5 seconds. These are menu item line "1,2, 3, and 4".
Some diagnostic values may be greater than 99999. In this case the display switches
to exponential display.
No.: Abbreviation Meaning Displayable Unit

value
STRKS Number of strokes 0 to 4.29E9
CHDIR Changes of direction 0 to 4.29E9
4CNT Fault counter 0 to 4.29E9
A1CNT Alarm counter 1 0 to 4.29E9
HOURS Operating hours 0 to 4.29E9 Hours
WAY Determined actuating path 0 to 130 mm or'
TUP Travel time up 0 to 1000
TDOWN Travel time down 0 to 1000
10 LEAK Leakage 0.0 to 100.0
11 P0 Potentiometer value below stop (0%) 0.0 to 100.0
12 P100 Potentiometer value bottom stop (100%) 0.0 to 100.0
13 IMPUP Impulse length up 2 to 100 ms
14 IMPDN Impulse length down 2 to 100 ms
15 DBOP Dead zone up 0.1 to 100.0
16 DBDN Dead zone down 0.1 to 100.0
17 SSUP Short step zone up 0.1 to 100.0
18 SSDN Short step zone down 0.1 to 100.0
19 TEMP .Current temperature -45 to 85
20 TMIN Minimum temperature -45 to 85
21 TMAX Maximum temperature -45 to 85
22 Tl Number of operating hours in Temperature range 1 0 to 4.29E9 Hours
23 T2 Number of operating hours in Temperature range 2 0to4.29E9 Hours
24 T3 Number of operating hours in Temperature range 3 0 to 4.29E9 Hours
31 VENT1 Number of cycles pre-control valve 1 0to4.29E9
32 VENT2 Number of cycles pre-control valve 2 0to4.29E9
Store current values as "last maintenance"
33 STORE
Press the up key for at least 5 seconds (store)
Table 2

• •:• >• •• • •
• • • • •
94 9 • •

INDUSTRIES
Service and maintenance

The positioner is largely maintenance-free. The positioner is fitted with filters in the
pneumatic connection as protection against coarse particles of dirt. If the pneumatic
energy supply contains particles of dirt, the filters may be clog and impair the
function of the positioner. In this case the filters can be cleaned as follows:
Step A: Switch off the pneumatic power supply and remove the pipes.
Step B: Unscrew the cover.
Step C: Remove the three screws from the pneumatic connector strip.
Step D: Remove the filters and O-rings behind the connector strip.
Step E: Clean the filters (e.g. with compressed air).

Step F: After cleaning first insert the filters in the recesses in the housing and then
place the O-rings on the filters.
Step G: Align the pneumatic connector strip on the two lugs and screw tight with
the three self-tapping screws.
Note: Make sure that the same thread is used. To do this, turn the screws anti-
clockwise until they snap into the thread audibly. Only then should the
screws be tightened.

INDUSTRIES
Table of contents
Feed water pumps
KSB Multitec
Operation and maintenance.
Data sheets
Datasheets.

Operating Instructions
1777.8/6-10 G3
High-Pressure Pumps in Ring-Section Design
Works No.:
Type Series:
These operating instructions contain fundamental

information and precautionary notes. Please read
the manual thoroughly prior to installation of unit, electri-
cal connection and commissioning.
^ This manual shall always be kept close to the unit's
location of operation or directly on the pump set.
Multitec
Contents
Page Page
1 General 4 7 Maintenance / Repair 14
2 Safety 4 7.1 General Instructions 14
2.1 Marking of Instructions in the Manual 4 7.2 Maintenance / Inspection 14
2.2 Personnel Qualification and Training 4 7.2.1 Supervision of Operation 14
2.3 Non-compliance with Safety Instructions 4 7.2.2 Bearings and Lubrication 14
2.4 Safety Awareness 4 7.2.3 Shaft Seal 15
2.5 Safety Instructions for the Operator / User 5 7.2.4 Coupling 15
2.6 Safety Instructions for Maintenance, Inspec- 7.3 Dismantling 15
tion and Installation Work 5 7.3.1 General Instructions 15
2.7 Unauthorized Modification and Manufacture 7.3.2 Preparations for Dismantling
5 15
of Spare Parts
5 7.3.3 Dismantling the Bearings 16
2.8 Unauthorized Modes of Operation
5 7.3.4 Dismantling and Replacement of Shaft Seal 18
3 Transport and Storage
c 7.3.5 Removing the Mechanical Seal 18
3.1 Transport / Handling
5 7.3.6 Dismantling the Hydraulic Elements 20
3.2 Storage / Preservation
7.3.7 Recommended Spare Parts Stock for 2
4 Description of the Product and Accesso-
ries 6 years 20
7.4 Reassembly 20
4.1 Technical Specification 6
6 7.4.1 Tightening Torques - Tie Bolts part No. 905 21
4.2 Designation
Q 7.4.2 Reassembly of Hydraulic System 21
4.3 Design Details
a 7.4.3 Seals 21
4.4 Fields of Application \j
7 7.4.4 Bearings 22
5 Installation at Site
7 7.5 Re-adjusting the Clearance Gaps 25
5.1 Safety Regulations/Special Instructions
7.5.1 Max. Clearance Gaps 25
5.2 Foundation/Checks to Be Carried out Prior to
Installation 7 7.5.2 Repairs 25
5.3 Installing the Pump / Unit 7 8 Trouble-shooting 26
5.3.1 Aligning the Pump / Drive 8 9 General Drawings 27-29
5.4 Connecting the Piping 9 9.1 List of Components 30
5.4.1 Vacuum Balance Line 10 Tightening of Shaft Nuts of the Multitec 23
5.5 Connection to Power Supply 10 Adjusting Dimensions for Coupling Alignment,
Pump sizes 32 to 65, Pump versions E, Ex, F, Fx, V,
5.5.1 Connecting the Motor 10 Vx 31
5.5.2 Setting the Time-Lag Relay 10
5.5.3 Checking the Direction of Rotation 10
6 Commissioning, Start-up / Shutdown 11
6.1 Commissioning 11
6.1.1 Lubricating agent 11
6.1.2 Priming the Pump and Checks to be Carried
out 11
6.1.3 Contact Guard 12
6.1.4 Connection to Power Supply 12
6.1.5 Start-up 12
6.1.6 Shutdown 12
6.1.7 Final Check 12
6.2 Operating Limits 13
6.2.1 Temperature of Medium Handled 13
6.2.2 Switching Frequency 13
6.2.3 Minimum Flows 13
6.2.4 Density of the Medium Handled 13
6.3 Shutdown / Storage / Preservation 13
6.3.1 The Unit/Pump Remains Installed, with pe-
riodic check of operation 13
6.3.2 The pump is removed from the pipe and
stored 13
6.4 Returning to Service after Storage 13
2
Multitec
Index
Section Page Section Page
Adjusting Dimensions for Coupling Align Removing the Mechanical Seal 7.3.5 18
ment, Pump sizes 32 to 65, Repairs 7.5.2 25
Pump versions E, Ex, F, Fx, V, Vx 31
Returning to Service after Storage 6.4 13
Aligning the Pump / Drive 5.3.1 8
Safety 2 4
Bearings 7.4.4 22
Safety Awareness 2.4 4
Bearings and Lubrication 7.2.2 14
Safety Instructions for Maintenance, In-
Checking the Direction of Rotation 5.5.3 10 spection and Installation Work 2.6 5
Commissioning 6.1 11 Safety Instructions for the Operator / User 2.5 5
Commissioning, Start-up / Shutdown 6 11 Safety Regulations/Special Instructions 5.1 7
Connecting the Motor 5.5.1 10 Seals 7.4.3 21
Connecting the Piping 5.4 9 Setting the Time-Lag Relay 5.5.2 10
Connection to Power Supply 5.5 10 Shaft Seal 7.2.3 15
Connection to Power Supply 6.1.4 12 Shutdown 6.1.6 12
Contact Guard 6.1.3 12 Shutdown / Storage / Preservation 6.3 13
Coupling 7.2.4 15 Start-up 6.1.5 12
Density of the Medium Handled 6.2.4 13 Storage / Preservation 3.2 5
Description of the Product and Accessories 4 6 Supervision of Operation 7.2.1 14
Design Details 4.3 6 Switching Frequency 6.2.2 13
Designation 4.2 6 Technical Specification 4.1 6
Dismantling 7.3 15 Temperature of Medium Handled 6.2.1 13
Dismantling and Replacement of Shaft The pump is removed from the pipe and
Seal 7.3.4 18 stored 6.3.2 13
Dismantling the Bearings 7.3.3 16 The Unit/Pump Remains Installed, with
Dismantling the Hydraulic Elements 7.3.6 20 periodic check of operation 6.3.1 13
Fields of Application 4.4 6 Tightening of Shaft Nuts of the Multitec 23
Final Check 6.1.7 12 Tightening Torques - Tie Bolts part No.
905 7.4.1 21
Foundation/Checks to Be Carried out Prior
to Installation 5.2 7 Transport / Handling 3.1 5
Transport and Storage 3 5
General 1 4
General Drawings 9 27-29 Trouble-shooting 8 26
General Instructions 7.1 14 Unauthorized Modes of Operation 2.8 5

General Instructions (Dismantling) 7.3.1 15 Unauthorized Modification and Manufac
ture of Spare Parts 2.7 5
Installation at Site 5 7
Vacuum Balance Line 5.4.1 10
Installing the Pump / Unit 5.3 7
List of Components 9.1 30
Lubricating agent 6.1.1 11
Maintenance / Inspection 7.2 14
Maintenance / Repair 7 14
Marking of Instructions in the Manual 2.1 4
Max. Clearance Gaps 7.5.1 25
Minimum Flows 6.2.3 13
Non-compliance with Safety Instructions 2.3 4
Operating Limits 6.2 13
Personnel Qualification and Training 2.2 4
Preparations for Dismantling 7.3.2 15
Priming the Pump and Checks to be
Carried out 6.1.2 11
Re-adjusting the Clearance Gaps 7.5 25
Reassembly 7.4 20
Reassembly of Hydraulic System 7.4.2 21
Recommended Spare Parts Stock for 2
years 7.3.7 20
Multitec
1 General the electrical danger warning sign is

The Multitec pump has been developed in accordance with
state-of-the-art technology; it is manufactured with utmost care
and subject to continuous quality control.
These operating instructions are intended to facilitate operation
<l
(safety sign in accordance with I EC 417-5036).
of the pump and help in commissioning and maintenance.
The manual contains important information for reliable, proper The word
and efficient operation.
These operating instructions do not take into account local Caution
regulations; the operator must ensure that such regulations are
strictly observed by all, including the personnel called in for is used to introduce safety instructions whose non-observance
installation. may lead to damage to the machine and its functions.
Multitec pumps must not be operated beyond the limit values Instructions attached directly to the machine, e.g.
specified in the technical documentation for the medium - arrow indicating the direction of rotation
handled, capacity, speed, density, pressure, temperature and - markings for auxiliary connections
motor rating. Make sure that operation is in accordance with the
instructions laid down in this manual or in the contract must always be complied with and be kept in perfectly legible
documentation. condition at all times. Non-compliance with these safely
The name plate indicates the type series / size and the main instructions will lead to forfeiture of manufacturer's warranties.
operating data; please quote this information in all
correspondence and particularly when ordering spare parts. 2.2 Personnel Qualification and Training
If you need any additional information or instructions exceeding All personnel involved in the operation, maintenance, inspec-
the scope of this manual or in case of damage please contact tion and installation of the machine must be fully qualified to
KSB's after-sales service. carry out the work involved.
Personnel responsibilities, competence and supervision must
be clearly defined by the operator. If the personnel in question is
2 Safety not already in possession of the requisite know-how, appropri-
These operating instructions contain fundamental information ate training and instruction must be provided. If required, the
which must be complied with during installation, operation and operator may commission the manufacturer / supplier to take
maintenance. Therefore this operating manual must be read care of such training. In addition, the operator is responsible for
and understood both by the installing personnel and the ensuring that the contents of the operating instructions are fully
responsible trained personnel / operators prior to installation understood by the responsible personnel.
and commissioning, and it must always be kept close to the
location of operation of the machine / unit for easy access. 2.3 Non-Compliance with Safety Instructions
Not only must the general safety instructions laid down in this Non-compliance with safety instructions can jeopardise the
chapter on "Safety" be complied with, but also the safety safety of personnel, the environment and the machine itself.
instructions outlined under specific headings, plus: Non-compliance with these safety instructions will also lead to
forfeiture of any and all rights to claims for damages.
- the general safety rules for working materials and protective
In particular, non-compliance can, for example, result in:
devices;
- the applicable organisational guidelines for the - failure of important machine / unit functions
commissioning of working materials and tools (work - failure of prescribed maintenance and servicing practices
guidelines R233-1 to R233-10 and decree no. 93-41 dd.
11.01.93, or country-specific guidelines). - hazard to persons by electrical, mechanical thermal and
chemical effects
2.1 Marking of Instructions in the Manual
- hazard to the environment due to leakage of hazardous
The safety instructions contained in this manual whose
substances.
nonobservance might cause hazards to persons are specially
marked with the general hazard sign, namely:
2.4 Safety Awareness
It is imperative to comply with the safety instructions contained
in this manual, the relevant national health and safety regula-
tions and the operator's own internal work, operation and safety
(safety sign in accordance with ISO 7000-0434). regulations.
Multitec
2.5 Safety Instructions for the Operator / User
- Any hot or cold components that could pose a hazard must
be equipped with a guard by the operator.
- Guards which are fitted to prevent accidental contact with
moving parts (e.g. coupling) must not be removed while the
machine is operating.
- Leakages (e.g. at the shaft seal) of hazardous media
handled (e.g. explosive, toxic, hot) must be contained so as
to avoid any danger to persons and the environment.
Pertinent legal provisions must be adhered to.
- Electrical hazards must be eliminated. (In this respect refer Fig. 2 Transport of the complete unit
to the relevant safety regulations applicable to different For transporting the unit, lifting ropes shall be attached to the
countries and/or the local energy supply companies.) pump and the motor as shown above. Never use the motor eye-
2.6 Safety Instructions for Maintenance, Inspection bolt for lifting the unit!
and Installation Work
The operator is responsible for ensuring that all maintenance,
inspection and installation work be performed by authorized,
qualified specialist personnel who are thoroughly familiar with
the manual.
Work on the machine must be carried out only during standstill.
The shutdown procedure described in the manual for taking the
machine out of service must be adhered to without fail
(See section 6.3).
Pumps or pump units handling media injurious to health must Fig. 3 Transport of close-coupled pumps and vertical
be decontaminated. pumps
Immediately following completion of the work, all safety-
relevant and protective devices must be re-installed and/or 3.2 Storage / Preservation
reactivated.
Unless otherwise stated in the purchase order confirmation, the
Please observe all instructions set out in the chapter on pumps are supplied by our factory duly preserved for a storage
"Commissioning" (6.1) before returning the machine to service. period of 3 months from delivery.
2.7 Unauthorized Modification and Manufacture of We recommend to take the following additional measures if the
Spare Parts pump is stored for a prolonged period of time prior to installation:
Indoor storage of new pumps:
Modifications or alterations of the machine are only permitted New pumps are preserved for indoor storage in a dry, closed
with KSB's prior approval. Original spare parts and accessories room in their original, unopened packaging for a maximum
authorized by KSB ensure safety. The use of other parts will in- period of 3 months.
validate KSB's liability for resultant damage.
Caution I P r o t e c t a " stored goods against humidity, dirt,
2.8 Unauthorized Modes of Operation
The warranty relating to the operating reliability and safety of
I ' vermin and unauthorized access! All openings of
the assembled unit components are closed and must only be
the pump is only valid if the machine is used in accordance with opened when required during installation.
its designated use as described by the technical data specified. Outdoor storage with the packaging unopened:
For further details please refer to the information in section 4 of
this operating manual. The limits stated in the data sheet must Protect the pump/unit against humidity, dirt, vermin and
not be exceeded under any circumstances. unauthorized access.
It is imperativto remove the preservative prior to normal
3 Transport and Storage commissioning by flushing through the system.
If the pump is to be stored for more than 3 months:
3.1 Transport/Handling
(optional, specified in the purchase order):
Transport of the unit requires proper preparation and handling. New pump/unit
A Never use the motor eyebolt for lifting the unit.
New pumps/units are specially preserved in the manufacturer's
factory. The preservative must be removed before normal
If the pump / unit slips out of the suspension commissioning of the pump/unit, by flushing the system
arrangement, it may cause personal injury and damage thoroughly.
to property.
Caution I "'"ne Pr°duct used for this purpose is not suited for
A Lifting tackle must not damage the pump (e.g. do not use
/ I \ chains).
I I potable water systems and, as the case may be,
must be removed completely by dismantling and subsequent
cleaning of all parts of the pump coming into contact with the
pumped medium if required. Further information in this regard is
noted in the order confirmation.
The unit/pump is installed sometime before the plant is

commissioned:
Special measures have to be taken after a prolonged shutdown
period, e. g., to make sure that the pump is always ready for
instant start-up and to prevent the formation of deposits within
the pump's hydraulic system and intake area.
Fig. 1 Transport of pump only These measures are described in section 6.3.1.
Multitec
4 Description of the Product and 4.2 Designation
Multitec A 32 / 8E - 2.1 12 . 65 (SP)
Accessories
4.1 Technical Specification
Multistage centrifugal pumps in ring-section design with suction
Type series
Installation type/pump version
DN discharge nozzle
J J
Number of stages/ impeller combination-1
impeller for low NPSH value (exception: MTC 32). Hydraulics
Material variant
Horizontal design, baseplate Shaft seal code
mounted, Code for special variants (optional) —
1 casing entry, drive end
1 rolling element bearing, drive end 4.3 Design Details
1 plain bearing, suction end
axial suction nozzle Design:
High-pressure centrifugal pump in long-coupled (baseplate
For the entire Q/H range
mounted) or close-coupled design, horizontal or vertical
same as installation type A, but version, axial or radial suction nozzle. Radial suction and
with radial suction nozzle
discharge nozzles can be turned by 90°.
B Bearings:
Radial bearings made as silicon carbide plain bearings (not for
versions C and D), self-aligning. Plain bearings lubricated by
the pumped product, fixed bearings made as rolling element
Horizontal design, baseplate
mounted, bearing, grease- or oil-lubricated.
2 casing entries, drive and suction Shaft seal:
end
2 rolling element bearings Uncooled gland packing with or without sealing liquid feed.
drive on discharge side Standardized mechanical seal to EN 12756, uncooled or
For the entire Q/H range cooled. Double-acting mechanical seal with standardized
mechanical seals to EN 12756 (back-to-back or tandem).
Same as installation type C, but
drive on suction side Drive:
Electric / Hydraulic drives or Diesel engines, or turbines up to
max. 4000 1/min.
Horizontal close coupled pump, 4.4 Fields of Application
common bearing for pump and mo-
E tor,
rigid coupling,
Municipal water supply:
pumping stations, water treatment and pressure boosting
Ex radial suction nozzle, plants.
Q/H range: up to 100 m3/h, 25 bar Water treatment: filtration, reverse osmosis.
Pumps in industrial applications: general water supply,
Same as installation type E, but
with axial suction nozzle
cold water, washing systems, recycling, cooling circuits,
Fx boiler feed systems, warm water, hot water, condensate
handling, process, organic and inorganic liquids, degreasing
Vertical close-coupled pump agents, washing or alkaline solutions, lubricants, cooling,
surface treatment.
Q/H range: up to 204 m3/h 25 bar Air-conditioning: large-scale air-conditioning systems,
upto100m 3 /h40bar
V highrise buildings
Irrigation: centre-pivot sprinkling systems, trickle irrigation
Vx systems, square sprinkling systems, flood irrigation systems.
Multitec
Installation at Site 5.3 Installing the Pump/Unit

Before placing the baseplate onto the foundation, make sure
5.1 Safety Regulations/Special Instructions that the concrete foundation is clean and smooth. The complete
L Electrical equipment operated in hazardous pump unit must be aligned horizontally with the help of a
/ locations must comply with the explosion protection precision spirit level.
regulations. This is indicated on the motor rating plate, Factory alignment of the unit on the baseplate must be
if the equipment is installed in hazardous locations, the re-aligned after the unit has been mounted on the foundation
applicable local explosion protection regulations and the and after connecting the piping (precision alignment).
regulations of the test certificate supplied with the equip- Align the complete pump unit with the help of a spirit level placed
ment and issued by the responsible approval authorities on the shaft/discharge nozzle. The correct distance between
must be observed and complied with. The test certificate the coupling halves as specified in the installation plan must be
must be kept close to the location of operation for easy observed. Shims shall be fitted between the baseplate/foun
access (e.g. foreman's office). dation frame and the foundation itself; they shall always be
inserted to the left and right of the foundation bolts and in close
yQi Centrifugal pumps will only give trouble-free
proximity to these bolts. For a bolt-to-bolt clearance of more
Z J A operation when carefully installed and maintained. than 800 mm, additional shims must be inserted halfway
N.B.: The pump's nameplate shows the type series, pump size, between the adjoining holes. All shims must lie perfectly flush.
version, product number, main operating data and the works Shim Shim
number (see also 4.2).
Please quote the type series / version in all queries, repeat
orders and particularly when ordering spare parts.
° MULTITEC KSB< o
Foundation bolts
Fig. 5 Fitting required shims
Tighten the foundation bolts evenly and firmly after the concrete
has set.
o 2N 3804-AxxXxxuO
is essent al t 0 m a k e s u r e t n a t t n e
Fig. 4 Nameplate IProceed

Caution I '* ' baseplate is
* not warped in axial or radial direction.
with utmost care when aligning the unit, as the pump
A This pump / unit must not be operated beyond the unit will only give trouble-free operation when correctly aligned.
/ I \ limit values specified on the nameplate for capacity, Non-compliance with these instructions will lead to forfeiture of
speed and temperature or other instructions laid down in all warranty claims.
this manual or in the contract documentation. Any data Baseplates made of U-rails (up to 400 mm wide) are torsion-
stipulated for the electrical connection of the unit and in- resistant in their own right and need not be grouted.
structions for maintenance and installation must be ad- After fastening, baseplates more than 400 mm wide shall be
hered to without fail. Operation beyond the conditions indi- grouted up to the upper frame edge using low shrinkage
cated above will lead to overloads the unit cannot concrete, making sure that no cavities remain.
withstand.
Close-coupled pumps
Trained personnel is essential to ensure trouble-free operation It is essential to make sure that the pump is not warped in axial
of the unit. or radial direction.
KSB will not accept any responsibility for the safe and If pump and motor are supplied separately, place the pump onto
reliable operation of the pump unit if these operating the foundation without the motor, align with the help of a
instructions are not complied with. precision spirit level (on the upper flange of the drive lantern),
In case of damage or if you need further information, please then fasten.
contact KSB's nearest customer service centre. Shims shall be fitted between the pump foot and the foundation
5.2 Foundation/Checks to be Carried out Prior to itself; they shall always be inserted to the left and right of the
Installation foundation bolts and in close proximity to these bolts. All shims
All structural work required must have been prepared in accor- must lie perfectly flush.
dance with the dimensions stated in the dimension table / instal- Tighten the foundation bolts evenly and firmly.
lation plan.
Shim
The concrete foundations shall have sufficient strength (min.
class XO) to ensure safe and functional installation in accor-
dance with DIN 1045 or equivalent standards.
Make sure that the concrete foundation has set firmly before
placing the unit on it. Its surface shall be truly horizontal and
even.
Fig. 6 Fitting required shims

Multitec
5.3.1 Aligning the Pump/Drive Caution I ' r ° r P r o d u c t temperatures of 120 DC and higher,
Coupling guard I * the foot bolts to secure the pump on the baseplate
are to be tightened with torques according to the following table:
I Caution I l n compliance with the accident prevention
* ' regulations the pump must not be operated Tcirque
without a coupling guard / a guard on the drive lantern. If the MTC Thread Strength
drive non-drive
customer specifically requests not to include a coupling guard /
lantern guard in our delivery, then the operator must supply one. 32 M12 4.6 30 Nm 15 Nm
50 M12 4.6 30 Nm 15 Nm
Baseplate-mounted units
A After fastening the baseplate on the foundation, the 65 M16 4.6 60 Nm 30 Nm
/ I \ coupling must be thoroughly checked and the pump 100 M20 4.6 120 Nm 60 Nm
unit be realigned (at the motor), if required. 125 M20 4.6 120 Nm 60 Nm
Prior to checking the alignment/realignment, loosen the pump 150 M30 4.6 450 Nm 200 Nm
feet and re-tighten without transmitting any stresses or strains.
This will avoid that longitudinal increase of the pump by
I Caution I C o u P'' n 9 check and realignment must be thermal expansion will lead to warping and deformation.
' effected even if pump and motor are supplied
completely assembled and aligned on a common baseplate. As the thermal expansion in height of pump and motor may
differ, this has to be considered when aligning the coupling of
pump units handling temperatures of 100 °C and higher.
Straight-edge To estimate the increase in height, the following equation can
serve as a guide to calculate by how much the motor has to
be elevated in relationship to the pump:
| AH [mm] = 1/100000 * (ATp * Hp - ATm * Hm) )
ATp = Temperature difference pump - environment (°C)

Hp = Height of pump axis [mm]
a ATm = Temperature difference motor - environment (°C)
Hm = Height of motor axis [mm]
L l nan case also wnen u s i n s correct on tne
Straight-edge " ~~ Gauge Iwarm

Caution I Y ' 9^ ' '
' coupling has to be re-aligmed when the unit is in
condition from operation.
Fig. 7: Aligning the coupling with the help of a
gauge and straight-edge
Close-coupled pumps and vertical pumps
Straight-edge Alignment between the motor and the pump is ensured by the
centering effect between the motor flange and the drive lantern
flange. It must be easy to rotate the shaft.
Caution I F o r t n e Multitec V32-65, the dimensions for the
a b I ' setting of the coupling alignment have to be
considered during assembly (see page 31)
•
-
Final check
a b Re-check the alignment as described in the sections above.
• - It must be easy to rotate the shaft by hand at the coupling.
Check the integrity and proper functioning of all connections.
Straight-edge ™ Gauge
Fig 8 Aligning a spacer-type coupling
The radial and axial deviation between the two coupling halves
shall not exceed 0.1 mm.
Multitec
5.4 Connecting the Piping Max. permissible pipeline forces

Suction lift lines shall be laid with a rising slope towards the (Material identification No. 10,11,12,13)
pump and suction head lines with a downward slope towards Nom. nozzle diameter
the pump, to avoid the formation of air pockets. 32 50 65 80 100 125 150 200 250
With short pipelines, the nominal diameters shall be at least Vertical nozzle, at a right angle to the shaft (N)
equal to the nominal diameters of the pump nozzles. For long
pipelines the most economical nominal diameter has to be de- Fx 245 510 640 700 1015 1470 1780 2700 -
termined from case to case. Fy 410 635 800 970 1270 1850 2220 3490 -
Adapters to larger diameters should have a diffuser angle of Fz 265 415 520 625 830 1220 1465 2220 -
approx. 8° in order to avoid any pressure losses caused by of
Horizontal nozzle, at a right angle to the shaft (N)
air pockets or gas.
It is recommended to install check and shut-off elements in the Fx 245 510 640 800 1015 1470 1780 2700 -
system, depending on the type of plant and pump. Fy 265 415 520 625 830 1220 1465 2220 -
Fz 410 635 800 970 1270 1850 2220 3490 -
Itransmitted
Caution I Never use the pump itself as an anchorage point
I for the piping. The forces and moments
to the pump flanges by the piping system (torsion,
Axial nozzle, parallel to the shaft (N)
Fx - - 800 - 1270 1850 2220 3490 4760
thermal expansion,...) must not exceed the permissible forces
and moments. Fy - - 520 - 830 1220 1465 2220 3180
The pipelines must be anchored in close proximity to the pump Fz - - 640 - 1015 1470 1780 2700 3810
and connected without transmitting any stresses or strains. Moments for all nozzles (Nm)
Their weight must not act on the pump unit.
Mx 260 330 460 680 950 1235 1640 2520 3580
l n c a s e welclin must be
IforCaution I 9 done on the piping when

I the pumps are already installed, the device used
electric welding may not be earthed on the pump or the base-
My
Mz
160
190
250
170
350
240
520
340
715
490
930
660
1260 1840 2710
840 1260 1740
plate so that current flowing through the rolling element bearings Example:
is avoided, which could cause their premature destruction Multitec 50 with radial suction nozzle
(pitting effect).
- for the suction nozzle, the values given in table column
Thermal expansion of the pipelines must be DN 80 apply.
compensated by appropriate measures so as not to — for the discharge nozzle, the values given in table column
impose any extra loads on the pump exceeding the permissible DN 50 apply.
pipeline forces and moments.
It may be necessary to provide expansion joints. An excessive, Max. permissible pipeline forces
impermissible increase in the pipeline forces may cause leaks (Material identification Nos. 20-30)
on the pump where the medium handled can escape into the
atmosphere. The values given for the material identification nos. 10,11,12,
13 shall be multiplied by the factor 1.4.
Danger of life when hot media are handled!
Protection against foreign matter
Before commissioning new installations thoroughly clean, flush
and blow through all vessels, pipelines and connections. Often
welding beads, scales and other impurities only come off after a
certain period of operation. Fit a strainer in the suction line to
prevent them from entering the pump. The total cross section of
the holes in the strainer shall be three times the cross section of
the pipeline in order to avoid excessive pressure loss across
the strainer due to clogging. Conical strainers with laid-in wire
mesh having a mesh width of 0,5 mm and a wire diameter of
0.25 mm, of corrosion-resistant material, shall pr used.
Fig. 9 Max. forces and moments at the pump nozzles

Direction of forces:
X = horizontal, parallel to the pump axis
Y = vertical to the pump axis
Z = horizontal, at a right angle to the pump axis
1 Strainer housing
Direction of moments: 2 Fine screen
MX = around the horizontal axis, parallel to the pump axis 3 Perforated plate
MY = around the vertical nozzle axis 4 Pump suction nozzle
MZ = around the horizontal axis, at a right angle to the pump 5 Differential pressure gauge
axis
Suction and discharge nozzle are regarded separately. Fig. 10: Conical strainer for the suction line
Multitec
5.4.1 Vacuum Balance Line Y starting (high voltage)
Where liquid has to be pumped out of a vessel under vacuum, it
is advisable to install a vacuum balance line. This line should Co o) o)
have a nominal size of at least 25 mm and must be arranged to W2 U2 V2
lead into the vessel at a point above the highest permissible
liquid level.
An additional pipeline fitted with a shut-off valve - from the
pump discharge nozzle to the balance line -facilitates venting LI L2 L3
of the pump before start-up.
Fig. 13: Connection diagram for three-phase motors,
Y starting
5.5.2 Setting the Time-Lag Relay
Make sure that in the case of three-phase motors with
star-delta starting method switching over from star to delta will
be effected at very short intervals. Prolonged switch-over inter-
vals may result in pump damage.
Time-lag relay setting recommended for star-delta starting: -
3-5 seconds, depending on motor rating.
EN 50014 (Regulation DIN VDE 0170/0171 Part 1) stipulates
that explosion-proof motors, type of protection IP 54,
"increased safety" (Ex)e, thermal class T3, must always be
connected via a motor protection switch.
5.5.3 Checking the Direction of Rotation
A Main shut-off valve Caution I O n P um P s f i t t e c l w i t n uni-directional mechanical
B Vacuum balance line
C Shut-off valve
I I seals (seal codes 62 and 63) the direction of
rotation must never be checked with the pump coupled to the
E Vacuum-tight shut-off valve motor. If the motor and pump need not be de-coupled, make
R Swing check valve sure that the pump has been primed before checking the
V Vessel under vacuum direction of rotation.
Z Intermediate flange The motor's direction of rotation must correspond to the
direction indicated by the arrow on the pump resp. motor
Fig. 11 Suction line and vacuum balance line (clockwise when seen from the motor end; on version D
anti-clockwise). This can be verified by switching the motor on
5.5 Connection to Power Supply and then off again immediately.
If the unit runs in the wrong direction of rotation, interchange two
I Connection to the power supply must be effected by a of the three phases L1, L2 or L3 of the power supply cable in the
' trained electrician only (see 5.1). The applicable motor terminal box.
DIN VDE regulations or country-specific guidelines must be
complied with.
Check available mains voltage against the data on the motor
rating plate and select appropriate start-up method.
Connection to the power supply must be effected in
accordance with the technical regulations of the
responsible local energy supply company.
We strongly recommend to use a motor protection switch.
5.5.1 Connecting the Motor
Connect the motor in accordance with the circuit diagram in the
terminal box or as illustrated in Fig. 5.5-1 / Fig. 5.5-2.
Pr or t 0 s t a r t i n tne
Ipossibly
Caution I ' 9 motor, check whether the
I connection of the terminals is tight and re-tighten
loose wires.
A starting (low voltage)
r; W2fOlU2 fO|V2!
U1 lOjVI lOiwi1
LI L2 L3
Fig. 12: Connection diagram for three-phase motors,

A starting
10
Multitec
6 Commissioning, Start-up / Shutdown Special notes regarding cooled mechanical seals

(Sealing Code 64)
Additional information for boiler feed pump operation - If the pump is equipped with a cooled mechanical seal, vent
Limit values for boiler feed water and condensate when using the seal chamber by opening the screwed plug 903.11 by a
cast iron pump parts: pH-value > 9.0 (value aimed at > 9.3) O2 quarter turn, then retighten.
content < 0.02 ppm.
Before entry into the pump, these values must be guaranteed Sizes 32 to 100
for all operating conditions . The fresh water content has to
903.11
amount to max. 25 %. 411.17
Water treatment shall be in accordance with the VdTUV
guidelines for feed and boiler water in steam plants of up to 64
bar.
The penetration of air into the system must be avoided by all
means.
6.1 Commissioning
Caution I B e f o r e starting up the pump make sure that the
I I following requirements have been met:
- The quality of the concrete foundation is in compliance with
^-^H i & w ^
_ L
the applicable regulations.
- The tolerances stipulated for mounting the unit on the
foundation, for shims and alignment have been met.
- The pipelines have been connected without warping the
pump nozzles.
- Electrical connection and relay setting correspond to the
motor rating and comply with the applicable regulations.
- The unit has been equipped with all hydraulic, electrical and
mechanical protection devices. Fig. 14
- The pump has been fully primed with the medium to be
handled. Sizes
125 and 150 903.11
- The unit's direction of rotation corresponds to the rotation 411.17
arrows.
- All connections are tight.
Caution I ' =or installation without foundation (e.g. on spring
I I e ( e m e n t s ) c a r e n a s t 0 b e taken that all
movements of the pump unit can be compensated, e.g. by
installation of expansion joints in the discharge and suction
lines.
6.1.1 Lubricating agent
Grease lubricated bearings
The grease lubricated bearings are packed with grease at the
factory (see section 7.2.2).
Oil lubricated bearings
Into the bearing cover fill oil of the quality ISO VG 46 (see sec-
tion 7.2.2).
6.1.2 Priming the Pump and Checks to Be Carried out
Before each start-up, the pump and suction line must be Fig. 15
completely vented and primed with the liquid to be pumped. The
pump has several plugged holes for venting; adequate venting
devices can be used in the pipelines. The shutoff element in the I Caution I T n e s ? a l c n a r n b e r has to be vented when the
* * pump is in cold condition before start-up. When
suction or feed line must be fully open. venting in hot condition, the steam will exit at the screwed plug
Fully open all auxiliary connections provided and check the during the venting process and there is the risk of scalding!
throughflow. Should it not be possible to avoid the opening of the seal
Open shut-off valve "C" in the vacuum balance line (if chamber in hot condition due to the situation in the plant, a pipe
applicable), close vacuum-tight shut-off valve "E" (see 5.4.1). with valve (not included in KSB's scope of supply) has to be
Caution I D r y r u n n i n 9 w ' " l e a d t 0 increased wear on the unit installed at the venting hole, in order to lead the exiting steam
I I and possibly to damage on the pumpl
If the discharge line is equipped with an automatic check valve,
during venting to another place where there is no danger of
scalding. It should be made certain that this valve cannot be
open the minimum flow valve and secure against inadvertent opened during operation.
closing.
Exceptions:
- If the check valve is not subjected to backpressure prior
to pump start-up, the check valve must be closed first.
- On pumps fitted with a mechanical seal, the mechanical seal
will leak only slightly or invisibly (vapour) during operation.
It is maintenance-free.
- If the pump is equipped with a gland packing, leakage during
operation is normal (see section 6.1.6).
11
Multitec
6.1.3 Contact Guard If the pump has to remain operational during shutdown periods,
it must be started up regularly for at least 5 minutes (see also
A In compliance with accident prevention regulations
the pump must not be operated without a coupling guard.
If the customer specifically requests not to include a coupling
6.3):
- fire-fighting pumps at least once a month
guard in our delivery, then the operator must supply one. - drinking water pumps at least once in 48 hours
- standby pumps at least once a week.
6.1.4 Connection to Power Supply (It is better to operate the pumps by alternating daily)
If the pump is equipped with an electric motor, connection to the During these periodic check runs, also check the tightness and
power supply must be effected by a trained electrician only. proper functioning of the auxiliary feed lines.
Check available mains voltage against the data on the motor
rating plate and select appropriate start-up method. 6.1.7 Final Check
Make sure that in the case of three-phase motors with star-delta After the pump has been primed, it must be easy to rotate the
starting method switching over from star to delta will be effected coupling/shaft by hand.
at very short intervals. Prolonged switch—over intervals may re- There must be no impermissible leakage at the shaft seal
sult in pump damage. during pump operation.
Time-lag relay setting for star-delta starting Gland packing
Motor rating Y-time to be set The gland packing has been fitted in the factory. Its permanent
s 30 kW 3 sec. ± 30 % compression can only be set after several hours of pump
> 30 kW 5 sec. ± 30 % operation. During this running-in period, seal leakage will be
higher than during normal pump operation. Check the
6.1.5 Start-up temperature of the leakage.
Start-up procedure: Final adjustment of the gland packing is made gradually after
- The discharge-side shut-off valve must be closed. having allowed for a sufficient running-in period, so that leakage
- Start-up must proceed without abnormal vibrations or is reduced to individual drops (approx. 20 drops per minute).
noises. Tightening the gland cover too early or too hard without allowing
- An automatic check valve installed must open steadily when a sufficient running-in period would cause a local temperature
the operating speed has been reached, without abnormal rise and insufficient lubrication, resulting in the destruction of
noises, vibrations or increased power consumption of the the gland packing, premature wear on the shaft protecting
unit. sleeve and higher, uncontrollable leakage.
- Open the discharge-side shutoff element. For speed controlled pumps or fluctuating inlet pressure, no
- After the duty point has been reached, check motor input packing should be used, if possible. Changing pressures make
power and bearing temperature. the setting of an even and controlled leakage rate very difficult
After the operating temperature has been reached, switch off to achieve.
the unit and re-tighten the bolts at the connecting flanges. . . th
ese conditions occur, leakage of the
Caution I ' n *^ e e v e n * °f abnormal noises, vibrations,
I p g
| Caution | gland packing may not be stopped during any
g y
operating condition whatsoever. With iincreased inleti pressure
immediatelyIandtemperatures or leakage,
re-start it only after theswitch
cause off
for the
the unit
problem and/or increased speed, the inevitably higher leakage of the
has been eliminated. gland packing must not be reduced by subsequent
Increased temperature of the rolling element bearings after re-tightening the gland bolts. The setting of the minimum
commissioning are caused by the running-in processes. The leakage may only be done at lowest speed and/or lowest inlet
final bearing temperature will be established only after some pressure.
operating time (depending on the conditions up to 48 hours).
Mechanical seal
6.1.6 Shutdown The mechanical seal assembly has been adjusted and installed
Close the shut-off element in the discharge line. in the factory. It is maintenance-free. Check the seal for leakage
If the discharge line is equipped with a non-return or check occasionally.
valve, the shut-off valve may remain open, provided there is During commissioning, increased leakage may occur for a
sufficient backpressure in the line. short period of time. If leakage remains high, immediately
- Switch off the drive, making sure that the pump set runs switch off the unit and investigate the leakage cause, e.g.
smoothly down to a standstill. contaminated medium handled or previous dry running due to
- In the case of prolonged shutdown, the shut-off valve in the inadequate venting of the pump.
inlet line has to be closed. Also close any shut-off elements
in the auxiliary feed lines.
- The shaft seal in pumps where the liquid is fed in under Cooled mechanical seal (seal code 64)
vacuum must also be fed with sealing liquid during standstill.. If the pump is fitted with a cooled mechanical seal (seal code
- In the event of frost and/or prolonged shutdowns, the pump 64), vent the seal chamber as described in section 6.1.1.
must be drained or otherwise protected against freezing.
12
Multitec
6.2 Operating Limits ln t n e c a s e of non zontal
The hydraulic system is designed for pure or slightly

contaminated liquids (solid matter content max. 20 ppm). Care
Iinstalled
Caution I ' pumps, vitually complete
I drainage of the stage casings of pumps in
condition can only ensured by opening the plugs on
needs to be taken that the operating limits indicated in the order the stage casings (option). If this is not possible, it is
confirmation are complied with. recommended to remove the pump and to proceed according
to
6.2.1 Temperature of the Medium Handled chap. 6.3.2.
Do not operate the pump at temperatures exceeding those
specified on the nameplate or the technical data sheet. 6.3.2 The pump is removed from the pipe and stored
Before putting the pump into storage carry out all checks and
6.2.2 Switching Frequency maintenance work specified in sections 7.1. Then preserve as
The permissible number of start-ups in a given period of time follows:
depends on the circumstances prevailing in the plant and the Drain pump as completely as possible. For vertical pumps, this
operating conditions. Overloading of the motor may generally can be done by opening the drai plugs on the suction casing.
result in: For horizontal pumps, an almost complete draining can be
- an abnormal increase in motor temperature exceeding the achieved through the draining holes on the stage casings
temperature limit of the winding or the bearing grease. (option) by opening the respective closing plug. The drainage
- premature coupling wear can also achieved by having the pump brought into vertical
- a reduced service life of the pump components position with the aid of a crane (see 3.1), with the suction nozzle
- irregularities or malfunctions in the plant pointing down, while turning the rotor by hand. However, in
To prevent abnormal temperature increases in the motor and addition, the seal chamber still has to be drained by opening the
excessive loads on the motor, coupling, pump, seals and respective drain plug.
bearings, the switching frequency must not exceed the A< If a complete draining is not possible, it is recommended
following number of start-ups per hour (h). Z i A to dismantle the pump and to dry the individual parts.
Afterwards, fill the pump with a water-repellent preservative,
Motor rating (kW) Max. start-ups/h
e.g. RUSTELO DEWATERING 924 (manufacturer CASTROL),
up to 3 kW 20 OSYRIS DW (manufacturer TOTAL) or equivalent.
from 4 to 11 kW 15 The pump shall be turned by hand several times in order to
from 11 to45kW 10 ensure even distribution of the preservative. Then drain the
45 kW and above 5 pump and close the suction and discharge nozzle.
Exposed blank metal parts are to be treated with a suitable
6.2.3 Minimum Flows anti-corrosive agent.
If the plant configuration is such that the pump might be tne um
operated against a closed discharge-side shut-off valve, the
following minimum flows are required during this time. IwithCaution I '* P P must be preserved for a longer
' storage period with KLUBERTOP K 01 -601 or
another preservative on the basis of glycol, the
t -10to + 100°C 15%ofQopt
t>100to + 140°C 20%ofQopt preservative must not be drained. In this case, the pump must
be filled completely with the preservative for storage. The
t > 140 to + 200 °C 25 % of Qopt preservative has to be drained before the pump is returned to
Contact KSB if exact minimum flows have to be calculated. operation. It can be re-used. Before re-use, it should be made
The minimum flows indicated above are for single pump sure that the water content in the preservative does not exceed
operation and prevent a thermal or mechanical overload of the 20 %.
pump. In case of parallel operation with pumps of identical or 6.4 Returning to Service after Storage
different design higher minimum flows may be required in some Before returning the pump to service, carry out all instructions
cases, to guarantee a stable operating behaviour. laid down in the sections on "Commissioning" (6.1) and
Continuous operation is permitted for Q > 35 % of Qopt. "Operating Limits" (6.2).
6.2.4 Density of the Medium Handled Upon completion of the work, all safety-related and protective
The power input of the pump will increase in proportion to the equipment must be properly refitted and/or reactivated before
density of the medium handled. To avoid overloading of the starting the pump set.
motor and the pump, the density of the medium must comply
with the data specified on the purchase order.
6.3 Shutdown / Storage / Preservation
6.3.1 The pump/unit remains installed; periodic check of
operation:
In order to make sure that the pump is always ready for instant
start-up and to prevent the formation of deposits within the
pump and the pump intake area, start up the pump set regularly
once a month or once every 3 months for a short time (approx. 5
minutes) during prolonged shutdown periods. Follow the
instructions for commissioning (see 6.1).
For pumps of material variants 10,13,20 and 21 (cast iron), lon-
ger shutdown periods have to be avoided especially when
pumping aggressive water qualities (high oxygen content). In
this case, the pumps should be left filled and the functional run
should be made at least every two days instead of in intervals of
1 to 3 months (see also 6.1.5).
In the event of frost and/or prolonged shutdowns, the pump
must be drained and protected against freezing and corrosion.
To drain the pump, open drain plug 6B.
13
Multitec
7 Maintenance / Repair 7.2.2 Bearings and Lubrication
For the variant with grease lubrication, the rolling element
7.1 General Instructions bearings of the Multitec 32 as well as the rolling element bearing
The operator is responsible for ensuring that all maintenance, of the non-drive end of the Multitec 50 and 65 in design C and
inspection and installation work is carried out by authorised, D are lubricated for life and do not require any relubrication. In
duly qualified staff who are thoroughly familiar with these this case, there are no lubricating nipples on the bearing
operating instructions. brackets.
A regular maintenance schedule will help avoid expensive
repairs and contribute to trouble-free, reliable operation of the
pump with a minimum of maintenance expenditure and work. Pump
L Before commencing any work on the pump unit, al- Depending on the pump version, the rolling element bearings
/ ways make sure that the drive unit (electric motor, are grease-lubricated or oil-lubricated.
turbine, I.C. motor,...) cannot be started up. Grease Quality / Grease Change
Pumps handling liquids posing health hazards must The bearings are packed with high-quality lithium-soap grease.
Depending on the size of the pump and the operating hours of
be decontaminated. When draining the medium see
the pump, the rolling element bearings must be re-lubricated or
to it that there is no risk to persons or the environment. All the grease in the rolling element bearings must be replaced.
relevant laws must be adhered to.
Speed (1/min)
7.2 Maintenance / Inspection
7.2.1 Supervision of Operation Size MTC <1800 -2950 ~3550
Caution I ^ n e PumP m u s t r u n quietly and free from 32-50-65 10000h 7200h 5700h
' vibrations at all times. 100-125 9000h 5700h 3900h
The pump must never be allowed to run dry.Max. ambient
temperature: 40 °C. 150 8300h 4000h 3100h
The bearing temperature may exceed ambient temperature by If re-lubrication intervals are short, it is recommended to
up to 50 °C but must never rise above +90 °C (measured on the completely exchange the grease once a year. If this is not the
outside of the bearing bracket), see section 7.4.4.1. case, a complete exchange must take place at least every two
years. When doing so, the rolling element bearings must be dis-
A Prolonged operation against a closed shut-off element is
not permitted, to prevent the medium handled from
heating up.
mantled, cleaned, and packed with new grease.
In case of unfavourable operating conditions, e.g.. high ambient
Caution: Required minimum flows see 6.2.3. temperatures and high air humidity, dust-filled air, aggressive
The shut-off element in the inlet line must not be closed industrial atmospheres etc., the bearings should be controlled
during pump operation. earlier and, if necessary, cleaned and packed with new grease.
The mechanical seal leaks only slightly or invisibly (vapour) Under normal conditions grease-lubricated rolling element
during operation. It is maintenance-free. bearings will run for 15,000 operating hours or 2 years. Thereaf-
Gland packings must leak slightly (individual drops). ter, the bearings have to be dismantled, cleaned and re-packed
Any stand-by pumps installed shall be switched on and then with grease. Under unfavourable operating conditions, e.g.
high room temperature, high atmospheric humidity, dust-laden
immediately off again once a week to keep them operational.
air, aggressive industrial atmosphere etc., the bearings should
Attention shall be paid to the correct functioning of the auxiliary
be checked earlier and cleaned and re-lubricated, if required.
connections.
Use a high-quality lithium-soap grease, free of resin and acid,
not liable to crumble and with good rust-preventive
characteristics. The grease shall have a penetration number
between 2 and 3, corresponding to a worked penetration
between 220 and 295 mm/10. Its drop point must not be below
175 °C. The bearing cavities must only be half-filled with
grease.
If required, the bearings may be lubricated with greases of other
soap bases. Since greases of differing soap bases must not be
mixed, the bearings must be thoroughly cleaned beforehand.
The re-lubrication intervals required must then be adjusted to
the greases used.
14
Multitec
Oil Quality /Oil Change 7.2.4 Coupling
Quality: ISO VG 46 When the flexible coupling elements show signs of wear after a
The first oil change shall be made after 300 operating hours, all certain operating period, they must be replaced in due time and
subsequent oil changes after every 3000 operating hours. the alignment motor/pump has to be checked.
Unscrew the plug in the re-fill hole and the drain hole. After the
bearing housing has been drained completely, plug the drain 7.3 Dismantling
hole again. If you need additional information or instructions, please
contact KSB's customer service!
7.3.1 General Instructions
Drainage/Flushing
If the pump was used for handling liquids posing health
hazards, see to it that there is no risk to persons or the
environment when draining the medium. All relevant laws must
be heeded. If required, wear safety clothing and a protective
mask.
The flushing liquid used and any liquid residues in the pump
Fig. 16 Oil fill must be properly collected and disposed of without posing any
risk to persons or the environment.
Hinge down the reservoir of the constant-level oiler 638.
Pour in the oil through the hole until oil appears in the vertical 7.3.2 Preparations for Dismantling
portion of the connection elbow (see Fig. 7.2-1). Then fill the Caution I M a ê sure to switch off the pump unit before start-
reservoir of the constant-level oiler with oil and snap it back into
operating position. After a short time check whether the oil level
I I ing any dismantling activities. Secure the pump
so as to make sure it cannot be switched on accidentally!
in the reservoir has dropped. The shut-off elements in the suction head/lift line and the dis-
It is important to keep the reservoir two thirds full at all times. charge line must be closed and secured against inadvertent
Lubricant quantities opening.
Grease quantities The pump must have cooled down to ambient temperature. The
pump casing must be drained and its pressure must be
Quantity per bearing unit in g released and the casing must be drained.
Pump size
Driven end non-drive end Noxious, explosive, hot or other hazardous media shall be
32 - -
drained without posing any risk to persons or the environment.
We strongly recommend to flush the pump after drainage.
50/65 15 - Flushing and cleaning the pump is an absolute necessity before
100/125 25 15 sending the pump to the workshop. In addition, all pumps must
150 40 30 be supplied with a cleaning certificate.
Note: For several designs the rolling element bearings are After a prolonged operating period, some components may be
lubricated for life. In these cases there is no lubricating nipple on hard to pull off. We recommend to use a brand name de-rusting
the bearing bracket. agent or a suitable pull-off device.
Oil quantities Under no circumstances use force.
Dismantling must always be carried out in accordance with the
Oil quantity in ml *) sectional drawings at the end of these operating instructions
Pump size
Driven end non-driven end (see section 9 - general drawings).
32 330 330
Heavy components must be sufficiently supported during
50 500
dismantling. The components shall be marked with their se-
330
quence of dismantling, to make sure that they will be re-
65 490 510
assembled in the correct sequence.
100/125 880 920
Thoroughly clean all dismantled components and inspect their
150 1000 1040
condition. Careful examination may help to find the cause for
*) oil quantity without oil in the reservoir of the constant level oiler
pump failure, if any. If in doubt, replace the components. Always
Motor replace parts which are subject to wear (gaskets, O-rings,
Motors without lubricating nipple: The rolling element bearings casing wear rings, rolling element bearings).
have been lubricated in the supplier's factory for an operating
period of 15000 h or 2 years under normal operating conditions.
Motors with lubricating nipple: The rolling element bearings
must be re-lubricated at the intervals indicated on the motor
nameplate (appr. 500 h).
7.2.3 Shaft Seal
Mechanical seal:
The mechanical seal is maintenance-free.
Gland packing:
The nuts of the gland cover must only be tightened slightly. The
gland cover must be at right angles to the shaft. After the pump
has been primed and prior to start-up, make sure.the gland
packing is set to allow a larger amount of leakage. After
approximately 1 operating hour, tighten the nuts at the gland
cover gradually until leakage has been reduced to individual
drops (approx. 7 l/h).
15
Multitec
7.3.3 Dismantling the Bearings
The sections below describe partial dismantling (bearings,
seals, etc.) and complete dismantling of the pump unit.
7.3.3.1 Dismantling the Non-Drive-End Bearings
Plain bearing
The plain bearing is removed without dismantling the hydraulic
system of the pump.
Axial suction nozzle:
Fig. 19
Rolling element bearings:
If the pump is oil-lubricated, drain the oil before dismantling.
- Unscrew bolts 901.4 or 914.5 and remove non-drive end
bearing cover 361.1 or 361.2.
- Unscrew nut 920.7 with lockwasher 931 or the nut with
castellated nut 920.6.
- pull out sleeve 520.2 with rolling element bearing 320.2
Grease lubrication
Multitec 32 -125 Multitec 150
901.4
920.6—.
Fig. 17
- Pull off bearing cover 160.2 using forcing screws.
- Remove circlip 932.1 (shaft in C45) or bolt 901.2 and disc
550.7 (shaft in 1.4021 /1.4462).
- Take out bearing sleeve 529.
520.2
- Pull out bearing cartridge 381 with its two O-rings 412.2.
N.B.: The anti-torsion pin 561.1 remains in position.
320.2-
Radial suction nozzle: Fig. 20 Fig. 21
Oil lubrication with lip seal
412.2 Multitec 32-125 Multitec 150
160.
361.2
914.5
550.10
412.12 920.6
320.2
Fig. 22 Fig. 23
Fig. 18 Oil lubrication with labyrinth seal
- Undo bolts 901.3 and remove cover 160.1 with O-ring
412.3 and bearing cartridge 381 with O-rings 412.2. Multitec 32 -125 Multitec 150
- Remove circlip 932.1 (shaft in C45) or screw 901.2 and disc
550.7 (for shafts in 1.4021/1.4462) 36I.2
- Take out bearing sleeve 529.

- Remove disc 550.6
N.B.: The anti-torsion pin 561.1 remains in position.
320.2
Fig. 24 Fig. 25
16
Multitec
7.3.3.2 Dismantling the Drive-End Rolling Element I The rotating unit is adjusted axialiy by means of
Bearings I spacers 551.1. When reassembling the pump
N.B.: The ceramic plain bearing installed at the non-drive end after partial dismantling (bearing or seal replacement), the
need not be dismantled in order to remove the drive-end rolling same spacer discs 551.1 must be mounted on the side of the
element bearings. If the pump is oil lubricated, the oil must be bearing to reproduce the original rotor adjustment (see also
drained before dismantling. Section 7.4.4).
- After loosening the grub screw in the coupling hub When dismantling keywayed nut 920.6, all relevant positions
pull out coupling half with key 940.3. such as sequence and orientation of the contact face must be
Grease lubrication (Fig 26 and 27) marked accordingly, to ensure identical reassembly (see also
- Remove joint ring (V-ring) 411.7 section 7.4.4).
- Undo bolt 901.1 - Undo nut 920.2 with lockwasher 931 or nut with
- Remove bearing cover 360.1 locknut 920.6, depending on the pump size.
Oil lubrication with radial seal (Fig. 28) To undo the nut, hold onto shaft with key 940.3.
- Loosen bolts 914.4 and pull out together with - Pull off shaft protecting sleeve 520.1 with rolling element
washer 550.10 and O - ring 412.12 bearing 320.1 (The shaft is centered in the sleeve without
- remove bearing cover 360.2 locking device.)
- Remove sleeve 520.4 with ring 500.1 (tolerance - Remove spacers 551.1, see text above.
ring) and O-ring 412.11
N. B.: In the versions V, Vx, E, Ex, F, Fx of sizes 32,50, 65 the
Oil lubrication with labyrinth seal (Fig. 29) pump does not have a fixed bearing as this function is being
- Pull out labyrinth ring 423.2 taken over by the motor bearings. In the versions Multitec V100,
- Loosen bolts 914.4 and pull out together with V125 and V150 the fixed bearing is located in the support
washer 550.10 and O-ring 412.12 lantern 342. Dismantling and installation are the same as for the
- remove bearing cover 360.2 horizontal versions.
Grease lubrication Design version V, Multitec 100/125/150

551.1 360.1 •901.1 (only grease lubrication)
-940.4
320.1
Fig. 27
320.1 520.1
Fig. 26
Oillubrication with Radial seal ring Oillubrication with labyrinth seal
551.1
551.1 914.4
550.10
412.12
920.2
931
423.1
Fig. 28-3 2 0 .
17
Multitec
7.3.4 Dismantling and Replacement of Shaft Seal 7.3.5 Removing the Mechanical Seal
Gland Packings 7.3.5.1 Removing the Mechanical Seal
7.3.4.1 Replacing the Packing Rings - Remove the bearings as described in sections
Access to packing rings without removing the bearing or the 7.3.3.1 and 7.3.3.2.
lantern: - For grease lubricated version pull V- ring 411.6 off
- Undo both nuts 920.3 and pull gland cover 452 out of spacer sleeve 525.1
- Remove O-ring 412.10
seal housing 441.1. - Pull off spaces sleeve 525.1
- Remove packing rings 461. - Remove any auxiliary pipe work (circulation, etc.),
7.3.4.2 Replacing the Shaft Protecting Sleeve depending on the pump version.
- Loosen nuts 920.3 at the mechanical seal cover
- Remove the bearing as described in sections 7.3.3.1 and until the spring is relaxed.
7.3.3.2. - Remove bearing housing 350.1.
- Remove packing rings as described in section 7.3.4.1. - Take off mechanical seal cover 471.1 with the seat ring and
- Grease-Lubricated version pull V-ring 411.6 off gasket 400.1, remove spring loaded ring (not in case of
spacer sleeve 525.1. bellows seal).
- Remove O-ring 412.10. - Remove key 940.2.
- Take off spacer sleeve 525.1. - Pull off sleeve 523.1 with the rotating assembly of the
- Remove bearing housing 350.1. mechanical seal. (Two holes are supplied in the sleeve for
- Remove the seal housing 441.1 together with gland engaging a pull-off device.)
cover 452. - Take off shaft seal housing 441.1
- Remove key 940 - Remove O-ring 412.4.
- Take off sleeve 524 with a pull-off device. Use the groove
in the sleeve to do so.
- Remove O-ring 412.4.
N.B.: If the sleeve 524 proves difficult to remove, the balance
drum can be used for leverage.
- Remove balance drum 59-4, disc 550.3 and sleeve 524 with
a pull-off device engaged in the threaded holes on the drum.
This is not possible on pumps without balance drum.
902.2 5 2 5 . 1 4 1 2 . 1 0
920.3
441.1 5 2 3 . 14 0 0 . 1 3 5 0 . 1 940.2 5 0 7
Fig. 32
59-4 .1 412.10
920.3
550.3 461 524 350.1 940.2 507
Fig. 30
Pump design without balance drum
Fig. 31
525.4
18
Multitec
7.3.5.2 Removing an Air-Cooled Mechanical Seal 7.3.5.3 Dismantling of a water-cooled mechanical seal
(Seal code 64) (Sealing Code 64)
506 4 1 2 . 4 4 4 1 . 4 5 2 3 . 1 9 0 1 . 1 1 9 4 0 . 5 4 1 2 . 10 6D
412.4 731.15 400.1 903.11 471.1
152 i 561.5 411.21 441.4 I 411.17 433.7
Fig. 33
N.B.: This mechanical seal design is used for
application temperatures from 140[JC to 200 °C and Multitec 525.8 | 523.1 I 412.13 66-2 902.2 940.5 421.1 551.1 525.1 412.10
506 350.1 920.3
sizes 32 to 100. The pump shall only be coupled to a motor with
enclosure IP 55.
- Remove bearing ace. to sections 7.3.3.1 or 7.3.3.2. Fig. 35
- Remove O-ring 412.10
- Pull off spacer sleeve 525.1. N.B.: This application concerns the operation at temperatures
- Loosen bolts 901.11. ranging from 140 to 200°C and sizes 125 and 150 (optional for
- Remove bearing housing 350.1 sizes 32 to 100).
- Remove mechanical seal cover 471.1 with the seat
ring and gasket 400.1. - Drain pump and unscrew circulation line using the pipe
- Remove key 940.5 unions 731.15
- Pull off sleeve 523.1 with the rotating assembly of - Remove rolling element bearing according to chapters
mechanical seal 433.7. (Two holes are supplied in 7.3.3.1 and 7.3.3.2
the sleeve for engaging a pull-off device.) - Remove O-ring 412.10
- Take off sealing housing 441.1 - Pull off spacer sleeve 525.1
- Remove O-ring 412.4. - Unscrew nuts 920.3
In case of a between-bearings pump (installation type/pump - Take off bearing housing 350.1
version C or D) the mechanical seal shall be removed as fol-
lows: - Remove mechanical seal cover 471.1 together with the seat-
- Remove screws 900.2 and hood 683.1. ring and gasket 400.1
- Undo axle 87-5 together with fan impeller 831.1 - Remove key 940.5
- the threaded insert 915 has to remain in the shaft 210 - Pull off sleeve 523.1 with the rotating assembly of the
mechanical seal 433.7. (Two holes are provided in the
Caution I ^ o r P r e v i o u s versions (prior to 03/2002) and
I I assembly in the factory, the axle 87-5 and the fan
impeller 831.1 were assembled using Loctite 222.
sleeve for engaging a pull-off device).
- Remove cooling jacket 66-2
Caution I ' = o r P r e v ' o u s versions and re-installation, the axle - Take off seal housing 441.4
I 87-5 and the fan impeller 831.1 must be - Remove O-ring 412.4
secured with Loctite 222. 7.3.5.4 Removing a Double-Acting Mechanical Seal
- Remove support 59-7. Mechanical seals in tandem, face-to-face and back-to-back
- Dismantle the bearing as described in section arrangement are fitted as per customer specifications. There is
7.3.3.1 as well as spacer sleeve 525.1 and bearing a wide variety of variants, types and brands. Please refer to the
housing 350.1. general drawing and the documentation supplied with the pump
The removal of the mechanical seal is done as described for orientation.
above.
831.1
Fig. 34 19
Multitec
7.3.6 Dismantling the Hydraulic Elements 7.3.7 Recommended Spare Parts Stock for 2 Years'
- Remove the bearings as described in sections 7.3.3.1 and Coutinuous Operation
7.3.3.2 and the shaft seals as described in sections I Caution I recommend to replace different wear parts
7.3.4 and 7.3.5.
' ' (such as rolling element bearings, sealing
If possible, place the hydraulic system in vertical position and elements, circiips etc.) whenever the entire hydraulic system is
start dismantling it from the discharge end. dismantled (See spare parts list below.)
- Loosen the four tie bolts 905. Part Description Number of pumps
- Remove discharge casing 107 and then the hydraulic No. (including stand-by pumps)
system. 2 3 4 5 6+7 8+9 10 and
N.B.: The pump versions A/B/C/D in material variants 22/23/30 more
have an intermediate bearing in the middle stage as of the
For shaft seal codes 65 and 66 (gland packing)
number of stages listed in the table (see Fig. 36).
210 Shaft with small parts 1 1 2 2 2 3 30%
Pump Size 32 50 65 100 125 150 230 lmpeller(set = S) 1 1 1 2 2 3 30%
231 Suction impeller 1 1 1 2 2 3 30%
No. of Stages 8 7 6 6 5 6 320.1 Fixed bearing (set) 1 1 2 2 3 4 50%
320.2 Radial bearing 1 1 2 2 3 4 50%
381 Bearing cartridge 1 1 2 2 3 4 50%
411 V-ring( set) 4 8 8 8 g 12 150%
412 O-ring(set = S) 4 8 8 8 9 12 150%
461 Gland packing (set) 4 6 8 8 9 12 150%
5021> Casing wear ring (set) 2 2 2 3 3 4 50%
520 Sleeve 1 1 2 2 3 4 50%
524 Shaft protecting aleeve 2 2 2 3 3 4 50%
525 Spacer sleeve 2 2 2 3 3 4 50%
529 Bearing sleeve 1 1 2 2 3 4 50%
540 Bush 1 1 1 2 2 3 30%
550.12> Disc 2 2 2 3 3 4 50%
59-4 Balance drum 1 1 1 2 2 3 30%
For shaft seal codes 61, 62,63 and 64 (with mechanical seal)
433 Complete mechanical seal 2 3 4 5 6 7 90%
523 3) 2 2 2 3 3 4 50%
Shaft sleeve (set)
For oillubrication
4214> Radial seal ring 4 8 8 8 9 12 150%
171.5 540.3 230.1
Fig. 36 423") Labyrinth ring 2 3 4 5 6 7 90%
540.3 Intermediate bearing-bush 1) only pump sizes 125 and 150

2) only pump sizes 32 to 100
171.5 Intermediate bearing-diffuser 3) Parts 461 and 524 unassembled
4) in ace. with version
N.B.: Please always indicate the works number stamped onto

the pump name plate when ordering spare parts.
7.4 Reassembly
e urn sna De
I Caution II ^with the

P P " ' reassembled in accordance
rules of sound engineering practice:
- Under no circumstances use force.
- Due to their weight, some pump components must be
supported during reassembly.
- Before reassembly, the locating surfaces of the individual
components must be coated with a mounting aid in
compliance with hygienic health and safety regulations.
- The properties of new pump components must not be
altered without prior consultation with our technical
departments.
- The parts must be clean and free from shavings or dust.
- Reassembly is effected in reverse order to dismantling.
- The tightening torques indicated must be complied with.
Avoid the use of mounting aids as far as possible. Should
a mounting aid be required after all, use a commercially
available contact adhesive, e.g. Pattex, HYLOMAR or
Epple 33, after prior consultation with our technical
departments. The adhesive must only be applied
at selected points and in thin layers. Do not use cyano-
acrylate adhesives (quick-setting adhesives).
20
Multitec
7.4.1 Tightening Torques - Tie Bolts part No. 905 The gland cover must be tightened by hand at first. Use a feeler
Material codes 10,11,12,13 (casing: cast iron) gauge to check the level position of the gland cover. It must be
easy to rotate the rotor by hand.
Pump size Tightening torque (Nm) Leakage is normal during pump commissioning. After approx.
Multitec 32 85 5 minutes' operating period, the amount of leakage can be
Multitec 50 140 reduced by steadily tightening the nuts of the gland cover by 1 /6
Multitec 65 250 of a turn. Keep an eye on the amount of leakage and the water
Multitec 100 395 temperature, it takes several hours of pump operation for the
Multitec 125 600 gland to be adjusted completely. There must be a high leakage
Multitec 150 700 rate during the running-in period.
Repeat this procedure every five minutes until a minimum value
Material codes 20 to 30 is reached.
(casing: steel or stainless steel) Pump size
Dimensions in
Operating pressure Tightening torque
Pump size mm 32 - 50 - 65 100 125 150
(bar) (Nm)
Multitec 32 150 Packing cross-
section
10D 12,5 • 16D
Multitec 50 240
Length of
Muititec 65 All 430
packing cord
= 181 «223 =254 «306
Multitec 100 680
Number of
Multitec 125 1370 5 6
packing rings
< 40 1500
Multitec 150 Gland housing
> 40 2000
7.4.2 Reassembly of Hydraulic System
Pump reassembly starts at the suction side and proceeds
towards the discharge side. It is advisable to place the pump in
vertical position for reassembly. The sequence of reassembly
does not pose special problems and should be done according
to detailed sectional drawings showing the list of individual
parts. The components shall be re-installed in the same place
as before dismantling.
A clearance of 0.7 to 1.2 mm shall be set between the last
impeller 230.1 or 230.3 and the balance drum 59-4 (or spacer
sleeve 525.4).
When tightening the tie bolts, proceed as follows:
- Tighten the nuts of the tie bolts 905 gently, with the pump
in vertical position.
Pump size di da I
- Place the pump in horizontal position upon its feet on the
assembly table. 32 - 50 - 65 45 65 50
- Tighten the nuts of tie bolts 905 in two steps (first step: 100 56 80 60
50 % of nominal torque, second step: nominal torque) in
the sequence 1.4.2.3. 125 66 90 72
150 78 110 96
o o Fig. 38 Gland chamber dimensions
1 2
3 4
Fig. 37
o o
7.4.3 Seals
Gland packing
Before re-packing, thoroughly clean the gland packing
chamber and the gland cover.
I Caution I P a c k i n 9 n n 9 s m u s t be inserted so that the cut
» * edge is displaced by approx. 90° to 120° in
relation to the previous one.
Slip the pre-stressed packing rings onto the shaft protecting
sleeve, press home the first packing ring with the help of the
gland follower. Each packing ring must be pressed into the
packing chamber individually, using the gland cover.
For gland packings with lantern ring (for use in vacuum oper-
ation), the lantern ring is mounted instead of the next to last
packing ring (the last packing ring is located in the seal chamber
on the pump side).
21
Multitec
Mechanical Seals 7.4.3.1 Leakage at the Mechanical Seal
- Check axial alignment of the seal.
I Caution I Mechanical seals are precision components. The
* seat ring and the spring-loaded ring must always
be replaced together, i.e. always replace the entire mechanical
- Check gasket 400.1.
- Remove seal cover 471.1 (471.2 for bellows seal) and check
seal. position of seat ring in the cover.
To ensure trouble-free operation of the mechanical seal. The - Check the O-ring on shaft sleeve 523.1.
seal faces and any tools used must be absolutely clean. - Check O-ring 412.4.
Mechanical seals must be installed with utmost care. 7.4.4. Bearings
The seal faces shall only be cleaned immediately before
assembly takes place. They must not be greasy (grease, Plain bearings
smudges...) or damaged. in installation types A, B, E, Ex, F, Fx, V, Vx are re-installed in
Individual seal components such as O-rings made of EPDM reverse order to dismantling.
must never come into contact with oil or grease. Rolling element bearings
The mechanical seal shall be re-assembled in the reverse The rolling element bearings are generally mounted on a
sequence of dismantling. bearing sleeve and tightened with the shaft nut
When mounting the seat ring, the shaft sleeve may be wetted 920.2/920.6/920.7. They are re-installed in reverse order to
with clean medium handled to reduce the friction forces. dismantling. The position of keywayed nuts 920.6 (contact
The seat ring and the spring-loaded ring shall always be surface = plane surface with recess) marked during dismant-
mounted by hand resp. fingers, making sure that pressure is ling (7.3.3.2) must be complied with.
applied evenly, without tipping. Check the concentricity and face run-out of ring 500.1 with a
dial gauge for variants with oil lubrication.
Horizontal baseplate-mounted pumps
Caution I ^ n PumP versions C and D, the rotational
I I direction has to be observed for mechanical seals
fitted with uni-directional springs.
Left-handspring Right-hand spring
View
towards
the spring-
Fig. 3 9 loaded ring
Sealing elements
I Caution I Sealing elements made of EPDM must never

I come into contact with oil or grease.
Defective O-rings (which have sustained mechanical damage
such as cuts, cracks and deformation as well as changes in
properties from deposits or embrittlement) must be replaced.
New gaskets shall be used whenever the pump is
reassembled.
If possible, sealing elements shall be mounted without the use
of mounting aids like grease or adhesives, unless authorised
mounting aids are used.
22
Multitec
I Caution I W n e n tightening shaft nuts, the following has to be observed:
The shaft nuts must be tightened according to the values indicated in the table "Tightening Torques of Shaft Nuts",
Tightening of the Shaft Nuts of the Multitec
Shaft nuts without lockwasher
Does nota
I Caution I PP' v to d r i v e s i d e o f M T C
32/50/65 with self-locking shaft nut.
Tightening torques for shaft nuts
DriveiEnd Non-dri ve End
Size A,B, C,D ",v A,B,I=,F,V c,D
Nut Nm Nut Nm Nut Nm Nut Nm
801) 80 1 ) 801)
MTC 32 M 25x1,5 40(***) M 25x1,5 40(***) M 25x1,5 40 M 25x1,5 40
100(*)
801) 801> 80 1 )
MTC 50 M 30x1,5 40(***) M 25x1,5 40(***) M 30x1,5 40 M 30x1,5 40
120(*)
1001) 80 D 100
MTC 65 M 35x1,5 50(***) M 30x1,5 40(***) M 35x1,5 50 M 35x1,5 50
1500
1501) 1501) 1501)
M 42x1,5 M 42x1,5 50 50 50
MTC 100 50
(2x) M 42x1,5 M 42x1,5
(2X)
1500 150D 1500

2001) 2001) 2001)
M 52x1,5 M 52x1,5 60 60(***)
MTC 125 60 60 M 50x1,5 M 52x1,5
(2x) (2x)
200(*) 200(*) 200(*)
2501) 2501) 2501)
M 62x1,5 M 62x1,5 80 80 M 62x1,5 80
MTC 150 (2x)
80
(2x) M 60x1,5 (2x)
250(*) 250(*) 250(*) 250(*)
1) loosen after first tightening
(*) block when tightening first nut
(**) self-locking nut
(***) bend over lockwasher
Tightening of the Shaft Nuts of the Multitec
Nut with lockwasher - (drive end and non-drive end for versions C and D)
1.) Tighten nut with torque M1, then loosen again

2.) Tighten with torque M2 and bend over lockwasher
Nut with counter-nut - drive end (and non-drive end for versions C and D)
1.) Tighten first nut with torque M1, then loosen again
2.) Tighten first nut with torque M2
3.) Tighten second nut with torque M3, at the same time block first nut
Nut with counter-nut- non-drive end (except for versions C and D)
1.) Tighten first nut with torque M1

2.) Tighten second nut with torque M2, at the same time block first nut
Self-locking nut - old design MTC E/F/V 32/50/65 (drive side) No torques specified.
No torques given
23
Multitec
If there is no suitable torque wrench available for the tightening After installation of the bearings, the following controls need
of the shaft nuts, proceed as follows with respect to each to be made:
design: - Grease lubricated bearings: Check the clearance
between cover 360.1 and bearing housing 350.1 after
Self-locking nut on drive end or non-drive end (versions having tightened the bolts 901.1. There should be a
C and D) clearance between 0.2 mm and 0.8 mm. The cover 360.1
• Tighten fast the shaft nut firmly must not rest on the bearing housing 350.1.
• Loosen the shaft nut again - Oil lubricated bearings: Check the clearance between
• Apply adhesive to thread (e.g. LOCTITE) cover 360.2 and bearing housing 350.1 by verifying the
• Moderately tighten the shaft nut dimensions prior to re-assembly (if bearings or cover
have to be replaced).
Nut with lockwasher on drive end (or non-drive end
versions C and D)
Rolling element bearings
• Tighten the shaft nut firmly Grease lubricated bearings
• Loosen the shaft nut again 0.2 ...0.8 mm
• Moderately tighten the shaft nut
• Bend over lockwasher
Nut with counter-nut on drive end or non-drive end
(versions C and D)
• Tighten fast first shaft nut firmly
• Loosen first shaft nut again
• Moderately tighten first shaft nut
• Block first shaft nut using suitable tool and tighten
counter-nut firmly against first shaft nut
Nut with counter-nut on non-drive end
(all versions except C and D)
• Moderately tighten first shaft nut
• Block first shaft nut using suitable tool and tighten
counter-nut closely against first shaft nut
Fixed bearings
The fixed bearing is the coupling-side bearing on the cou-
pling end. Deep groove ball bearings are installed in size 32.
The other sizes are equipped with angular contact ball Fig. 40
bearings mounted in X arrangement (see sectional drawing). Pump stee Drive end 320.1 Non-drive end 320.2
The spacer discs 551.1 serve to position the rotor in axial 32 6309ZZC3-HT 6309ZZC3-HT
direction. 50 2 x 7309 BUA 6309ZZC3-HT
Axial adjustment of the rotor in not required. 65 2X7309BUA 6309ZZC3-HT
The correct axial position of the rotor is achieved by putting in 100 2x7312 BUA 6312 C3
the bearing housing 350.1 spacer discs 551.1 to a total 125 2x7312 BUA 6312 C3
thickness of 1.6 mm (1 x 1 mm + 3 x 0.2 mm) on the side of 150 2x7315 BUA 6315 C3
the bearing (or angular contact ball bearings).
I Caution I ^ n P r e v ' o u s versions, the axial alignment of the
• * rotor is set by putting on both sides of the bearing Oil-lubricated bearings
(or the angular contact ball bearing) spacer discs 551.1 to a total 0.2... 0.8 mm
thickness of 1.6 mm.
The tightening of the cover bolts 901.1 (or 901.8 for
oil-lubricated bearings) must be done in diagonally opposite
sequence taking into consideration the tightening torques as
follows:
MTC 32/50/65: 30 Nm
MTC 100/125/150 40 Nm
Fig. 41
The same rolling element bearings will be installed for oil
lubrication as for grease lubrication.
Exception: Instead of bearing design 6309 ZZC3-HAT, rolling
element bearing type 6309C will be used for oil lubrication.
24
Multitec
Radial bearing
Versions C and D are equipped with a deep-groove ball bearing 7.5.2 Repairs
as radial bearing. (The other versions are fitted with a plain Clearance between impeller 231 and suction casing:
bearing in the suction casing.) The outer race of the Pump size 32 to 65 for material codes 10,11,12,13:
deep-groove ball bearing must have axial play. The bearing is Re-working the suction casing and mounting a spare casing
installed without spacer discs 551.1. wear ring as per ZN 1095 and re-working the impeller.
For other pump sizes and material codes:
Replacing the casing wear ring 521.1 by a spare ring as per
ZN 1095 and re-working the impeller.
Clearance between impeller 230 and disc 550.1 resp.
casing wear ring 502.2:
(Size 125 and 150):
Replace the casing wear ring 502.2 with a spare ring as per
ZN 1095 and re-working the impeller.
(Size 32 to 100):
Two repair methods are possible:
a) Replacing the impellers 230 and discs 550.1 with new parts.
Quick repair method, no re-work of parts required.
b) Re-working the impellers at the impeller eye by deposit
welding and subsequently machining to the original diameter.
This repair method is used for impellers made of stainless steel.
Fig. 42 Clearance gaps between impeller 230 and diffusor:

a) Re-working the impellers at the sealing gaps of the hubs.
Re-working the diffusors and installing a interstage bush acc.to
7.4.4.1 Temperature of the Rolling Element Bearings ZN 140.
Caution I T n e temperature of the rolling element bearings, b) Should hub thickness be insufficient after re-working, replace
I ' which run at 3000 1/min and more, can be 90°C.
Manual temperature checks are not sufficient!
the impeller or install a spacer sleeve (see drawing below). The
spacer sleeve must be driven by the impeller key. Attention
- The bearings only reach their normal operating temperature should be given that the carrying key length in the impeller is at
after some hours of operation. least 2/3 of the total (carrying) key length.
- When a new pump is started up, the bearing temperature
may exceed 95°C. After 2 or 3 operating hours, it will sink
slowly and level out to a constant value after approxi
mately one week.
- A temperature rise may occur after service activities
comprising re-placement of bearings or dismantling of
hydraulic system.
Should the temperature exceed 100 °C during pump start-up,
switch off the pump and perform the following checks:
- Check whether the unit is correctly aligned
- Remove the bearings, check grease quantity.
An excessive grease quantity will cause excessive
temperatures.
- Check the bearing type and arrangement (see 7.4.4.4)
- Restart the pump. Ensure tight press fit between outer races
and cover (fixed bearing).
7.5 Re-adjusting the Clearance Gaps
7.5.1 Maximum Clearance Gaps
The following max. diameters of clearances apply: Fig. 43
D
Installation and Re-commissioning
Impellers 230 and 231 Please refer to the appropriate sections of these operating
Suction side clearance gap 0.8 mm instructions.
Clearance gap at the hub 0.8 mm
Balance drum 59-4 0.8 mm
Suction casing 106.1 and 1.0 mm if the product is
spacer sleeve 525.2 (only for pumped from a vessel under
pump versions C and D) vacuum conditions
2.5 mm for all other operating
conditions
Should wider clearances be found, the parts subject to wear
must be replaced.
N.B.: The performance of the pump is adversely affected by
excessive clearances. Losses in efficiency and head will occur.
25
Multitec
8 Trouble-Shooting
Cause Remedy
Pump delivers against an excessively high discharge pressure. Re-adjust duty point.
Check plant for Impurities.
Fit one or several larger Impellers.
Increase the speed (turbine, I.C, engine).
Pump or piping are not completely vented or primed. Vent and/or prime.
Supply line or impeller clogged. Remove deposits in the pump and/or piping.
Formation of air pockets in the piping. Alter piping layout.
Fit a vent valve.
Suction head is too high/NPSH available (positive suction head) Is too low. Check/alter liquid level.
Fully open shut-off valve in the suction line.
Change suction line, If the friction losses in the suction line are too high.
Check strainer / foot valve and suction line for clogging.
Air Intake at the shaft seal. Clean sealing liquid channel, supply with external sealing liquid 2) 3)> if
required, or increase its pressure.
Fit new shaft seal.
Reverse rotation. Interchange two of the phases of the power supply cable.
Speed is too low.2) Increase speed.
Wear of internal pump parts. Replace worn components by new ones.
Pump back pressure is lower than specified in the purchase order. Adjust duty point accurately.
Density or viscosity of the fluid pumped is higher than stated in the

purchase order.
Gland cover too tight or askew. Correct. Increase leakage slightly.

Speed is too high. Reduce the speed.2)
Tie bolts/seals and gaskets. Tighten the bolts.
Fit new seals and gaskets.
Worn shaft seal. Fit new shaft seal.

Check sealing liquid pressure 2>3>
Score marks or roughness on shaft protecting sleeve / shaft sleeve. Fit new shaft protecting sleeve / shaft sleeve.
Fit new shaft seal.
Vibrations during pump operation. Improve suction conditions.

Re-align the pump.
Re-balance the rotor.
Increase the pressure at the pump suction nozzle.
The unit is misaligned. Re-align.
The pump Is warped or sympathetic vibrations in the piping. Check pipeline connections and secure fixing of pump; if required, reduce
the distances between the pipe clamps.
Fix the pipelines using anti-vibration material.
Outer bearing races of fixed bearing are loo: Clamp outer bearing races axiatly.
Increased axial thrust.2) Check rotor clearances, axial adjustment and clearance on throttling bush/
balance drum
Insufficient or excessive quantity of lubricant or unsuitable lubricant. Top up, reduce or change lubricant.
Non-compliance with specified coupling distance. Correct distance according to the installation plan.
The motor is running on two phases only. Replace the defective fuse.
Check the electric cable connections.
Rotor is out of balance. Clean the impellers.
Re-balance the rotor.
Defective bearings. Fit new bearings.

Insufficient rate of flow. Increase the minimum rate of flow.
Fault in circulation line Increase the free cross-section.
In case of parallel operation, check valve defective or missing. Check.
Incorrect installation of gland packing. Check.
Unsuitable packing material.
Inadequate cooling of shaft seal chamber. Check the free cross-section of the cooling liquid feed line.
Change in the free cross-section of the return line of the balancing liquid. Check the balancing line.
Wear in balancing device. Check the clearance on the throttling bush/balance drum
1) The pump pressure must be released before attempting to remedy faults on parts which are subjected to pressure.
2) Contact KSB.
3) Pump version with sealing liquid supply only available on request.
26
Multitec
9 General Drawing
Sizes 32 to 100
Radial suction nozzle 106.1 412.1 230.1 905
903.2 920.4
411.2 .1 550 4
- 107 *11-2 59-4 S40.1
350.1
81-92
411.7
940.3
412
Design without balance drum
Axial suction nozzle

up to pump size 50
Axial suction nozzle

pump size 65 and above
nL411.a 903.4 731.3
411.4 ii
1) only for version with mechanical seal

2) from pump sjze 65
3) from pump size 100
4 except for pump size 32
5) only pump size 32 and 50
6) only hydraulics 9.2/10.2/11.1 and 12.1
7) only for variant with balance drum
27
Multitec
Close-coupled pump up to size 65
Radial suction nozzle B61.1 901.5 901.6 920.10
1O6,1 412.1 230.1
903.2
411-2 I ?¥i I 550.1
Vertical version
Pump size 100,125 and 150
aoo-
901.7—~
920.10
661.2 •
920.9-
901.5-
861.1-
902.1-
920.1

4 except for pump size 32
5) only pump size 32 and 50
6) only hydraulics 9.2/10.2/11.1 and 12.1
7) only for variant with balance drum
28
Multitec
Pump size 125 and 150
Version B 106.1 171.1 230.1
350.1
81-92
7) 732.1
59-4 902.1 900.4 551.1901.1 411.7
940.3
520.1
320.1
903.1 411.25] 903.1

411.1 7 3 14 411.1 Material codes 20, 2 1 , 22, 23 and 30
6B 411.23| 6B
731.1 502.2 940.2 550.3 903.3
12E 411,3
Version C
--W-
182
914.1
932.2
Bypass of balancing line

MTC 150, 2-po!e
920.7 320
931

.16 903.1 7 1 0 . 3 411.25 903.4 731.17 710.1
4 except for pump size 32 . 8 4 1 1 . 1 71 7 3 1 . 4 4 1 1 . 4 7) 71
5) only pump size 32 and 50 6B 411.23
6) only hydraulics 9.2/10.2/11.1 and 12.1 731.1
7) only for variant with balance drum 1ZE
1)
29
Multitec
his list of components contains all spare parts mentioned in this document.
Part No. Description Part No. Description
106.1 1.2 Suction casing 540.1/2 Bush 1>
107 Discharge casing 550.1/2/3/4/6/8/9/10/11 Disc1)
108.1 Stage casing 551.1 1.2 Spacer disc
160.1 1.2 Cover 561.1 Grooved pin
171.1 Diffuser 565 Rivet
181 Pump stool 59-4 Balance drum 1)
182 Foot 59-7 Support
210 Shaft 1> 636 Lubricating nipple
1
230 Impeller ) 638 Constant level oiler
1
231 Suction impeller ) 681.2 Coupling guard
320.1 1.2 Rolling element bearing 1) 683.1 Hood
341 Drive lantern 710.1/2 Pipe
342 Thrust bearing lantern 723.1 Flange
350 Bearing housing 731.1/3/4/5 Pipe union
360.1 Bearing cover 800 Motor
361.1 Non-drive end bearing cover 831.1 Fan impeller
1
381 Bearing cartridge ) 861.1/2/3/4 Coupling half
400.1 Gasket 87-5 Axle
411.1/2/3/4/5/6/7/8/13 Joint ring 1) 89-8 Foundation rail
412.1/2/3/4/5/10/11/12 O-ring 1) 900.2 Screw
421.1/2/3 Radial seal ring 901.1/2/3/4/5/6/7/8/9/
423.1/2 Labyrinh ring 10/11/12 Hex. head bolt
433.1/7/10 Mechanical seal 902.2 Stud

903.1/2/3/4/5/9/10/11/
441.1/4 Seal housing
14 Screwed plug
452 Gland cover 905 Tie bolt
461 Gland packing 1) 914.1 Socket head cap screw
471.1/2 Seal cover 920.1/2/3/4/5/6/7/9/10/
500.1 Ring 11 Nut
1 931
502.1/2 Casing wear ring ) Lockwasher
1 932.1/2 Circlip
520.1/2/3/4 Sleeve >
523.1 Shaft sleeve 940.1/2/3/4/5 Key
524 Shaft protecting sleeve 1) 950.2/3 Spring
525.1/2 Spacer sleeve 1) 971.1 Plate
1
529 Bearing sleeve SiC )
1) recommended spare parts (see section 7.3.7 on page 20)
30
Multitec
Adjusting Dimensions for Coupling Alignment, Pump sizes 32 to 65, Pump Versions E, Ex, F, Fx, V, Vx
Cotes de reglage pour alignement de raccouplement tailles 32 jusqu'a 65, Executions E, Ex, F, Fx, V, Vx
EinstellmaBe fur Kupplungsausrichtung BaugroRen 32 bis 65, Ausfiihrung E, Ex, F, Fx, V, Vx
0 Bride raoteur
0 Motor flange
fl Motor flansch
-Cale de reglage
Adjusting disci
Einsiellscheibsn
SSI. 7
Bild 44
Fig. 44
A n c l e n ac coup L ement N o u v e l accoup lament

Last coupling Nev c o u p l i n g
L B t z r e Kup p I ung Neu e K u p p l u n g
Arors noreur Cole de reglage Arbre mateur [•te de reglage

0 Bride noteur Shafrend motor Adjusting length t Bride noteur ShaFtend motor Adjusting length
9 Mater flange Wellende motor EinsleilMll 0 Motor flange We.lenrje motor [inslellnan
MUUITEC • 0.25 MULTITEC
(3 Motor flansch 0 Nolor flanuh *0.25
» iq -o.?1; « Iq -0.25
F165 32-50 24 50 80 F165 32-50 24 50 90
F215 32-50-65 28 60 90 F215 32-50-65 28 60 100
F265 32-50-65 38 80 110 F265 32-50-65 38 80 120
F300 32-50-65 42/48 110 140 F300 32-50-65 42/48 110 150
F350 65 48/55 110 140 F350 65 4B/55 110 150
F350 32-50 48/55 110 143 F350 32-50 46/55 110 153
F400 32-50-65 55 110 143 F400 32-50-65 55 110 153
F400/500 32-50-65 60 140 173 F400/500 32-50-65 60 140 183
F500/600 65 65 140 173 F500/600 65 65 140 183
F600 65 B0 no 203 F600 65 80 170 213
lAttenzionl T ' 1 e m o t o r s °f versions Ex, Fx and Vx are special motors with reinforced bearing which cannot be replaced by
i standard motors!
Caution I L " es m o t e u r s P o u r l e s versions Ex, Fx et Vx sont des moteurs speciaux a paliers renforces qui ne peuvent pas etre
! remplaces par des moteurs standard!
I Achtuna II Bei den Motoren
wiotoren furmr die aie Version
version Ex,
tx, Fx
t-x und
una Vx handelt es sich urn Sondermotoren mit verstarkter Lagerung, die nicht
vx nana
I 91 durch Standard-Motoren ersetzt werden konnen!
31
Data sheet
KSB b.
Page 1 V.3.4.0
Date 05.05.04 Offer no. 45419364
Enquiry No. Position (Item) 1
Client Item No. PO1
high-pressure pump MULTITEC Quantity

MTC A 65/5C-05.1 10.3.62
Operating data
FlowQ 62.5 m3/h pumped liquid
Flow rate by wt. 60.73 t/h Boiler feed water AF ( 0 2 specified)
mnimumflow 11.92 m3/h Quality AF, pH>9 (aim >=9.3) at 25 oC
Discharge head 308.96 m Content of O2 <= 0.02 mg/kg
Pumping pressure 29.46 bar solids content
NPSH available 5.52 m (max. 20 ppm)
Pump NPSH 2.85 m Operating temperature t/o 80 C
inlet pressure 0.00 bar Density (t/o) 0.972 kg/dm3
discharge pressure 29.46 bar viscosity (t/o) 0.37 mm2/s
adm. op. press, (t/o) 40 bar vapor pressure (t /o) 0.47 barabs
discharge pressure 34.15 bar Design speed 3564 1/min
Q=0 (+/- 5%) Efficiency 71 %
discharge pressure 35.13 bar Power input of pump (P2) 72.03 kW
(Density =1) motor power 84 kW
Head (enquiry) 294 m
Direct'n of rot. from drv. end clockwise
Design (version)
nozzle DN PN / Standard Position (*)

Suet, nozzle DN 125 PN16/EN1092T2 axial
Disch. nozzle DN 65 PN40/EN1092T2 top
no. of stages 05 (*) viewed from th drive
side
Shaft seal Mechanical seal

seal code 62 Materiai-Code AQ1EGG
bar
Bearing bracket bearing type Lubrication
suction side Plain bearing pumped liquid

discharge side Anti-frict bearings grease lubrication
installation variant A : horizontal baseplate design

Axial thrust balance balancing drum
Mode of operation Single pump
KSB
Data sheet
Page 2 V.3.4.0
Date 05.05.04 Offer no. 45419364
Enquiry No. Position (Item)
Client Item No. PO1
high-pressure pump MULTITEC Quantity

MTC A 65/5C-05.1 10.3.62
Materials
Material-Code 10
Suction casing JL1040 Bearing housing JL1040
Pressure (delivery) casing JL1040 Shaft seal housing JL1040
Stage casing JL1040 Wear ring 1.4571
Diffuser JL1040 Shaft sleeve 1.4057
Shaft 1.4021+QT Plain bearing SiC/SiC
Impeller 1.4408 casing gasket EPDM 80
Suction impeller 1.4408 tie bolts C45K
Balance drum 1.4021 Bush JL1040
Accessories Drive
Coupling Eupex Electric motor IMB3 60Hz ;46C
Size NH160 Rated power P2 84 kW
Spacer 140 mm size / insu. class 280S
Material JL1040 Type of protection IP55
PTC resistor 3
VIK version -
Motor standstill heater -
Model (make) KSB
Drive supplied by KSB
Baseplate
code GP12 internal piping
Material Steel
balancing pipe
Coupling guard
Size BS189
Material Steel monitoring (roling element bearings)
Foothold measuring hole for:

Size
Material
Anchor bolts
Coating, packing, nameplates

Coating std., top coat water-based pnt
RAL 5002, ultramarine blue
Packaging Standard packaging
Plates english
KSB b.
Page V.3.4.0
Date 05.05.04 Offer no. 45419364
Enquiry No. Position (Item) 1
Client Item No. PO1
Type series MTCA65/5C-05.1 10.3.62 Design speed 3564 1/min
n u i t tec 65-5C
350 • »
300 1 s
\
s
\
•»
100
100
••••£
II**
-*—
——
*-—
r
*——
-—*
•^.
- 60
- i
rcj
£ 40 /
an
**- - i i
»••'•*
—***
«-*
^ ^
^
— p. - ^
20 40 60 80 Q [m3/h)
* Obligatory values for operating point see data sheet

INDUSTRIES
Table of contents
Chemical dosing pump

Operation and maintenance.

SUMMARY
I GENERAL Page
1.1 Introduction G1.1
1.2 Operating principle G1.1
1.3 Technical characteristics G1.2
II INSTALLATION
2.1 Unpacking and storage G2.1
2.2 Recommendations for installing the pump G2.1
2.3 Electrical installation G2.2
2.4 Hydraulic system G2.2
2.5 Installation sketches G2.3
2.6 Installation of accessories G2.5
2.7 Calculations for installation G2.6
III OPERATION A N D MAINTENANCE

3.1 Checking before switching on G3.1
3.2 Start up G3.1
3.3 Routine checks G3.1
3.4 Preventive maintenance G3.1
3.5 Ordering spare parts G3.2
3.6 Product identification G3.2
3.7 Servicing and maintenance of the liquid end G3.3
3.8 Servicing and maintenance of mechanical assembly G3.8
3.9 Lubrication G3.14
IV FAULT LOCATION PROCEDURES G4.1

DOSAPRO
MILTON ROY
INSTRUCTION MANUAL
FOR INSTALLATION,
OPERATING,
AND MAINTENANCE.
Dosing pump
mROY A & B
This manual should be made available to the person responsible for installation,
operating and maintenance.
Date: 12/99 O / Ref: T.160.0401.001.Rev. E

GENERALITES
1.1-INTRODUCTION
The mRoy pump is a dosing pump with incorporated hydraulic diaphragm, oil-lubricated with sealed housing,
with a variable swept-volume adjustment which can be set when stopped or running. It is designed for
continuous service in industrial operation.
1.2 - OPERATING PRINCIPLE
- Worm (052A) / tangent wheel (052) pair drives connecting rod (214) through means of the
eccentric of wheel (052).
- Connecting rod (214) gives piston (012) a reciprocating motion with constant stroke.
- Through means of oil contained in chamber (D), the piston drives diaphragm (298A) held fast
between 2 contour plates (298).
- Relief valve (212A) protects the pump.
Suction phase:
Piston (012) draws back and sucks in the oil (H) behind diaphragm (298A). The differential pressure which is
created is transmitted by flexible diaphragm (298A) enabling the pumped fluid to be drawn in with perfect
separation between the pump mechanical parts and the pumped fluid. When adjusting sleeve (E) linked
mechanically to piston (012) opens orifice (B) of oil bypass (C), the additional oil is supplied by housing (081).
Discharge phase:
Piston (012) moves forward and forces the oil back to housing (081) through by-pass (C) and orifice (B) until
this orifice is blocked by adjustment sleeve (E). The oil then pushes diaphragm (298A) which moues forward
proportionally to the fraction of remaining swept-volume, after blocking orifice (B). The dosed liquid is pushed
back by the diaphragm through the discharge check-valves.
Flowrate adjustment:
The discharge flowrate is adjustable when running, from 0 to 100%, by turning adjustment knob (255) which
displaces, in the oil bath, and thus without any effort, adjustable liner (012A) and thus the position of orifice
(B).
Fig.1
A = stroke. I = backward
G1.1
1.3 - TECHNICAL CHARACTERISTICS
The nominal pump flow depends on the piston diameter and the actual pumping stroke speed. The influence
of pressure is low, on the order of-2% per section of 10 bars.
1.3.1 Technical characteristics for mRoy A
Type of pump mRoy A
piston diameter _ 0 11.1 15.9 27
(1) (2) Maximum discharge pressure in bars relative 123 123 46 59 21

(4) Maximum suction pressure in bars (Pa) 35 17.5 6
(3) Maximum flow in L/H (Q): at pressure of 10 b 2.6 10 5.5 22 66
at maximum pressure 1.95 7.8 4.1 19.8 64.5
Speed in strokes / min 29 112 29 112 112
Motor power in kW 0.25

Motor speed in rpm 1440
Motor mounting: Flange F130
Shaft 14x30
(5) Maximum height of suction in mce (Ha) 2
Volume of pulsation dampener in suction 0.13 L
Volume of pulsation dampener in discharge 0.13 L

Pre-expansion of pulsation dampener in discharge 60% of service pressure
Noise level: Acoustic pressure < 70 dB (A)
Simplex pump weight 25
Duplex pump weight 40
1.3.2 Technical characteristics for mRoy B with 0 1 5 piston
Type of pump mRoyB
piston diameter 0 15
(1) (2) Maximum discharge pressure in bars relative 105

(4) Maximum suction pressure in bars (Pa) 35
(3) Maximum flow in L/H (Q): at pressure of 10 b 14 21 34 53
at maximum pressure 11 17. 27 42
Speed in strokes / min 36 56 90 140
Motor power in kW 0.55 0.75 0.55 0.75
Motor speed in rpm 900 1440 900 1440

Shaft 19x40
(5) Maximum height of suction in mce (Ha) 1.5
Volume of pulsation dampener in suction 0.13


•G1.2
1.3.3 Technical characteristics for mRoy B with a 0 22.2 piston
Type of pump mRoyB
piston diameter 0 22.2
(1) (2) Maximum discharge pressure in bars relative 49 70 49 70 49 | 70 49 70

(4) Maximum suction pressure in bars (Pa) 17.5
(3)Maximum flowrate in L/H (Q):at pressure of 10b 30 30 46 46 74 74 114 114
at maximum pressure 27 26 42 40 68 65 105 100

Motor power in kW 0.55 0.75 0.55 0.75 0.55 0.75 0.75 1.1
Shaft 19x40 24x50 19x40 19x40 19x40 24x50 19x40 24xS0

1.3.4 Technical characteristics for mRoy B with a 0 36.5 piston
Type of pump mRoyB
piston diameter 0 36.5
(1) (2) Maximum discharge pressure in bars relative 14 28 14 28 14 28 14 28
(4) Maximum suction pressure in bars (Pa) 6
(3)Maximum flowrate in UH (Q):at pressure of 10b 80 80 124 124 200 200 310 310
at maximum pressure 79 77 123 119 198 192 307 298
Motor power in kW 0.55 0.75 0.55 | 0.75 0.55 0.75 0.75 1.5
Shaft 19x40 19x40 19x40 19x40 19x40 24x50 19x40 19x50


(1) Contact us for higher oressures

(2) 10 bars for the "P" versions
(3) Flow obtained on standard configuration, with water
(4) 6 Bars for "P" versions
(5) mce = Water column meter
G1.3
II. INSTALLATION
2.1 - UNPACKING AND STORAGE
The packing must be carefully examined at reception in order to ensure that the contents have not suffered
any obvious damage. Open the packing carefully; one should be careful not to damage certain accessories
which may be fastened to the inside of the packing. Examine the contents and check them against the
delivery slip.
The packing contains:
- One pump.
- Oil, depending on versions (see chapter 3.9)
- A list of wear-and-tear parts, accompanied by section drawings and space-requirement drawings.
- An instruction manual for pump installation, upkeep and maintenance
Storage precautions
For storage less than 6 months:
Storage is to be carried out preferably in the original packing and protected from inclement weather
conditions.
For storage longer than 6 months:
Preserve the original packing. Also provide packing under plastic heat-sealing wrapping and dehydrating
bags. Store the pump in protected, covered premises with full oil charge.
2.2 - R E C O M M E N D A T I O N FOR INSTALLING T H E PUMP
2.2.1 Manutention
Put the sling under the motor terminal box and under
the motor flange.
Cross the two ends of the sling and close the loop
(see diagrams).
Before attempting to move it, check that the entire
unit is well balanced.
Nota: As soon as the pump is in position, fasten it

down.
2.2.2 - Installing the pump

- Fasten the pump to a horizontal support using its fastening holes. Arrange enough free space around the
pump so as to be able to have easy access, and to ensure the upkeep and adjustments (accessibility to the
liquid end, filling, and housing oil draining).
- Connect the priming drain of the liquid end to a drip-collecting tank
- If the service pressure is greater than 3.5 bars, remove the spring located in the discharge check-valve box.
CAUTION: Pumps installed outdoors must be protected from the elements.
2.2.3 Oil filling (Fig. 1A).
- Unscrew the oil filler plug located on top of
thepump. n „. _ Oil filler plug.
Ol1 level indicator
- Unscrew the level indicator located on the ^ P=C
side of the pump.
- Pour the oil in until it reaches the threading
DrainplU9
of the level indicator.
- Screw the level indicator back in. F"9-1A
- Fill up with oil to the middle of the level
indicator.
- Screw the oil filler plug back on.
G2.1
2.3 - ELECTRICAL INSTALLATION
Verify the motor data against your available mains supply for the plant before carrying out connections.
Connect the motor according to the indications given in the terminal box.
A
For 230 V delta connection
For 440 V delta connection
Before operating the pump, check the direction of rotation of the motor which must be
according to the arrow stamped on the motor (Counter-clockwise direction when seen
from top). To reverse the direction of rotation, just reverse A and B or A and C.
CAUTION : DO NOT FORGET TO CONNECT THE PUMP TO EARTH

Electric protection of the motor (thermic protection or by means of fuses) is to correspond to the rated
current indicated on the motor data plate.
2.4 - HYDRAULIC SYSTEM

Pipework - Generalities
As far as possible, avoid exerting stresses due to incorrect alignments between rigid pipes and the centreline
of valve boxes. Provide facilities for disassembly (union-pieces, and so forth...). Clean piping before
assembly.
2.4.1 Suction pipings

The pump is to be located as close as possible to the suction point and the piping is to be as short and as
direct as possible. If possible, have the suction point located slightly above the pump; in the event of long
period of rest, the pump will not unprime.
The diameter of the piping must be bigger or equal to the connection diameter of the liquid end. The suction
piping is to be ABSOLUTELY AIR TIGHT (check after assembly). When it is not possible to avoid long
suction pipework, use a RESERVOIR tank or a balancing column located as close as possible to the suction
aperture of the pump.
2.4.2 Delivery pipework

The diameter of the piping is to be bigger or equal to the connection diameter to the liquid end. Be sure that
the piping and accessories fitted on the delivery line are sufficiently strong to withstand the delivery pressure.
G2.2
Ill
2.5 - INSTALLATION SKETCHES
2.5.1 Installation on suction side
2.5.1.1 Recommended installations
[
D -,
n
\
L1
y Ha Ha
L
T1
Fi
Fig.2 Fig.3 9-4
Fig.2: The pump in suction placed above the tank(Ha = maximum 2.5 m water column) is equipped with a
foot valve fitted at the suction end (F). Vertical suction.
Fig.3: Long sized pipework (L) requires the installation of a damper which is to be placed as close as
possible to the pump. L1 = Maximum 10 metres water column.
Fig. 4: The pump "in suction" offset in relation to the tank (Height [Ha] see chapter 1.3), is equipped with a
foot valve (F).
2.5.1.2 Installations to be avoided
Fig.5 Fig.6 Fig.7

Inclined suction pipe, risk of Suction piping long. Suction
height too great. Accumulation of gas (goose
un-priming (See Fig. 4, Chap.
neck) and risk of unpriming.
2.5.1.1)
2.5.1.3 Special installation

Degassing liquids.
1: Max level
2: Min level
V: Valves
G: Vent
R:degassing vessel
Fig.8
Fig. 8: Setting up a degassing vessel (Chap. 2.6.3.) at the pump suction (one thus avoids frequent un-
priming). Connection between the pump and the inclined degassing vessel in order to facilitate degassing.
G2.3
2.5.2 Installations on delivery line
2.5.2.1 Recommended installation
lr--.gr-
Fig.10
Fig.9
Fig. 9: Long pipe lengths and delivery in a pressurized conduit (P): Install an injection pipe (E), a buffer tank
(D) and a safety valve (C).
Fig. 10: Long pipe lengths and delivery in a non-pressurized conduit: Install a nonreturn valve (B) or check
valve (A) and a buffer tank (D).
For short lengths of discharge pipe (L), the buffer tank (D) can be dispensed with although it increases the
service life of the metering pump and of the installation.
If the delivery pressure is less than 2 bars, an injection pipe or nonreturn valve should be used.
2.5.2.2 Installations to be avoided

• D
Fig.11 Fig.12 Fig.13

Pulsation dampener (D) not very Pulsation dampener (D) inefficient, Siphoning,
efficient, (pulsation dampener (D) (nonreturn valve installed before
too far from the liquid end) pulsation dampener (D)).
G2.4
2.6 - INSTALLATION OF ACCESSORIES
Proper functioning of the pump depends on whether certain accessories available from DOSAPRO MILTON
ROY are fitted or not. The salesman is at your disposal to determine the accessories which are best adapted
to your plant.
2.6.1 Non return valve (F)

Necessary when the pump is fitted above the suction point. Thus minimizing the risk of unpriming; it is fitted
with a filter.
2.6.2 Filter
It is very CAUTION when there is gravity feed; it avoids accumulation of solid particles in the valve
assemblies and guarantees precision and pump life.
2.6.3 Safety valve (C)

The safety valve is to be vertically installed just above the liquid end, after the damper and before any other
accessory. The return line of the valve should be connected to the drainage tank or to the sump. The safety
valve protects the metering pump, the piping and accessories in the event of accidental overpressure (e.g.
shutting off of valve). This accessory contributes to safety for users by eliminating risks of the bursting or
rupture of components under pressure. It is recommended that a safety valve should be fitted on all
installations.
2.6.4 Damper (D)

Compressible gas-reserve device; this dampens the flow and pressure pulsations caused naturally by the
dosing pump. It is absolutely essential that the pulsation dampener be installed vertically on the discharge
and/or suction piping of the dosing pump, as near as possible to the latter, before any other accessory and
for it to be placed in the flow. For the volume and the pre-expansion of the dampener, see chapter 1.3.
CAUTION: Dampener construction materials must be compatible with the liquid to be pumped and with the
pumping pressure.
2.6.5 Non return valve (A)

The non-return valve is to be installed in line on the delivery piping. Its operation may be improved by
installing a dampener located upwards on the line.
2.6.6 Injection nozzle (E)

Fitted at the injection point, it acts as a non-return valve. It isolates the processed fluid from the main fluid
(often water).
A 2.6.7 Insulation Valve (F)

When the pump is not running, it is essential to insulate it from the pressure circuit with a manual or automatic
valve, to prevent any return pressure in the liquid end, which could damage the pressure plate of the oil-
actuated diaphragm.
G2.5
2.7 - INSTALLATION CALCULATIONS
2.7.1 General
Sizing of the plant suction line corresponds to the NPSH calculation (Net Positive Suction Head) and it aims
to avoid any risk of cavitation. Very often when processing non viscous liquids (typically less than 50 cp), the
NPSH calculation is needed to verify the following condition:
with
W= Liquid density.
Pa = Suction pressure (bars absolute).
Tv = Vapour pressure (in bars).
Ha = Suction height (in m). (Ha is negative with the pump placed above the suction point; it is positive when
gravity fed).
L = Length of the piping (in m).
Q = Max flowrate of the pump (in l/h).
N = No of pump strokes (in str./min).
d = Inside diameter of the piping (in mm).
2.7.2 Example
Calculation carried out to deliver a flow of 200 L/H.
W 1 L 1
Pa 1 Q 560
Tv 0.025 N 144
Ha d :12.5
1x144x560
This condition shows: (1-0.025) + l> 2 + 0.016
;
thus: 10.945 > 4.064 12.52
The condition is met and the pump will not give rise to cavitation.
When the NPSH condition is not obtained, the installation conditions must be improved by making or
envisaging the following modifications:
- Place the pump under load: Ha increases
- Place the pump near the tank : L decreases
- Increase the diameter of the piping: d increases (the most effective solution)
- Place an pulsation dampener at the suction (see chapter 1.3)
Do not hesitate to consult your usual DMR representative for complete calculations.
G2.6
I l l OPERATION AND MAINTENANCE
3.1 - CHECKING BEFOR SWITCHING ON

- Check that the pump is properly mounted on its base
- Check the oil level.
- Check that the pump is set at 0%
- Check that all the isolating valves on the suction and discharge circuits are open.
- Check that the pump is properly supplied with liquid.
- If hot cold machine parts lead to a potential danger,
check that the these parts are protected against accidental constact at site.
3.2 - STARTUP
- Tun the pump ON
- Place the vernier on the 50% position, for 10 minutes.
- Untighten by around 1/4 turn, drain plug (B) located on the liquid end (Fig. 19) and (Fig.
20). Thus, the air trapped in the suction piping and the pump head can escape via the drain. Wait
until the liquid comes up to the evacuation level of this drain.
Let it flow for a few seconds in order to degas it completely, then retighten the drain plug.
3.3 - ROUTINE CHECKS

Periodically, it is necessary to check:
- The level and cleanliness of the oil.
- Leaks or unusual noises.
3.4 - PREVENTIVE MAINTENANCE

Before any servicing operation on the pump, it is necessary to turn the motor power supply OFF.
3.4.1 Servicing-intervention principles for preventive maintenance*:
Intervention Frequence * *
- Renewal of check-valve boxes (Chap. 3.7.1. to Chap. 3.7.3). 8000 h
- Renewal of diaphragm(s) (Chap. 3.7.4 and Chap. 3.7.5). 8000 h
- Renewal of safety valve assembly (Chap. 3.8.1 and Chap. 3.8.2). 8000 h
- Renewal of worm bearings (Chap. 3.8.10). 20000 h
- Renewal of worm and wheel (Chap. 3.8.11). 20000 h
- Renewal of sleeve liner O-rings (Chap. 3.8.3). 16000 h
* See list of wear parts for the ordering of the various parts.
* * Approximate no of hours when operating under max performance and normal conditions of
use.
G3.1
3.5 - ORDERING OF SPARE PARTS
To simplify your order and ensure the best delivery times of spare parts, we recommend giving
our services the correct code of your pump and its DOSAPRO MILTON ROY serial no. This
information is shown on the Nameplate fixed on the side of the pump.
Pump code f •
TYPE
DOSAPRO
MILTON ROY
A 112 F 3 H 2 1
PONT ST PIERRE
2 7 3 6 0 FRANCE
^
1
1
Dmax II "Ml IICPHIIl/h 1
Pmax Ilbarll IIPSI lln/mfl
DOSAPRO MILTON ROY Date 1
serial no N* 92.01.100A.01.01 1
Item 1
N'serie 1
J
3.6 - PRODUCT IDENTIFICATION
Our product identification tells us precisely the kind of equipment involved and gives us details on
each item comprising it.
Code : 1 A | 112 | F | 3 1 H I 21 |
I I I I I I
Zone : 1 2 3 4 5 6
The makeup of a standard mRoy pump is divided up into 6 zones:

Zone 1 : Type of pump (A: mRoy A; B: mRoy B)
Zone 2 : Stroke rate of the pump in spm
Zone 3 : Motor power
Zone 4 : Piston diameter
Zone 5 : Type of liquid end
Zone 6 : Service pressure
and, where applicable, a seventh zone which will be "DX" for a duplex pump.
G3.2
3.7 - SERVICING AND MAINTENANCE OF LIQUID END
Before carrying out any servicing operation on the metering unit or pipes, take the necessary
steps to ensure that the harmful liquid they contain cannot escape or come into contact with
• personnel. Suitable protective equipment must be provided. Check that there is no pressure
before proceeding with dismantling.
3.7.1 Renewal of check-valve boxes - General

Before any other servicing operation on the check-valve boxes place the vernier on the 0% position, check
that the isolating valves are closed, then disconnect the piping. When putting the check-valve boxes back
in place, systematically replace all the seals.
3.7.2 Renewal of seals / balls / valves _ metallic version
013 -~-_g
080A \~~~S;
003 0\$:
021B—\^\!
438A s\\ /
024.
438
-0^4
\J ft
438B ^ _ ;
mm
k F<
Fig. 14
Discharge check vdve assembly Fig.15
Suction check valve assembly
Suction check valve assembly Discharge check valve assembly

Disassembly Disassembly
- Unscrew counternut (209) by one-quarter - Unscrew cap (013) of the check-valve
of a turn, box by one-quarter of a turn
- Completely unscrew the cartridge of - Completely unscrew the cartridge of
check-valve box (021A), check-valve box (021B).
- Remove circlips (080) and balls (437A) - Completely unscrew cap (013) from the
(437) check-valve box.
- Clean the box completely. - Remove spring (080A), ball guide (003),
balls (437), seat (024).
- Clean the check-valve box completely.
Reassembly Reassembly
- Fit ball (437), then ball (437A) and - Fit O-ring (438) on seat (024)
circlips (080) - Fit balls (437), seat (024), ball guide
- Position spiral seal (408) in the sink of (003), spring (080A).
counternut (209) - Fit O-ring (438A) on cap (013)
- Fit O-ring (438B) against spiral seal (408). - Hand-tighten cap (013) on the check-
- Screw the box cartridge in the liquid end valve box.
so as to align it with the piping. - Fit O-ring (438B), screw the check-valve
- Screw on counternut (209).* box on the liquid end.
- Tighten the cap on the check-valve box*
- Connect the piping making sure of perfect
watertightness.
Note: O-rings (438B) and spiral seals (408) of the check-valve boxes must be replaced with new seals
each time they are removed.
* For information concerning tightening torque as well as which spanners to use, see Chapter 3.7.7.*
G3.3
3.7.3 Renewal of check-valve boxes _ plastic version
438B-
Fig. 17
Discharge check valve assembly
438A-
Fig. 18
Suction check valve assembly
Fig.16
Plastic liquid end
Disassembly
- Unscrew both nuts (435) located on pressure plate (004).
- Remove pressure plate (004) with both washers (434)
- Remove the Discharge check valve assembly.
- Pull on strap bolt (032) to release the suction check valve assembly
- Remove box cap (013), spring (080), ball guide (003), seal (438), ball (407).
Reassembly
- Fit spring (080), ball guide (003) and seal (438) on box cap (013), and mount ball (407) on its
seat (A).
- Fit seals (438B) and (438A) on the check-valve boxes.
- Fit the check-valve boxes onthe liquid end.
- Fit the pressure plate on strap bolt (032) with two washers (434).
- Hand-tighten screws (435) by pressing on the pressure plate.
- Orient the suction check valve assembly, then tighten two nuts (435).*
Connect the piping making sure of perfect watertightness.
Note: The items comprising the suction check valve assembly cannot be taken apart; this is also the case
for ball (B) and seat (A) of the Discharge check vaVe assembly.
* For information concerning tightening torque as well as which spanners to use, see Chapter 3.7.7.
G3.4
3.7.4 Diaphragm Renewal
Before carrying out any operations, place the vernier on the 0% position, check that all the isolating valves
are closed, then disconnect the piping.
Disassembly Reassembly
- Drain the pump (Chapter 3.9.2). - Mount contour plate (298B). It is CAUTION for
- Lay the pump on the side opposite one of holes in the contour plate to be placed at
the liquid end the highest point (see detail C).
- Remove suction check valve
assembly (A) (Chapter 3.7.2 or CAUTION: For metallic versions, contour plate (298B) on
Chap. 3.7.3) the mechanical side is made of steel and contour plate
- Remove screws (405A) (Fig. 19) or (298) on liquid end side is made of stainless steel.
(405) (Fig. 20) from the liquid end. - Fit diaphragm (298A).
- Remove diaphragm (298A) and - Fit contour plate (298). It is CAUTION for one
pressure plates (298), (298B) using a of the holes in the contour plate to be placed at
pointed object. the highest point (see C detail)
- Clean all the parts. - Fit the liquid end and tighten screws (405A) or
(405) in star-pattern (Fig. 22).*
- Refit the suction check valve assembly
(Chap. 3.7.2 or Chap. 3.7.3).
- Fill up with oil (Chap. 3.9.2).
- Put into service (Chap. 3.1, Chap. 3.2)
298
405
Fig. 19 Fig.20
Metallic version Plastic version
A In order to prime the pump, it is necessary to purge the liquid end (to release air) by opening
purge nozzle (B). For toxic liquids, it is recommended to collect this fluid to safe drain point during
this operation.
* For information concerning tightening torque as well as which spanners to use, see Chap. 3.7.7.
G3.5
3.7.5 Renewal of double diaphragm, "C" type
Before carrying out any operation, place the vernier on the 0% position, check that all the isolating valves
are closed, then disconnect the piping.
Disassembly
- Drain the pump (Chap. 3.9.2).
- Untighten ring pipe fitting (432A) by 1/2 turn.
- Lay the pump on the side opposite the liquid end
- Remove suction check valve assembly (A) Chap. 3.7.2 or Chap. 3.7.3)
- Unscrew the tightening screws from liquid end (405A), beginning with those in support lug (050A).
- Remove the two diaphragms (298) and the 2 contour plates (098).
- Clean all of the parts.
Reassembly
- Fit contour plate (098) on the mechanical side.
- Centre diaphragm (298) on contour plate (098).
- Fit double-diaphragm body (050) on diaphragm (298).
- Centre second diaphragm (298) on double diaphragm body (050).
- Centre second pressure plate (098) on double diaphragm body assembly (050)
- Fit the liquid end and hand-tighten 2 tightening screws (405A) diametrically opposite.
- Fit support lug (050A) and its detection.
- Connect the detection pipe of double-diaphragm body (050) to ring connection (432A).
- Hand-tighten the connection and tighten by 1/4 to 1/2 turn.
- Pre-screw in star-pattern (Fig. 22) tightening screws (405A) of the liquid end
(torque: 2 Nm)
- Tighten tightening screws (405A) of the liquid end in star-pattern. *
- Refit the suction check valve assembly (Chap. 3.7.2 or Chap. 3.7.3).
- Fill up with oil (See Chapter 3.9.2).
- Put into service (Chap. 3.1, Chap. 3,2)
- Degas the double diaphragm (Chap. 3.7.6)
Fig.21
Type "C" double diaphragm, metallic version
* For information concerning tightening torque as well as which spanners to use, see Chapter 3.7.7.
G3.6
3.7.6 Degassing of double-diaphragm
body, "C"type
- Remove the detection (A)

- Remove the retaining ring (092)
- Remove the ball (437)
- Put a little oil in the body of nonreturn valve
(432).
- Set the adjustment knob on 10%, then start
the pump up
- Allow to run for 10 minutes
- Fit the ball (437)
- Fit the retaining ring (092)
- Fit the detection (A) on the nonreturn valve
(432)
Fig.21A
B detail of Fig. 21
If the degassing can not be done by the above procedure there some possibility to perform this operation
with a syringe. This syringe is available on request at the Spare Part Departement
Degassing with syringe
- Fit the syringe (1+2) on the nonreturn valve

(432)
- Inject and pump 4 or 5 time slowly the
degassing liquid
- Remove the syringe and fit the ball (437) and
the retaining ring (092)
- Fit the syringe (1) witout his plunger
- Put the pump into servio3 and adjust the
capacity until 100%
- Remove the syringe (1) with the degassing
liquid
- Fit the detection (A) on the nonreturn valve
(432)
3.7.7 Tightening torque table
Tiqhteninq torque (Nm) Spanner used
tnRov A mRov B mRov A mRov B
Screw / Nut HP BP HP BP HP&BP HP BP
H head screw of liquid end for metallic versions 20 20 40 60 13 16 18
H head screw (l/3/5/7/6/8)of liquid end for plastic versions 15 15 15 15 13 16 18
H head screw (2/4) of liquid end for plastic versions 15 15 15 15 13 16 18
Check-valve box nut, metallic version 50 50 32 41
Check-valve box, metallic version 50 50 32 38
Strap bolt nut for liquid ends, plastic version 10 13
H head screw of lantern / / 7 8
He head-screw of relief valve / / 3/16" 3/16"
He head-screw of connectinq rod shaft / / 3 3
He head-screw pointed end of connectinq rod shaft / / / 2
Nut for He screw of connectinq rod shaft / / / 7
He screw (402) of duplex housinq (Fiq. 27) / / / 10
Fig. 22
Tightening in star-pattern-shape
G3.2
IB
3.8 - SERVICING AND MAINTENANCE OF THE MECHANICAL ASSEMBLY
3.8.1 Relief valve

CAUTION: Set in the plant, it must in no case be put out of adjustment, since it protects your pump.
3.8.2 Renewal of relief valve (Fig. 23)
Disassembly
- Place the vernier on the 0% position
- Clean the threaded hole of screw (023) to make it appear
- Note dimension H
- Completely unscrew and remove screw (023) with the hexagonal spanner
(Chap. 3.7.7).
- Remove spring (080) and its valve (212A).
Reassembly
- Cause new valve (212A) to adhere to spring (080) using a little grease.
- Lower the assembly into its housing.
- Screw in tightening screw (023) to the H measurement with the hexagonal spanner
(Chap. 3.7.7).
-023
Fig.23
Disassembly of the relief valve
G3.1
3.8.3 Renewal of adjustment liner O-rings(Fig. 24, Fig. 25, Fig. 26)
Disassembly
- Remove the lantern (Chap. 3.8.8)
- Remove circlips (434) (Fig. 25).
- Completely unscrew adjustment knob (255).
- Unscrew screw (256).
- Pull liner (012A) of housing toward you. (Fig. 26)
- Remove 3 O-rings (438B) located on liner (012A) (Fig. 24).
- Remove sleeve (E) from drive pin (214A) (Fig. 26)
- Clean the housing as well as the liner / sleeve assembly
Reassembly
- Refit the 3 O-rings (438B) using the tool (011) (Fig. 24):
-Reference 0110031071 forthemRoyA.
-Reference 0110032071 forthemRoyB.
- Coat the 3 O-rings (438B) with tallow.
- Fit sleeve (E) on drive pin (214A) (Fig. 26).
- Insert liner (012A) very slowly in the housing, turning it whilst holding sleeve (E) in the axis of liner
(012A).
- Screw in screw (256).
- Screw in adjustment knob (255) (Fig. 25)
- Fit circlips (434).
- Fit lantern (Chap. 3.8.8)
- Fill up with oil (see Chap. 3.9.2).
-011 -438B 012A
Fig.24
Liner / sleeve
255
434
Fig.25
Adjustment knob
G3.2
3.8.4 Renewal of eccentric shaft seals (Fig. 26).
For disassembly and reassembly of the eccentric shaft, the pump adjustment knob must be opposite you.
Disassembly
- Remove the 2 circlips (434A) from eccentric shaft (068)
- Drive out eccentric shaft (068) to the right to release seal (438A).
- Remove seal (438A)
- Drive out eccentric shaft (068) to the left to release seal (438A)
- Remove the other seal (438A)
Reassembly
Before reassembly, degrease all parts
- Fit an O-ring (438A) on eccentric shaft (068)
- Put glue (loctite 638) on the end of eccentric shaft (068) until it exceeds the other side of the housing by
one centimetre.
- Fit the other O-ring (438A) on eccentric shaft (068); put glue (loctite 638) on the end of eccentric
shaft (068)
- Position eccentric shaft (068) in the centre of the housing (see Fig. 26)
- Fit circlips (434A) on each end of eccentric shaft (068)
- Allow the glue to harden for 30 minutes
- Fill up with oil (see chap. 3.9.2).
438A
Fig.26
Simplex pump
Fig.27
Duplex pump
G3.3
3.8.5 Renewal of connecting rod and shaft for mRoy A, simplex and duplex (Fig. 26, Fig. 28).
Disassembly
- Remove eccentric shaft (068) (Chap. 3.8.4)
- Unscrew screws (435) and remove drive pin (214A) (Fig. 26)*
- Remove plunger assembly (012) / connecting rod (214) / wheel (052) from the housing, by lifting
wheel (052)
- Drive out connecting rod shaft (011)
- Clean the housing and the parts removed
Reassembly
- Refit piston (012) / connecting rod shaft (011) / connecting rod (214) assembly by gluing the end of
connecting rod shaft (011) with Ioctite glue 556 and being careful to position the lubricating groove (detail: A)
of connecting rod (214) opposite the threaded holes of the piston (Fig. 28)
- Insert piston / connecting rod assembly in housing
- Fit wheel (052) with connecting rod (214) (Fig.26)
- Fit concentric shaft (068) (Chap. 3.8.4)
- Fit drive pin (214A), then screw in and glue (Ioctite 221) the two screws (435)
- Refit the lantern (Chap. 3.8.8).
- Put into service (Chap. 3.1, Chap. 3.2)
"012
Fig.28
Piston / connecting rod assembly
' Fur information concerning which spanners are to be used, see Chapter 3.7.7.
G3.4
fii
3.8.6 Renewal of connecting rod and shaft for mRoy B, simplex (Fig. 26, Fig. 28).
- Drain the pump (Chap. 3.9.2). - Refit piston (012) / connecting rod shaft (011) /
- Remove the lantern (Chap. 3.8.8) connecting rod (214) assembly, being careful to
- Unscrew nut (435F) and screws position the lubricating groove (detail: A) of
(435), (435E) Fig. 26)*. connecting rod (214) opposite the threaded holes of
- Remove eccentric shaft (068) the piston. (Fig. 28)
(Chap. 3.8.4) - Screw in and glue (loctite 566), locking screw (435E)
- Remove drive pin (214A) on the side where the groove of connecting rod shaft
- Remove plunger assembly (012) / (011) is located
connecting rod (214) / wheel (052) - Insert piston / connecting rod assembly in housing
from the housing, by lifting wheel - Fit wheel (052) with connecting rod (214) (Fig.26)
(052) - Fit eccentric shaft (068) (Chap. 3.8.4)
- Drive out connecting rod shaft (011) - Fit drive pin (214A), then screw in and glue
(Fig. 28) (loctite 221) screw (435) and nut (435F)
- Clean the housing and the parts - Refit lantern (chap. 3.8.8)
removed. - Allow glue to harden 30 minutes
- Carry out startup and operating procedures
(Chap. 3.1, Chap. 3.2).
3.8.7 Renewal of connecting rod and shaft for mRoy B, duplex

(Fig. 26, Fig. 27, Fig. 28).
- Drain the pump (Chap. 3.9.2). - Place plunger (012) in the housing tapped holes up
- Remove the lantern (Chap. 3.8.8) ward
- Unscrew 2 screws (402) (Fig. 27) - Assemble connecting rods (214) with wheel (052)
- Unscrew nut (435F) and screws being careful to position the lubricating groove
(435), (435E) (Fig. 26). (detail: A) of connecting rod (214) downwards
- Remove drive pin (214A) (Fig. 26) (Fig. 28)
- Drive out the 2 shafts of connecting - Place excentric wheel (052) / connecting rod (214)
rod shaft (011) by the threaded holes assembly in the housing
of screws (402) - Fit eccentric shaft (068) (Chap. 3.8.4)
- Remove eccentric shaft (068) - Fit the 2 shafts of connecting rod shaft (011) by the
(chap. 3.8.4) threaded holes of screws (402) (Fig. 27)
- Remove excentric wheel (052) / - Screw in and glue (loctite 566) locking screws
connecting rod (214) assembly in the (435E) of the side where the groove of connecting
housing rod shaft (011) is located
- Remove plunger assembly (012) / - Fit drive pin (214A) then screw in and glue
connecting rod (214) / wheel (052) (loctite 221) screw (435) and nut (435F) (Fig. 26)*
- Remove plunger (012) off the housing - Refit the lantern (Chap. 3.8.8).
- Clean the housing and the parts - Screw in and glue screws (402) with loctite glue 221
removed. (Fig. 27).
- Allow the glue to harden 30 minutes.
- Carry out startup and operating procedures
(Chap. 3.1, Chap. 3.2).
For information concerning which spanners are to be used, see Chapter 3.7.7.
G3.5
3.8.8 Disassembly of the lantern (Fig. 26, Fig. 29)
Disassembly *
- Disconnect the power supply cables from the motor
- Unscrew 4 screws (435A), (434C) from lantern (072) and turn while pulling up the
lantern vertically with the motor
Reassembly
- Put sealing compound on side B (Fig. 26)
- Fit lantern (072) being careful not to bump drive pin (214A) with the worm shaft
- Screw in screws (435A) (434C)
- Connect the motor power supply cables
3.8.9 Renewal of the worm shaft (Fig. 29).
Disassembly
- Unscrew screw (435B) from coupling (052D).
- Remove the 2 washers (280) and washer (219) being careful not to separate them.
- Remove the worm.
Reassembly
- Fit washers (280) / washer (219)
- Fit coupling (052D) on the screw whilst adhering to measurement H (H = 5 mm for the mRoy B, or fit
coupling (052D) in mechanical thrust block for the mRoy A)
- Screw in screw (435B)
- Fit the lantern (Chap. 3.8.8)
- Mount the motor
3.8.10 Renewal of worm bearing.
Same procedure as for the Renewal of the worm shaft (Chap. 3.8.9), but by replacing bearings (409A) and
(409).
3.8.11 Renewal of the wheel / worm.
Same procedure as for Renewal of the connecting rod and shaft (Chap. 3.8.5 to Chap. 3.8.7), but without
removing connecting rod shaft (011) (Fig. 28) for the mRoy A
435D/434B/435C
409
Fig.29
Motor lantern
* For information concerning which spanners are to be used, see chapter 3.7.7.
G3.6
3.9 - LUBRICATION
The oil level must be checked every month. Fill the housing up to the middle of the level indicator. Use the oil
supplied with the pump or an equivalent oil (see table below). The oil must be changed every 2500 hours of
operation or every six months. The pump must be placed in a zone where the ambient temperature is
between -5°C and 50°C.
3.9.1 Table of oils

ISO.VG 150 oil. Pure mineral oil
QUANTITY:
mROYA mROYB
Simplex 1L 3L
Duplex 2L 4L
TABLE OF CHARACTERISTICS
Viscosity to 40°C 151 Cst

Viscosity to 100 ° C 15Cst
Viscosity Index 100
ISOVG 150
Density to 15 ° C 0.897 k/l
Flash-point 244°C
Pour-point -12°C
EQUIVALENCY TABLE
Make Type
COFRAN MECANEP 150
B.P. GRXP150
CASTROL ALPHA SP 150
ELF REDUCTELFSP150
FINA GIRAN 150
IGOL DYNAMSP150
MOBIL OIL MOBILGEAR 629
SHELL OMALA150
TOTAL CARTER EP 150
ESSO SPARTAN EP 150
3.9.2 Draining the pump

To drain the pump, unscrew the filler plug and the drain plug completely (Fig. 1 A).
To fill up with oil, screw the drain plug back on with Teflon strip to ensure proper impermeability, and see
Chapter 2.2.2.
Note: For information concerning how much oil to use, see the table in Chapter 3.9.1.
G3.1
IV FAULT LOCATION PROCEDURES
If, during the initial startup, the pump does not work properly, check the pump installation (SECTION:
INSTALLATION II).
4.1 - THE PUMP DOES NOT DELIVER:
CAUSE REMEDY
A - Motor stopped A-
- The thermal relay has been overloaded and has tripped. - Reset the thermal relay (Check the
reason for the overload)
B - No more product to pump.
B - Check the product level
C - Piping clogged up.
C - Unclog the piping
D - Filter blocked.
D - Clean the filter
E - Suction piping valve closed.
E - Open the valve
F - Diaphragm pierced.
F - Change the diaphragm
4.2 -THE PUMP DOES NOT DELIVER AT THE SPECIFIED FLOWRATE:

CAUSE REMEDY
A - The pump flow is improperly adjusted A - Set the vernier on the right percentage
B - Poor impermeability in the suction piping B - Change the piping seals

- Pumped liquid level too low (air intake)
C - suction piping dirty
C - Clean the piping
D - Filter dirty
D - Clean the filter
E - Check-valve box seat dirty or worn
E - Clean or change the check-valve box
F - Operating-pressure too high
F - Use the pump at the pressure specified on the
data-plate
G4.1
Connecting diagram for
chemical dosing pump unit.
012
Dosing line not A I supply.
The distances between the dosing pump and feedwater line max. 4 mtrs. Fitting
Dosing tine 012 x 1.5mm. Standless steel or (steel).
-J A I supply.
Shutdown valve 3/8'BSP. :
U pcs of fittings 3/8"BSP / 012 as sketch.
r
%
Controtvalve boiler feed water
CM
3
Oil fired boiler Hotwell Feed water pump Dosing pump
> ••• «
II TABLE OF CONTENTS
AALBORG
INDUSTRIES
Table of contents
Salinometer, type SL 700

Description 1
Installation 2
Maintenance 3

AALBORG SALINOMETER, TYPE SL 700 OM8210#34.0
INDUSTRIES
Description
The salinometer is used in combination with a conductive electrode to measure and
supervise the salinity of feed water. Figure 1 illustrates the control device and
electrode.
The control device is provided with indication LED's for monitoring the salinity
level and two LED's for alarm purpose. The measuring range as well as the
adjustable alarm range is 0 - 20 ppm (sea salt). The alarm limit can be adjusted by
means of the set screw located on the front panel. The alarm limit is indicated by a
flashing LED in the indication LED row. If the salinity level exceeds the alarm limit
the alarm LED's start flashing.
During commissioning it is not necessary to carry out any adjustments of the
equipment except setting the alarm limit. When the power is turned on, the
salinometer will perform a self test. This calibration will take approximately 5 sec.
Illustration of the control device
Connector
plug
1 2 3 4 5 6 7 6 9 10 12 14 16 18 20
Alarm jg^. Alarm set |

AALBORG I
INDUSTRIES Salinometer lype SL 700
Packing
Gold-plated
electrodes
Terminals
Figure 1 sl700c.cdr
Installation
The conductive electrode may be installed vertically, horizontally, or radial inclined.
However, the electrode tips must be constantly submerged in feed water. Figure 2
illustrates the salinity system.

INDUSTRIES
Illustration of the salinity system

ake-up
Condensate
Figure 2 sI700d.cdr
2.1 Wiring
The wiring should be carried out in accordance with the diagram shown in Figure 3.
Wiring diagram
4-20 mA
i & & & + I

11 12 13 14 15 16 117 18 I
90-115 VAC
Figure 3 s!700e.cdr

INDUSTRIES
The mains supply of the control device is 90-115 VAc or 190-230 VAC, 50-60 Hz.
Ensure that the mains supply is secured against over current by a fuse (max. 100mA).
The recommended cable for the conductive electrode is a multi-screened twin
twisted pair like Farnell no. 385-4334, where the screen is connected to connector
14, one pair is used for connector 11+12, and the other pair is used for connector
13+15. The length of the cable must not exceed 200 m.
Important: The cable may not be placed together with power cables, as this
will cause damage to the gold plating on the electrodes.
Maintenance
The accuracy of the salinometer equipment is very dependent on the electrodes are
kept clean. The electrodes should be taken out and cleaned at least once a week. Use
only a clean and soft reg. When cleaning the electrodes it is important that oil or
other chemicals do not pollute the electrodes. Any pollution will immediately result
in an inaccurate measurement of the salinometer.
Note: Avoid damaging the gold plating. If the gold plating is damaged, the
conductive electrode must be replaced.
The expected longevity of the conductive electrode is approximately 1.2 - 2.2 years.

INDUSTRIES
Table of contents
Oil detection equipment

General 1
Sensor installation 2
Control unit installation 3
Applications 4
Spares and fault finding 5

AALBORG OIL DETECTION EQUIPMENT OM9410#01.0
INDUSTRIES
Oil detection equipment
1 General
This chapter contains installation, operation, and maintenance instructions for the
ultrasonic interface detection system, Mobrey type 402 SD, using control unit type
MCU200.
Each Mobrey ultrasonic control system requires a sensor to suit the specific
application, plus a control unit. These instructions cover the control units in the
MCU200 series.
Sensor installation
2.1 General description
The ultrasonic sensor contains two piezoelectric crystals. A high frequency signal
(3.7 MHz) generated by the control unit is transmitted to one piezoelectric crystal by
coaxial cable. This crystal converts the electrical signal into an ultrasonic oscillation.
The sensor design allows the ultrasonic oscillation to pass from the transmitter
crystal to the receiver piezoelectric crystal. The sensors of type 402 are "gap" type
sensors, where the two piezoelectric crystals are separated by a gap. When the gap is
in liquid the signal reaches the receiver, because of the low ultrasonic attenuation of
the liquid. When the gap is filled with air, no ultrasonic signal can pass from
transmitter to receiver. See Figure 1.
Working principle of the oil detection equipment
Seiuorgabwot
The ultrasonic beam

reaches receiver aytlol
i TTT^t^Ti
•«•
Transmitter Raoaiver"™ ~™ ~™" ~

oysW cry*tal
Control unit ^ Relay
1 1
Figure 1 mobrey01.tif

INDUSTRIES
When the gap is filled with liquid, the piezoelectric receiver crystal converts the
ultrasonic wave into an electrical signal, which is transmitted back to the control unit
using a second coaxial cable. Usually the two coaxial cables to the sensor are in one
overall sheath. The control unit circuitry is a feedback amplifier, which oscillates
when the sensor is wet, and is quiescent for the sensor dry. The "oscillating" or
"non-oscillating" sensor states dictate the output relay states of the MCU200.
For interface detection the sensor "oscillates" in a clear liquid, and is "non-
oscillating" at the interface.
2.2 Switching levels and orientation

The gap sensors should normally be mounted with the gap vertical, to avoid build up
of solids on the sensor faces on either side of the gap. In this condition the switching
level will be halfway up the face: if the sensor is mounted from the side of the tank
this is normally on the centreline of the cylindrical body.
Occasionally such sensors are mounted with the sensor faces horizontal, either to
avoid air bubbles passing through the gap or for convenience of installation. In this
case the switching level will be at the sensor face at the top of the gap.
2.3 Installation of sensor

The sensor must be handled with care - it is a measuring instrument. Before
installation, check that sensor, cable and control unit have not been damaged in
transit. Drill and tap a hole with a suitable thread. It is advisable to use a boss or
similar on thin walls. The sensor has a tapered thread. Use Ptfe tape or similar to
seal the thread. Mark the sensor hexagon to identify the gap orientation of the
sensor, if appropriate. Take care not to damage the sensor cable during tightening.
The cable should be laid on cable trays and separated from any high voltage or
mains cables. The normal cable termination is a plastic gland (to fit the MCU200
control box drilled hole) and crimped terminal pins to suit the MCU200 terminals.
2.4 Extensions cables

Extension cables up to 50 metres long can be fitted to most Mobrey ultrasonic
sensors in the factory to special order but a better site arrangement is to have a
separate extension cable. Table 1 shows a list of suitable extension cables.
50 m SO -100 m Above 100 m

RG174 URM76
Consult Aalborg Industries
RG178 RG58
Table 1
When double coaxial cable needs to be extended, two sets of coaxial plugs and
sockets will be needed, one set for transmit and one receive. Care must be taken that
the connectors are not connected to earth or shorted together in any way, to prevent
cross-talk or pick-up. The coaxial connections must be made in a waterproof
junction box. Terminal blocks should not be used.

INDUSTRIES
The extension cable needs to be of 50 Ohm characteristic impedance. Suitable dual

coaxial extension cables can be purchased from Aalborg Industries. For extensions
over 50 metres it is recommended two runs of single coaxial low loss cable is used,
with the transmit and return cable runs separated by 0.15 metres to minimise cross-
talk.
If several sensor cables are being run together then all the transmit cables (those
connected to E2) should be grouped together and all receive cables (those connected
to IE) grouped together maintaining the separation specified above.
Two cables are required per sensor. The RG178 should be used where the cable
itself is subject to temperatures exceeding 74°C.
Control unit installation
3.1 Mechanical
The control unit is supplied with three holes drilled in the bottom (longer) side of the
box. Two glands are supplied for the power input cable and relay output cable. The
sensor is normally supplied fitted with a suitable gland on the cable. Two further
holes can be drilled in the bottom side of the box should these be needed: it is
recommended that the circuit board is removed whilst drilling extra gland holes.
Figure 2 shows the dimensions of the MCU200 housing box.
MCU200 Housing dimensions
Mounting
Holes
All cable connections are made to the terminal blocks along the bottom edge of the
pcb, see Figure 3. Release the terminal screw before inserting the wire.

INDUSTRIES
MCU201 PC board
Output
Logic Switches - LED
Indicators
Cain
Controls
DANGER LIVE TERMINALS

Frequency • e
Selection
AUX.
IWUT
• a_ __
NC> C l NOl HOZ C3
__
D D
N 11SVS30V F Mounting
Cable Check 3 4 Screws (4)
Selection
' SEE INSUX L I D FOR
SWITCH ANO CI»*CCTION DETAILS
3.2 External connections
3.2.1 AC mains
AC mains is connected between the "N" terminal for neutral and one of the "115V"
or "230V" terminals depending on the voltage supply available - BEWARE - the
terminal not connected externally will be "live" once the transformer is powered via
the other terminals.
3.2.2 Mains earth
Mains earth should be connected to the terminal marked "E". This provides an earth
contact for the pcb mounting pints.
3.2.3 The relay
The relay output connections are labelled:
• NC - Normally closed (relay de-energised)
• C - Common
• NO - Normally open (relay de-energised)
There are also two sets of contacts for DPCO relay, labelled 1 & 2.
3.2.4 The sensor
The sensor connections are labelled "1", "E" for the receiver crystal and "2", "E" for
the coax cable to the transmitter crystal. The screens of these coax cables are
connected to the terminals marked "E".

INDUSTRIES
3.2.5 The auxiliary input

The auxiliary input is a terminal which can be connected to a "push to reset" button
to achieve a latching alarm, or to another Mobrey Control unit, to give a pump
control from the MCU200 unit relay output. If a short circuit is connected between
terminals 3 & 4, the MCU200 relay, once de-energised, is held de-energised. Even if
the sensor attached to the MCU200 changes state, to that which should energise the
output relay, this relay will not energise until the link between terminals 3 & 4 is
broken in the circuit external to the MCU200.
3.3 Switch settings in MCU200 series
3.3.1 Gain switch and potentiometer

See section 4.
3.3.2 Frequency selection

This slide switch is labelled "FREQ" and is located between the sensor terminal
block E2, and the Aux. input terminals. This selects the operating frequency of the
MCU200 oscillator, which for the present installation must be set to 3.7 MHz
(switch in the "up" position). The setting required is dictated by the sensor type
connected to the control unit.
3.3.3 Cable check option selection

This slide switch is located directly above the sensor terminal block E2. It is labelled
"Cable Check" and the ex factory setting is "OUT" with the slide switch to the right.
By sliding this switch to the left, the cable check circuitry is brought into action.
This circuitry monitors the continuity of the screens of the two coaxial cables
attached to the sensors: normally these are linked at the sensor to the metal body of
the fitting (or to each other in the case of non metallic sensors). If this continuity is
broken, the "FAULT" LED" will illuminate giving an indication that the sensor
cable is damaged, and the MCU200 will give the "ALARM" output relay state (see
Figure 4).
3.3.4 Relay output and LED logic selection

The bank of six slide switches towards the top of the pcb sets the relay output state
logic relative to the sensor state, associated time delays and the LEDs. These are
slide switches, best adjusted with a pencil, and the ex factory wetting is with all
switches to the right.
Each switch is colour coded as shown in Figure 4, and the PC board labels give brief
function information.

INDUSTRIES
Relay output and LED logic switch
Colour Code No.

/<-
3rown 1
30s
Red 2
Orange 3 \
E = Red
Yellow 4
Delay to E
Green 5
OSC = NE
Blue 6
Note: At Figure 4 OSC means sensor oscillating. £ means relay energised, NE

means de-energised.
Set the switches in the following order, starting at the bottom and working upwards:
BLUE:
If the MCU200 relay is to be energised (E) when the sensor is oscillating (OSC)
then set the No 6 blue switch to the right (OSC=E). This is the preferred setting, to
give a de-energised relay in the ALARM state for a gap sensor as a low level alarm.
GREEN:
This selects the relay change which is subject to the time delay selected on the top
switches. When the No.5 green switch is set to the right, the delay occurs between
the sensor changing state and the relay de-energising or becoming "not energised"
(NE). This time delay is a minimum of 0.15 seconds, (achieved by switching the top
BROWN switch to the right) and is used to prevent relay chatter at the changeover
point. Longer time delays are selected on the top three slide switches as shown in
Figure 5.
The relay change in the opposite direction is immediate (within 50 milliseconds).

INDUSTRIES
The top three slide switches
Colour Code No. 1
Brown 1
• * • 2
Red 2
- * - 3
Orange 3
2 seconds* 8 seconds' 30 seconds*
YELLOW:
Only one of the GREEN or RED LEDs will be illuminated at any one time. These
LEDs show the state of the MCU200 output relay. The RED LED is labelled
"ALARM" and the GREEN LED is labelled "NORMAL". The yellow slide switch
(Number 4) determines which LED will be illuminated when the relay is energised
(E). It is usual to have the GREEN/NORMAL condition occur with the relay
energised, i.e. with switch Number 4 to the right (E=GREEN).
4 Applications
4.1 Gain adjustment
Correct adjustment of the gain (HI/LO switch and potentiometer) is essential for
proper operation of any ultrasonic sensor system. This adjusts the gain of the
feedback amplifier in the control unit, which produces oscillation of the sensor when
the coupling between the ultrasonic crystals is sufficient. Therefore the higher the
gain setting, the lower the coupling needed to produce an oscillating sensor.
The universal control unit of the MCU200 operates with many sensors, so the
correct setting for the particular sensor and application should be found on site by
experiment, if possible. This will take account of particular site conditions like RF
coupling between extension cables, which can affect the maximum allowed gain.
Other liquid characteristics, such as presence of suspended solids, or air bubbles, can
mean that for reliable operation the MCU200 gain must be set as high as possible, to
overcome future solids build up, but at least one potentiometer division below the
maximum allowed level, to ensure temperature and component ageing stability.
The particular procedures outlined below for gain adjustments give the mid point
gain settings, which may need to be adjusted to meet specific site/sensor future
requirements as indicated above.

INDUSTRIES
4.2 Interface detection
4.2.1 Interface detection between two dissimilar liquids

Viscous liquids, emulsions and liquids containing solid particles have a greater
ultrasonic attenuation than clear liquids. This technique is used to detect which
liquid is present at the sensor, for example for the separation of oil and water. For
this duty Mobrey 402 sensors are used, operating at 3.7 MHz to produce the
maximum ultrasonic difference between two liquids monitored.
The gain is adjusted so that the sensor oscillates only in the liquid with the lower
ultrasonic attenuation: this is usually the clearer liquid (water in the example of
Figure 6). Note that the signal when oil is present in the sensor gap will be the same
as that for air in the gasp, and that emulsion layers give a very high attenuation.
Mobrey 402 Sensor as oil/water interface
OIL miiiniil
JT
Receiver Transmitter
Crystal Crystal
Sensor in Oil. The ultrasonic beam

is attenuated and will not reach
• receiver crystal.
WATER
— - Receiver Transmitter
Crystal Crystal
Figure 6 mobreyl5.tif
Step A: Reduce the gain potentiometer with the sensor immersed in one of the
liquids until a "false dry" indication is obtained. Note the position of the
pot.
Step B: Repeat for the sensor immersed in the other liquid.
Step C: Set the potentiometer half way between these two values. Correct
performance requires a total difference between the two set points of at
least 3 divisions.

••••
• • • • I

INDUSTRIES
Interface detection between two immiscible similar liquids

When liquids are ultrasonically very similar - as happens for example with paraffin
or oil and water - the procedure in section 4.2.1. produces very little difference
between the two "false dry" points. In this case the "reflection" method of interface
detection is used. An illustration of this method is shown in Figure 7.
Note: The Mobrey 402 sensor in the hot well tank is installed as shown in
Figure 7.
If an ultrasonic beam is transmitted from one liquid to another at a suitable angle

(10%) it is split at the interface into a reflected and a refracted beam, so that it does
not reach the receiver crystal. If there is no interference in the gap, but only one
liquid, the beam is received and the sensor oscillates.
Interface detector by reflection method
Paraffin
Water
Sensor at interface level. The

ultrasonic beam is reflected/refracted
and will not reach receiver crystal.
Paraffin
Transmitter
Crystal
i Receiver
Crystal
Figure 7 mobreyl6.tif
The gain adjustment is made so that the gain is 3 divisions higher than the highest
false dry position obtained, as in section 4.2.1. Performance at the interface should
then be checked.
Note: That the non oscillating state of the sensor, at the interface, also occurs
throughout any emulsion layer at the interface, and also when the sensor
is in air.

INDUSTRIES
Spares and fault finding
5.1 Spares
The following parts are suitable for replacements on the MCU201:

• Main pcb complete: K2641
• LED indicator pcb: K2643
• LED pcb spacers: K2623
• LED pcb connector: K2624/50
• Box assembly: K2662
• Gland Assembly: K746/K747/K748
There are no consumable items such as fuses.
5.2 Fault finding
Step A: At least one LED should be illuminated. If not check the power supply to
the unit.
Step B: If the "Fault" LED is on, check the coax cable to the sensor for incorrect
wiring or damage. Particularly check continuity of extension cables,
connection of crimped connectors on cable ends. The pcb board can be
checked by linking the two terminals labelled E on the sensor terminals -
this should cancel the fault indication LED.
Step C: If the sensor is giving incorrect indications check the gain adjustment (see
section 4.0).
Check for correct sensor operation whenever the gain is adjusted away from the
normal set point. Assume an overlap of 2 divisions between the "LO" and "HI" gain
ranges.
Step D: Check that the incorrect operation has not been produced by incorrect
setting of the frequency selection switch, or an external short circuit on the
Auxiliary input terminals.
Step E: The circuit board can be checked by linking the sensor terminals 1 and 2
with a wire, to simulate an oscillating sensor.

INDUSTRIES
Table of contents
Steam dump equipment
General description
General description 1
Steam dump valve 2
Actuator 3
I/P positioner 4
Steam pipe connections to dump valve 5
Process controller/local panel 6
Pressure transmitter 7
Air reducing set 8
General 1
Operation 2
Maintenance 3
Pneumatic actuator, type DP
General 1
Reversal of the actuator action 2
Manual operation device 3
Maintenance 4
General 1
Mechanic connection of the positioner 2
Electric connection of the positioner 3
Pneumatic connection 4
Commissioning 5
Diagnosis 6
Service and maintenance 7

AALBORG STEAM DUMP EQUIPMENT OM6050#03.1
INDUSTRIES
Steam dump equipment

1 General description
The steam dump equipment is designed for dumping excess steam generated by the
boiler plant from the steam system to an atmospheric dump condenser.
This chapter contains some general instructions, which should be taken into
consideration before installing and during operation of the steam dump equipment.
More detailed instructions related to the components of the equipment can be found
in other sections.
Note: It is essential that the condenser is dimensioned to be able to absorb the

amount of steam generated in the exhaust gas boiler(s). Or if a composite
boiler is installed the amount of steam generated by the exhaust gas part
of the composite boiler(s).
Schematic illustration of the steam dump system
Main steam line

1 - Steam dump valve -
2 - I/P positioner
3 - Pneumatic actuator
4 - A i r reducing set
5 - Process controller/local panel
6 - Pressure transmitter
7 - Steam trap
Steam/condensate line
Control air (instrument air)
To atmospheric dump condenser Electrical signal
Figure 1 steamdump2.cdr

f f I f f f •

INDUSTRIES
Figure 1 shows a schematically illustration of the system, which consists of the

following components:
• Control valve with pneumatic actuator.
• I/P positioner.
• Air reduction set.
• Process controller or local panel.
• Pressure transmitter.
• Steam trap.
The equipment is working by measuring the steam pressure (e.g. in the boiler, the
steam drum or the main steam pipe) with a pressure transmitter (6). The transmitter
sends an electrical signal (4-20 mA DC) to the process controller/local panel (5). In
the control system the signal is compared with a pre-set adjustable value.
The steam pressure is then regulated when the control system sends an electrical
signal to the I/P positioner (2). It converts the signal and via the pneumatic actuator
(3) controls the position of the steam dump valve (1), through which the excess
steam is lead to the atmospheric dump condenser.
The control valve will automatically close in case of air or power failure. A hand
wheel enables manual operation of the valve. Figure 2 shows a complete control
valve arrangement consisting of valve, I/P positioner and actuator.
Arrangement of control valve, positioner and actuator
•ndwheel
Actuator
VP Positioner
Control valve
Figure 2 k7462 02.tif

INDUSTRIES
Under normal circumstances the control valve, actuator and I/P positioner is
delivered as a complete unit already assembled.
The air supply to the actuator is controlled by the air reduction set (4). The
compressed air at the inlet of the air filter must have a max. pressure of 17 bar and a
temperature laying in the interval from -20 to +65°C. Furthermore, the supplied air
must be instrument air.
Any adjustment of the system must be carried out on the process controller/local
panel (5).
Note: AH pipes must be thoroughly cleaned before commissioning
Steam dump valve

Depending on the amount of steam that the system is designed to be able to dump,
the control valve can be of two different types, either type 23.440 DP or type 23.470
DP. The construction of the valves are slightly different as can be seen on Figure 3.
The steam dump valve together with actuator and positioner are suitable for
installation in dry or damp locations, and in order to avoid damage to the drives it is
recommended to install the components in an up-right position.
Ambient temperatures on the valve drive should not fall below -15°C or rice above
50°C. Precautions should however be taken when using the equipment where the
ambient temperature are likely to drop below 0°C to prevent condensation of water
in the instrument air.
Drawings of the two types of control valves

23.470 DP
1 - Body 23.440 DP
2 - Seatring
3 - Mounting bonnet
4 - Guiding bush
5-Plug
6 - Spindle
7 - Gland flange
8 - Spindle guiding
10-Stuffing box
14-Gasket
15-Studs
17-Hexagon nut
19 - Spring-type straight pin
Figure 3 k7462 03a.cdr

INDUSTRIES
The installation point should allow sufficient space to ensure correct maintenance of
the valve and actuator. The valve should be inserted so that the spindle has a vertical
position and the actuator being up above. The valve can also be tilted to a maximum
horizontal position if the installation point does not allow any better condition. If
painting is necessary, ensure that valve and actuator spindle as well as mechanical
links are free from paint. The flow direction is signalled through an arrow on the
valve body. The valves should be insulated against high temperatures to guard the
actuator. Sufficient space must be left to undertake maintenance on the spindle-
sealing.
stretches of the piping should be of straight piping length min. 2 times pipe diameter
by inlet and 6 times by outlet. The piping must be aligned to prevent any strain on
the valve. Precautions to restrict strain on the piping should be regarded. In no case
supporting must be fitted to the valve to hold the piping system.
The piping should be rinsed to clear out any pollution, welding beads, rust etc.
before inserting the control valves. A strainer should be fitted in front of the control
valve to catch remaining particles. Bolts should be re-tightened after taking into
operation.
When the piping system is filled and set under pressure, the spindle sealing should
be checked for leakage, and if necessary be carefully tightened until the leakage is
stopped. The PTFE-V-ring unit does not require any re-tightening, the spring tension
maintains the necessary force.
The bolts must be tightened gradually in steps, diametrically in pairs but not tighter
than it is necessary for sealing.
Flange connections bolts should never be loosened or tightened when the valve is
under temperature or pressure, even if a leakage may arise.
Actuator
Select the site of installation so that the actuator is readily accessible and that there
is adequate room for later maintenance work.
The mounting position is preferably with the actuator and valve spindle in the
vertical position. For assembly onto the valve please see the separate instructions
described in the sections for valve and actuator (see also Figure 4).
The instrument air supply should be dry for low temperature service. A heat-guard
should be installed for high temperature service.
Note: Please observe the maintenance instructions for valves.

The pneumatic supply tube must be connected to the diaphragm housing.
The thread connection for the actuators DP 32 and DP 33 is R 1/4" and for the
actuator DP 34 R 3/8".

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stay free.
Assembling of the actuator on valve
Pneumatic oonnecton
Figure 4 acu 06.tif
I/P positioner
The positioner must be installed and commissioned in exactly the same sequence as
described in the section for the positioner. It is essential that the warnings in the
relevant sections are heeded during this process.
Warning: This instrument must only be installed and commissioned by

qualified personnel. The degree of electrical safety is determined
solely by the devices supplying the power.
Warning: Pneumatic drives generate considerable positioning forces. Safety

precautions must therefore be scrupulously observed during
installation and commissioning in order to prevent injuries. Your
attention is drawn, if applicable, to the relevant regulations
regarding operation in hazardous areas.

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Steam pipe connections to dump valve

Referring to the diagram in Figure 1, some remarks have to be made on the piping
system before and after the dump valve. This is due to the fact that a proper
functioning of the steam dump equipment (i.e. the equipment is able to blow off the
required amount of steam) requires as low a resistance in the piping system as
possible.
In order to obtain this low resistance the following topics should be considered:
• The dump valve should be placed as near the dump condenser as possible.
• According to the amount of steam that the system is dimensioned to dump the
diameter of the pipe before the dump valve must be of a certain size, which can
be deduced from Table 1.
• The steam pipe after the dump valve must as written in Table 1 be at least 2
sizes larger than the pipe before the dump valve.
• It is essential the transitions from pipes to the dump valve both before and after
the valve are smooth and without any sudden contractions or expansions.
• Furthermore should the pipe section be as short as possible and preferably
without bends.
• If there are valves placed in the system before and/or after the dump valve these
should be of the straightway type and of the same size as the pipes.
Dump pressure: 5 barg

lilll ;is;;is;;iy& IHllHilliiliiiilllilllill
Size of dump valve, DN 20 25 32 40 50 65 80
Max. steam amount, kg/h 260 400 640 1030 1600 2580 4000
Pipe size before valve, DN 32 40 50 65 80 100 125
Pipe size after valve, DN 50 65 80 100 125 150 175
Size of dump valve, DN 20 25 32 40 50 - 65 80

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Max. steam amount, kg/h. 520 850 1360 2180 3400 5200 8500
Table 1
Process controller/local panel

The process controller or local panel are installed in the boiler control panel. For
instructions regarding one or the other please see the specified instructions in the
control system sections.
Warning: This is an electrically-operated device. Certain parts in electrical

devices carry dangerous voltages during operation. Severe injury or
damage to property could therefore occur if the warnings are not
observed. Staff working with this device should be suitably qualified.
Reliable and safe operation of these devices depend on correct
transport, storage, assembly and operation.

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Pressure transmitter
The pressure transmitter converts the steam pressure to an electrical signal
proportional with the pressure. The unit is supplied as two-wire transmitters with an
output signal of 4-20 mA.
7.1 Installation conditions

The zero point is factory-set with the pressure connector pointing downwards. If the
unit is installed in another position the zero point will be displaced approx. 1% as far
as the lowest pressure range is concerned, decreasing in the higher pressure ranges.
The displacement can be eliminated by using a zero-point potentiometer.
To protect the pressure element against temperatures higher than the maximum
permissible temperature of the element (100°C), it is recommended to insert a water-
filled loop. An example of such an installation is shown on Figure 5, which also
shows an example of insulation against radiant heat.
Example of installation/connection of transmitter
4— Max. 70 °C
Thin (= Low heat conductivity) uninsulated tube
- Condensed liquid
Figure 5 emp2_2a.cdr
There are facilities for adjusting zero point and span. Zero point adjustment is
necessary to equalise pressure arising from any differences in level between the
pressure transmitter and the medium being measured. Zero point adjustment results
in a parallel adjustment of span.
8 Air reducing set
8.1 Installation
Before installation the operating conditions of temperature and pressure must be
checked. The unit should be mounted securely in an accessible and visible location

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upstream from lubricators and near components being served. Strain on pipe work
and fittings should be avoided and directional flow arrows observed.
With cyclic demand systems the filter-regulator should be installed upstream of
directional control valves. Airline piping should be the same size as unit ports with
air flow in the direction of the arrow. A pressure gauge may be connected to the
appropriate 1/8 port after removing the plug and should have a range exceeding the
maximum proposed outlet setting. Figure 6 shows an illustration of the filter-
regulator.
Filter-regulator
Figure 6 bO7 f.tif
8.2 Adjustment
With the regulator adjustment completely backed-off the air supply can be turned
on. The adjusting knob can be rotated clockwise to increase the spring load and the
pressure increase observed on the gauge.
Minor adjustment after setting changes can be avoided by always approaching the
desired setting from the lower level. When a lower setting is required, firstly reduce
to a lower level and then increase to the desired setting.
Decreasing the pressure setting on a relieving type regulator will cause air to exhaust
through the bonnet vent hole.
The non rising adjusting knob includes a locking feature;
• Push knob in after setting to lock and prevent adjustment.
• To release pull knob out.
If the adjustment knob is fitted with the tamper resistant screw option, the screw
must be removed to enable the knob to be unlocked.
Auto drain units should have a 1/4" (6 mm) bore flexible tube pushed over the
bottom protrusion to pipe away expelled liquid. Avoid restricting the drain pipe.
Manual drain units must be drained before the contaminant level reaches the
element. Should this occur then liquid contaminant will be carried downstream.

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1 General
This type of control valve is suited to regulate fluids, gases and steams. The valve
plug is normally a parabolic plug, but can also be supplied in a perforated design.
Both types of plugs can have either linear or equal percentage flow characteristic.
The flow direction for parabolic plugs is always against the closing direction.
However, with perforated plugs for steam and gases, it is in the closing direction. If
a valve with a perforated plug is operated by means of a pneumatic actuator with the
flow in the closing direction, the pneumatic actuator should have a stronger thrust
force. This is necessary to prevent thumping near to the closing position.
All control valves can be fitted alternately with manual-, pneumatic-, electric- or
hydraulic operation devices.
Illustration of control valves type 470 and 471
Control valve, type 470 Control valve, type 471
Figure 1 va!47x.cdr

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Part Designation Part Designation Part Designation

Body Gland flange 15.1 Studs
Seat ring 7.1 Screw joint 17 Hexagon nuts
Mounting bonnet Spindle guiding 17.1 Hexagon nuts
3.1 Mounting bonnet 10 Stuffing box 19 Spring-type straight pin
Guiding bush 10.1 Stuffing-box packing 21 Set-pin
Plug 14 Gasket 25 Bellow housing
Spindle 14.1 Gasket 26 Bellow unit
6.1 Spindle 15 Studs
Table 1
Operation

The valve should be inserted so that the spindle has a vertical position together with
the actuator. The valve can also be tilted to a maximum horizontal position if the
installation point does not allow any better condition.
stretches of the piping should be of straight piping length (min. two times the pipe
diameter by inlet and six times by outlet). The piping should be rinsed to clear out
any pollution, welding beads, rust, etc. before inserting the control valves. A strainer
should be fitted in front of the control valve to catch the remaining particles. Bolts
should be tightened after taking into operation.
The flow direction is signalled by an arrow on the valve body. The valves should be
insulated against high temperatures to guard the actuator.
2.2 Actuator assembly

The control valves are normally delivered with actuators already fitted. For
alternations or maintenance of actuator, the assembly should occur in accordance
with the operation instructions for the actuator.
2.3 Setting into operation

When the piping system is filled, the spindle sealing should be checked for leakage
and, if necessary, tightened. A PTFE-V-ring unit does not require any tightening as
the spring tension maintains the necessary force.
The bolts must be tightened gradually in steps, diametrically in pairs, but not tighter
than it is necessary for the sealing. Flange connection bolts should never be loosened
or tightened when the valve is under temperature or pressure even if a leakage may
arise.
For actuators please see to the appropriate actuator operation instructions.

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Maintenance
Before any maintenance of the control valve is carried out, the piping system must
be shut off and pressure free.
3.1 Exchange of the stuffing-box packing
A leak stuffing-box packing should initially be carefully tightened to stop the

leakage. If this does not help, a new layer should be inserted, or the complete
packing should be replaced.
3.1.1 Additional packing layer
Step A: Open the valve fully and unscrew the hexagon nuts (17).
Step B: Lift the gland flange (7) and the spindle guiding (8) upwards.
Step C: Insert adequate quantity of packing rings (split ring-displacement, splitting

at 180° to avoid overlapping).
Step D: Fix the hexagon nuts (17) properly.
3.1.2 Exchange
Step B: Unscrew the hexagon nuts (17) from the studs (15).
Step C: Remove the gland flange (7), the spindle guiding (8) and the old stuffing
box (10) and clean the packing compartment.
Step D: Clean the valve spindle and check for damage and if necessary replace. If
the damaged spindle is not replaced, the new packing will leak after a short
period.
Step E: Insert the new packing rings (split ring-displacement, splitting at 180° to
avoid overlapping).
Step F: Fix the hexagon nuts (17) properly.
Note: Strenuous tightening will prevent leakage, but will also have a brake
effect on the spindle which aggravates the movement of the spindle.
3.2 Exchange of a PTFE-V-ring sealing unit
A PTFE-V-ring unit is spring loaded and has enough set pressure to ensure a good
seal even by low operation pressures. It is replaced as mentioned above.
The PTFE-V-ring sealing unit should be lubricated before it is inserted. The sealing
lips must face against the pressure direction.

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Note: Special care should be given to the spindle surface. Rough surfaces wear
the sealing lips enormously and can be due to failure of the packing unit.
3.3 Exchange of the bellow unit
Step B: Unscrew the screw joint (7.1).
Step C: Unscrew the hexagon nuts (17) and remove the bellow housing (25).
Dismantle the plug as described in the next section.
Step D: Unscrew the hexagon nuts (17.1) and dismantle the mounting bonnet (3.1).
Step E: The bellow unit (26) is removed from the bellow housing (25).
Step F: Replace the two gaskets (14.1) and the gasket (14).
Step G: When the bellow unit (26) is replaced, the proper position of the anti-
twisting device must be observed.
Step H: The set pins (21) have to drive within the slots of the anti-twisting device.
Check for friction-free movement.
Step I: Replace mounting bonnet (3.1) and screw down the hexagon nuts (17.1)
crosswise.
3.4 Exchange of the plug-spindle unit
Step B: Unscrew the gland flange (7).
Step A: Unscrew the hexagon nuts (17) and dismantle the mounting bonnet (3).
Step B: Pull out the plug with the spindle and exchange this unit.
Step C: Remove the spring-type straight pin (19) and unscrew the spindle (6).
Step D: Replace the old parts and assemble it.
Step E: Drill a hole through the plug shaft and insert a new pin.
Step F: Replace the gasket (14) and assemble the mounting bonnet (3).
Step G: Tighten the nuts (17) evenly, crosswise.

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Step A: Unscrew the hexagon nuts (17) and dismantle the bellow housing (25) with
plug (5).
Step B: Drive the spindle in the bottom position and remove the spring-type straight
pin (19).
Step C: Unscrew the plug.
Step D: Screw a new plug at the spindle and drill through the shaft. Drive the
spring-type straight pin (19) into the hole.
Step E: Replace the gasket (14).
Step F: Assemble the bellow housing (25) with plug (5) together with the body (1)
and fix it by screwing the hexagon nuts (17) crosswise.
The spindle can only be completely replaced together with the bellow.
3.5 Changing the seat ring
The seat ring is screwed into the valve body. The seat ring can be obtained after
removing the bonnet and can then be refinished or replaced as required.
Step A: Clean and lubricate the thread and conical sealing surface before insertion.

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Pneumatic actuator, type dp

1 General
The pneumatic linear actuator is designed to be mounted directly on a control valve.
The pneumatic actuator converts positioning command signals into stem thrust
forces. The required back setting force is produced by the spring arrangement inside
the actuator. The rolling-diaphragm produces linear spindle movements over the
complete stroke.
The preferred mounting position is with the actuator and valve spindle in vertical
position.
The mode of operation for the actuator depends on how the springs are inserted
when the actuator is assembled. Even when the actuator is fitted in a piping system,
the mode of operation can be changed.
The pneumatic actuator can be operated as:
• Spring opens valve/air closes valve operation mode
• Air opens valve/spring closes valve operation mode
Illustration of a pneumatic actuator
Operation mode:
Spring opens - Air closes Air opens - Spring closes
Figure 1 dpactuat.tif

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Table 1 below shows a list of the position numbers in Figure 1 and Figure 2.
Part Denomination Part Denomination

Rolling diaphragm 15 Stroke indicator
Diaphragm housing 16 Hexagon nut
Diaphragm lid 17 Mounting rod
Diaphragm plate 18 Bellow
Spindle 19 Collar nut
Spring 21 O-ring (spindle)
10 Coupling flange 22 O-ring (bushing)
11 Guide flange 26 Slotted guide bearing
12 Rotation guard 27 Spindle guide
13 Socket screw 30 Hexagon nut
14 Threaded bushing 31 Hexagon nut
Table 1

The air supply should be dry and at a low service temperature. A heat-guard should
be installed to prevent high service temperature.
The pneumatic supply tube must be connected to the diaphragm housing (2) by
operation mode "spring closes" and to the diaphragm lid (3) by operation mode
"spring opens".
By air failure the stem automatically returns into the original position caused by the
inserted springs.
remain open.
1.2 Assembly of the actuator on the valve

The assembling of the actuator on the valve is shown in Figure 2. For both "spring
closes" and "spring opens" operation modes the following assembling procedure
should be followed:
Step A: If the actuator and the valve are separated, press the plug and spindle unit
(5) into the closed position for operation mode "spring closes" or into the
open position for operation mode "spring opens".
Warning: Make sure that the plug does not turn while pressing on the seat
during assembly.
Step B: Loosen the socket screws (13), remove the rotation guard (12) and the guide
flange (11). The threaded bushing (14) is now free.

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Step C: Turn the locking hexagon nut (30) onto the valve spindle. Place the rotation
guard (12) and the guide flange (11) over the valve spindle and then turn
the threaded bushing (14) onto the valve spindle.
Step D: Check the actuator for proper operation mode and connect the pneumatic
supply to the connection piece in the diaphragm housing (2) for operation
mode "spring closes" or in the diaphragm lid (3) for operation mode "spring
opens".
Step E: Drive the actuator into approximately mid-stroke position over the air
supply and mount it onto the valve (read the value from the pressure gauge
- middle of the spring range).
Step F: Tighten the hexagon nuts (31).
Assembly of the actuator on the valve
Operation mode: Spring closes valve - Air opens valve Operation mode: Spring opens valve - Air closes valve
Figure 2 dpactspr.tif

• • • I
( • • • •

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1.3 Adjustment of the starting pressure signal
Step A: Drive the actuator to the required spring-starting point over the air supply.
Step B: Turn the threaded bushing (14) up against the coupling flange (10) so that
the collar enters into the flange and presses against it. Make sure that the
plug is lying on the valve seat.
Attention: Note that sufficient thread of the valve spindle is inside the threaded
bushing (14). If not, turn the coupling flange (10) downwards from
the actuator spindle and pull the threaded bushing (14) against it.
Step C: For operation mode: "spring closes":
— Attach the guide flange (11) and the rotation guard (12) with the socket screws
(13) to the coupling flange (10).
— Check that the plug lifts off the seat at the required spring starting point.
Step D: For operation mode: "spring opens":
— Check that the plug leaves the end position at the required spring starting point,
and finishes the valve stroke at the spring-range end value.
— The plug must then also press on the valve seat.
Step E: After the test operation set the stroke indicators (15) into the end positions.
Step F: Lock the hexagon nuts (16 + 30) at the valve mid-stroke.
Step G: Do not turn the plug on the seat when it is under force.
Reversal of the actuator action

The actuator action can be reversed even when the valve is installed in a piping
system. The position numbers mentioned in this section refer to Figure 1 and Figure
2.
Step A: Drive the actuator into approximately mid-stroke position with the air
supply.
Step B: Loosen and remove the socket screws (13) from the coupling flange (10)
and drop the rotation guard (12) over the valve spindle.
Step C: Remove the hexagon nuts (31) from the actuator and lift off the valve.
Step D: Reduce the air supply until the chamber is pressure free.

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Step E: Loosen and remove the diaphragm lid screws.
Step F: Remove the diaphragm lid (3).
Warning: The actuators DP 32 and DP 33 have two longer screws when fitted
with stronger spring ranges. The actuator DP 34 has four. These
screws should be the last screws to be loosened, and must be
loosened evenly to reduce the high spring tension.
Step G: For reversal from "spring closes" into "spring opens":
— Remove the springs (7) and the diaphragm plate (4) with the diaphragm (1) and
the spindle (5).
— Loosen and remove the seal lock nut (19) and remove the spindle (5). Turn over
the diaphragm plate (4) with the diaphragm (1) and the diaphragm clamping
flange, and place it over the spindle (5).
damaged.
— Place the diaphragm plate (4) with the diaphragm (1) into the diaphragm lid (3).
— Place the diaphragm housing with the spindle sealing unit over the spindle, and
screw it together. Make sure that the springs stay properly arranged.
the diaphragm lid (3).
Step H: For reversal from "spring opens" into "spring closes":
— Remove the diaphragm (1) and the diaphragm plate (4) with the spindle (5) and
the springs (7).
— Loosen and remove the seal lock nut (19) from the spindle (5). Turn over the
diaphragm plate (4) with the diaphragm (1) and the diaphragm clamping flange,
and place it on the spindle (5).
damaged.
— Stick the diaphragm plate (4) with the diaphragm (1) and the spindle (5) into the
diaphragm housing (2).
Language UK ' Page 5/6

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Place the diaphragm lid (3) on the top, and screw it together. Make sure that the
springs (7) stay properly arranged.
the diaphragm housing (2).
Manual operation device

Some actuators are fitted with a manual operation device. The device is connected to
the actuator by means of a new diaphragm lid, a spindle extension with a USIT-ring
and a spindle sealing unit.
The manual operation device is equipped with stroke indicators. The stroke
indicators of both the actuator and the manual operation device must be in the same
end positions when the actuator is pressure free.
The manual operation device must be set into neutral position when the actuator is
running automatically.
The locking device of the manual operation device must be unlocked before
operating.
The locking device prevents an unwanted disarrangement of the setting during
operation, e.g. due to vibration, etc.
Maintenance
The pneumatic actuator is maintenance free. To maintain a disturbance free
operation, the air should be supplied by an air-supply station.
The diaphragm, spindle sealing unit and springs are wear parts and should be
replaced when necessary.
4.1 Exchange of spindle sealing

When the spindle sealing is changed, the slotted PTFE-guide bearing and the 0-ring
should be replaced. The spindle surface must be clean and undamaged. Before the
actuator is assembled, the spindle unit and the spindle must be greased.

INDUSTRIES

1 General
The following instruction is a general description of SIPART positioners and covers
the complete range in the PS2 6DR5000 series.
The electronic pneumatic positioner is used as the final control element of a
pneumatic linear actuator or a part-turn actuator (rotary movements). The positioner
converts a current output signal (4 to 20 mA) from a process controller or control
system to a set point value and into a corresponding movement. The positioner
changes the pressure in a pneumatic actuator chamber or cylinder until the position
corresponds to the set point value.
The positioner can be set up either as a single-action positioner or a double-action
positioner. The single-action positioner is mainly used together with a control valve.
The opposite movement for the control valve is supplied by means of springs. The
double-action positioner is mainly used to control an air damper via a pneumatic
cylinder (actuator). All movements of the pneumatic cylinder are supplied by the
positioner. An illustration of the function diagram for the positioner is shown in
Figure 1. The function diagram is shown with option modules.
Comparison of the set point and the actual value takes place electronically in a micro
controller. If the micro controller detects a deviation, it uses a 5-way switch
procedure to control the piezoelectric valves, which in turn regulate the flow of air
into the actuating chambers. When connected in a two-wire system, the SIPART
PS2 draws its power exclusively from the 4 to 20 mA set point signal.
The piezoelectric valve converts the command into a pneumatic positional
increment. The positioner outputs a continuous signal in the area where there is a
large control deviation (high-speed zone). In areas of moderate control deviation
(slow-speed zone) it outputs a sequence of pulses. No positioning signals are output
in the case of a small control deviation (adaptive or variable dead zone).
initialisation, the micro controller automatically determines the zero, full-scale
value, direction of action, and positioning speed of the actuator. It uses these to
determine the minimum pulse time and dead zone, thus optimising the control.
SIPART PS2.
The installation of the positioner must be carried out in the following order:
• Mechanic connection
• Electric connection
• Pneumatic connection
• Commissioning

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Illustration of a function diagram
Supply OH
"straloj
1 Motherboard with microcontroller and input circuit

2 Control panel with LC-display and momentary action switch
3 Plezo-vatve unit, always built-in
4 Valve unit with double action positioner always built-in
5 ly-module for positioner SIPART PS2
6 Alarm module for three alarm outputs and one digital input
7 SIA-module (Slot Initiator-Alarm-module)
8 Spring-loaded pneumatic actuator (single action)
9 Spring-loaded pneumatic actuator (double action)
Figure 1 sips2_5a.tif
Mechanic connection of the positioner

Normally the positioner is pre-mounted on the actuator or cylinder. If not, follow the
installation guide lines below.
2.1 Mechanic connection to an actuator

Figure 2 shows the mechanic connection of the positioner to an actuator for a control
valve.
Step A: Mount clamping assembly (3) with hexagon socket cap screws (17) and
lock washers (16) on the actuator spindle.
Step B: Insert the pick-up bracket (2) into the recesses of the clamping assembly.
Set the necessary length and tighten the screws so that the pick-up bracket
can still be shifted.

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Step C: Push the roll (5), spring (13), and guide washer (22) onto the pin (4).
StepD: Insert the pin in the lever (6) and assemble with nut (18), spring washer
(14), and U-washer (12).
Step E: The value of the stroke range specified on the actuator should be set or if
this does not exist as a scaling value, the next greatest scaling value should
be set. The centre of the pin must be in line with the scaling value. The
same value can be set later under parameter "3.YWAY" in commissioning
to display the way in [mm] after initialisation.
Step F: Assemble the hexagon socket cap screw (17), spring washer (16), washer
(12), and square nut (19) on the lever.
Step G: Push the pre-mounted lever onto the positioner axis up to the stop and fix
with the hexagon socket cap screw (17).
Step H: Fit the mounting bracket (1) with two hexagon head screws (9), lock
washer (10), and flat washer (11) on the rear of the positioner.
Step I: Selection of the row of holes depends on the width of the actuator yoke. The
roll (5) should engage in the pick-up bracket (2) as close as possible to the
spindle but may not touch the clamping assembly.
Step J: Hold the positioner with the mounting bracket on the actuator so that the pin
(4) is guided within the pick-up bracket (2).
Step K: Tighten the pick-up bracket.
Step L: Position the mounting parts according to the type of actuator.
— Actuator with ledge: hexagon head screw (8), flat washer (11), and lock washer
(10).
— Actuator with plane surface: four hexagon head screws (8), flat washer (11), and
lock washer (10).
— Actuator with columns: two U-boIts (7), four hexagon nuts (21) with flat washer
(11), and lock washer (10).
Step M: Secure the positioner onto the yoke using the previously positioned
mounting parts.
Note: Set the height of the positioner so that the horizontal lever position is
reached as close to the stroke centre as possible. The lever scale can be
used as orientation. It must be guaranteed that the horizontal lever
position is passed through within the stroke range.

INDUSTRIES
Mechanic connection of the positioner (linear actuator)
17 22
1) 2) 4
11
10
3)
Mounting on yoke Mounting on yoke

11 with ledge with plane surface
Mounting on yoke
with columns
As required
Figure 2 sips2_5b.tif

INDUSTRIES
2.2 Mechanic connection to a pneumatic cylinder

The positioner is connected to a pneumatic cylinder by means of fixing bracket,
lever arm with Allen screw, extension arm, and roller.
The pneumatic piston is connected to a guide rail with an oblique angle via a
linkage. The guide rail moves together with the piston, and the roller/lever
connection senses the position of the piston. By operating both sides of the
pneumatic cylinder, the set point is reached. A spring inserted between the fixing
bracket and the lever arm secures that the roller is pressed down against the guide
rail.
2.3 Mechanic connection to a rotary actuator
Figure 3 shows the mechanic connection of the positioner to a rotary actuator.

Step A: Attach the mounting console (9, actuator specific) onto the rear of the
positioner and secure using the hexagon head screws (14) and lock washers
(15).
Step B: Adhere pointer (4.2) onto the mounting console in the centre of the centring
hole.
Step C: Push coupling wheel (2) onto the positioner axis, pull back by about 1 mm
and tighten the hexagon socket head screw (18) with the Allen key
provided.
Step D: Place the carrier (3) onto the end of the actuator and secure using Fillister
head screw (16) and washer (17).
Step E: Carefully place the positioner with mounting console onto the actuator such
that the pin of the coupling wheel engages in the driver.
Step F: Align the positioner/mounting console assembly in the centre of the actuator
and screw tight (screws are not included in the delivery, they are part of the
actuator mounting console).
Step G: Follow the start-up sequence as described later. Drive the actuator to the
end position and adhere the scale (4.1) onto the coupling wheel (2)
according to the direction of rotation and rotary actuator. The scale is self-
adhesive.

INDUSTRIES
Mechanic connection of the positioner (rotary actuator)
Figure 3 sips2_5c.tif

INDUSTRIES
Electric connection of the positioner

When the positioner is connected in a two-wire system, the positioner draws its
power exclusively from the 4 to 20 mA set point signal. Figure 4 indicates the input
circuits for the positioner.
View of the controls and connections
12
11 10
1 Input: Supply air 7 Silencer

2 Output: Actuating pressure Y1 8 Transmission rMib selector
3 Display 9 Adjusting wheel sijfcciutch
4 Output; Actuating pressure Y2 ** 10 Termiha)s,ppttons modules
5 Operating keys 12 .prnmy'iplug . - \ :.•' :
e Restrictbr 13 • Serewîypa cable-gland •..,
8.1 Resiifctor Y1 . 14 Terrtiina!; plafeori'tsoyer
5.2 ResirictorY2*) 15 Purglngair switch-
Figure 4 sips2_5d.tif
Ensure that the air quality is suitable. Grease-free instrumental air with a solid
content < 30 um and a pressure dew point 20 K below the lowest ambient
temperature must be supplied.
Warning: For reasons of safety, pneumatic power may only be supplied after
assembly when the positioner is switched to operating level "P
manual" operation with electrical signal applied.
4.1.1 Selection of P manual mode

Before pneumatic power is connected, the positioner must be in P manual mode.
The display must show "NOINIT" in the bottom line.

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4.1.2 Pneumatic connections

Figure 4 shows a view of the positioner controls and connections.
Step A: If required, connect a manometer block for supply air and actuating
pressure.
Step B: The silencer in the exhaust output can be removed if necessary.
Step C: Connect actuating pressure Yl and/or Y2 (Y2** is only used with double-
acting actuators) according to the desired safety position.
Step D: Connect the supply air (1). The pressure should be between 1.4 to 7 bar.
Note: In order for spring-loaded pneumatic actuators to be able to reliably

exploit the maximum possible actuating path, the supply pressure must
be sufficiently greater than the maximum required final pressure of the
actuator.
4.1.3 Safety position when the electric power supply fails

For a single-action actuator is Yl deaerated. For a double-action actuator is Yl
equal to the supply air pressure and Y2 is deaerated.
4.1.4 Restrictors
To increase the positioning times for fast actuators when necessary, the air flow can
be reduced with the restrictors Yl and Y2 (only for double-action valves). Turning
the restrictors in the clockwise direction reduces the air flow until it is shut off. To
set the restrictors it is recommended to first close them and then open them again
slowly (see initialisation process RUN 3).
4.1.5 Purging air switchover

The purging air changeover switch located above the pneumatic terminal block on
the valve manifold can be accessed when the housing is open. When the switch is in
position "IN" the interior of the housing is purged with very small quantities of
clean and dry instrument air. In position "OUT" the purging air is led directly out of
the instrument.
Commissioning
initialisation, the micro controller automatically determines the zero value, full-scale
value, direction of action and positioning speed of the actuator. It uses these to
determine the minimum pulse time and dead zone, hereby optimising the control.
SIPART PS2.
The commissioning of the positioner can be divided into the following steps:
• Preparation for initialisation
• Start the automatic initialisation procedure

INDUSTRIES
• Set additional parameters if required

• Select automatic mode
Figure 5 shows the possible operation modes for the positioner and gives an
overview of how to change between them. The levels are P-manual mode,
configuration and initialisation, manual mode, automatic mode, and diagnostic
display. From these modes it is possible to select operation mode, set operation
parameters, restore to factory setting, run an automatic initialisation, etc.
Operation levels
Mode Display
Figure 5 sips2_5e.tif
5.1 Preparation for initialisation
Step A: Check and set the gear transmission switch to the correct position. Figure 4
(position 8) indicates the location of the switch. For linear actuators the gear
transmission switch is set according to the stroke range as described in
Table 1 for the parameter "3.YWAY". For part-turn actuators 90° must be
selected.
Step B: Check that the pneumatic supply power (inlet air) is present. The operating
pressure should be at least one bar greater than is necessary for
closing/opening the valve during initialisation.

INDUSTRIES
Step C: Without initialisation the positioner is in "P manual mode" and "NOINIT"
flashes in the display. This level can also be reached by using "55.PRST"
function (see Table 1).
Step D: Check the free running of the mechanics in the whole actuating range by
moving the actuator with the keys " | " and " | " and driving to the respective
end position.
Step E: With linear actuators drive the actuator to horizontal lever position. The
display must indicate 48% to 52%. If necessary, correct the value by
adjusting the sliding clutch. After the check is completed, the actuator must
be approximately half way along its stroke. This is due to establishment of
the action direction during automatic initialisation.
5.2 Automatic initialisation
Figure 6 shows the configuration mode including the operation in this mode and
Table 1 shows the parameter/configuration list. Figure 7 shows the initialisation
process of the positioner. The initialisation process is stored in the microprocessor.
This means that an additional initialisation only is necessary if any parts of the unit
have been changed.
Note: The numerical values used in Figure 5, Figure 6, and Figure 7 are
examples.
Step A: Call the configuration mode by pressing the hand symbol key for longer
than 5 seconds.
Step B: Set the actuator type, linear or part-turn, in the menu item line "l.YFCT".
Step C: Switch to the second parameter by pressing the hand symbol key briefly.
Step D: Set the rated angle of rotation for feedback in the menu item line
"2.YAGL". It is vital that this value corresponds to the setting of the gear
transmission ratio selector (Figure 4, position 8), 33° or 90°.
Step E: Switch to the next parameter by pressing the hand symbol key briefly.
Step F: This parameter ("3.YWAY") is only set for linear actuators and if the total
stroke in mm should be displayed at the end of the initialisation phase. To
do this, select the same value in the display to which the carrier pin to the
scale on the lever is set to.
Step G: Switch to the following parameter by pressing the hand symbol key briefly.
Step H: Start the initialisation ("4.INITA") by pressing the "f" key for longer than 5
seconds.

INDUSTRIES
Step I: During the initialisation phase "RUN1" to "RUN5" appear one after another
in the bottom of the display. Please note that the initialisation process may
last up to 15 minutes depending on the actuator.
Note: The ongoing initialisation can be aborted at any time by pressing the
hand symbol key. The previous settings are retained. AH the parameters
are reset to the factory setting only after performing a preset
"55.PRST".
Step J: If problems occur, carry out the measures as described in the table "Possible
messages" shown in Figure 7.
Step K: The initialisation is completed when "FINSH" appears in the bottom of the
display.
Step L: When pressing the hand symbol key briefly the menu item line "4.INITA"
is displayed.
Step M: To exit the configuration operating mode, press the hand symbol key for
longer than 5 seconds. The software version is displayed after about 5
seconds. The instrument is in manual operation after releasing the key.
Step N: The positioner can be changed to automatic mode by pressing the " j " key
once as indicated in Figure 5.
Step O: The automatic mode is the normal mode. In this mode the positioner
compares the set point current with the current position and moves the
actuator until the control deviation reaches the dead zone.
Operation in the configuration mode
at the same time
at the same time
Figure 6 sips2_5f.tif

INDUSTRIES
Initialisation process
Automatic In Hi al start-up (starting with factory setting) Possible messages
Step Meaning Display Meaning Measures
turn 90° Acknowledge message

Parti urn
actuator Actuatordoos using the hand synrbol key
1 VFCT 2 YAGL 324 not move
RUN 1 Check reslrictor (Q and open
linear WAY 33° Strt ifnecessary
actuator 1 VFCT 2 YAGL 3 YWW P 32.4 Drive actuator to working range
ERROR using the up and down keys
Press the up key for > 5 sec.
Strt Restart initialisation
4 INTA Remalnhg steps are carried out automatical
Change gearing (7)
Ccntinueushg up key
P 324 Direction of action is determined
a RUN 1 Down tolerance Or adjust slicing clutch up
P 88.4 todspby
H dim IU band violated
Checking oftravel and adjustment of
92.4 zero andstroke (from stop to stop)
RUN 2
Deterrriration and display of positioning time Then only
P 824 down(dxx.x), up(uxx.x).Stopwiththedownkey Centime ushg the down key
rj RUN 3 Pressing t he up key initiates leakage measurement Linearactuator set pick-up
Clice the slipping lever into horizontal position
SEt dutch has been using the tp and down keys
P 32.4 Determination of m'nimumhcrement length MIDDL adjusted
D RUN 4 Continueushg hand symbol key
P 524 Optimisati on of transient respon se Acknowledge Dressage

G RUN 5 Up tolerance band using the hand symbol key
98.3
Initialisafon terminated successfully UP > violated Set the next highest travel
(travel in m mf or linear actu at as) value on the lever
324
(angle ofrotation for part-tum actuators)
Restart iriti alisSbn
Continueushg hand symbol ley
Additionally possible with rotary
actuators:
Adjust using up and down keys
up to displa y: *
92.8
SO 9 5
Continue ushg hand symbol key
Acknowledge message
using the rand symbol key
19.8 Up/down span
Set the ne<t lowest travel
violated
value on tre lever
Restart initialisation
Adjust positioning time ushg

1.3 Actuatordoes resrictor(s)
NOZZL not move.
Positioning Continueushg the
time is possibl e up ordown key
1.8 to adjust
NOZZL
Figure 7 sips2_5g.cdr
5.3 Parameters
Table 1 shows the parameter list for the positioner. The parameter name is written in
plain text in the "menu line" column. The function of the parameter is described
briefly in the "Function column". In addition, the possible parameter values, the
physical unit and the factory setting of the parameters are shown.
After the initialisation process, the positioner can be configured to meet the
requirements of a specified task. The factory settings correspond to the requirements
for a typical application. This means that normally only a few parameters will need
to be changed.
The positioner can be installed and configured to fit linear and part-turn actuators
with reverse action. E.g. linear actuators with the set point in the falling direction or

INDUSTRIES
part-turn actuators for counter clockwise operation direction. In this case the
parameters "7.SDIR" and 38."YDIR" should be set to "FALL".
Parameter list
Customer
setting
turn (part-turn actuator)
WAY (linear actuator)
LWAY (linear actuator
without sine correction)
l.YFCT Type of actuator WAY
ncSt (part-turn actuator
withNCS)
-ncSt (part-turn actuator
with NCS, inverted)
Rated angle of rotation for feedback 90°
2.YAGL0 Degrees 33°
(must correspond to gear ratio) 33° .
Stroke range (optional setting) OFF
5 , 10, 15 , 20
When used, the value must correspond with (short lever 33°)
the set of the leverage ratio on the actuator
3.YWAY2' 25 , 30, 35 mm OFF
(short lever 90°)
Driver pin must be set to the value of the
40,50,60,70,
actuator travel or, if this value is not scaled,
90,110,130
to the next lager scale value
(long lever 90°)
4.INITA Initialisation (automatically) noini/no/###.#/Strt no
5.INITM Initialisation (manually) noini/###J/Strt no
„ . . . . . 0 to 20 mA 0MA
6.SCUR Current range of set point 4 1 0 20 mA 4MA
4MA
riSE
7.SDIR Set point direction fir riSE
FALL
8.SPRA Set point for start of split range 0.0 to 100.0 % 0.0
9.SPRE Set point for end of split range 0.0 to 100.0 % 0.0
Auto
10.TSUP Set point ramp up s 0
0 to 400
ll.TSDO Set point ramp down 0 to 400 s 0
Set point function
Linear Lin
12.SFCT Equal-percentage 1:25,1:33,1:50 1-25 ,1-33 ,1-50 Lin
Inverse equal-percentage 1:25,1:33,1:50 nl-25 , nl-33 , nl-50
Freely adjustable FrEE
13.SLC Set point turning point at 0% 0.0
14.SL1 5% 5.0
to to 0.0 to 100.0 % to
32.SL19 95% 95.0
33.SL20 100% 100.0
Auto
34.DEBA Dead zone of controller % Auto
0.1 to 10.0
35.YA Start of manipulated variable limiting 0.0 to 100.0 % 0.0
36.YE End of manipulated variable limiting 0.0 to 100.0 % 100.0
Standardisation of To mech. travel MPOS
37.YNRM MPOS
manipulated variable To flow FLOW
Direction of manipulated Rising riSE
38.YDIR riSE
variable for display Falling FALL
Without no
Tight closing with Top only UP
39.YCLS no
manipulated variable Bottom only do
Top and bottom uPdo

AALBORG POSITIONER, S1PART PS2 6DR5000 OM5510#05.1
INDUSTRIES
Parameter list continued

Customer
setting
40.YCDO Value for tight closing, bottom 0.0 to 100.0 % 0.5
41.YCUP Value for tight closing, top 0.0 to 100.0 % 99.5
Function of B I 1 :
None OFF
Only message (NO/NC contact) on / -on
Block configuring (NO contact) bLocl
42.BIN14) Block configuring and manual (NO contact) bLoc2
OFF
Block movement (NO/NC contact) StoP / - StoP
Function of BI 2:
None OFF
4) Only message (NO/NC contact) on / -on
43.BIN2 Drive valve to pos. up (NO/NC contact) uP/-uP
OFF
Block movement (NO/NC contact) StoP / -StoP
Without OFF
5) ., - Al=min. A2=max. N,NA OFF
44.AFCT Alarm function ., . .„
Al=mm. A2=mm. N,N
Al=max. A2=max. NA,NA
Function of alarm output
On fault 4
47.L,FCT6) Fault + not automatic hnA h
Fault + not automatic + BI hnAb
("+" means logical OR operation)
Monitoring time for fault message Auto
48. L, TIM s Auto
"control deviation" 0 to 100
Response threshold for fault message Auto
49.HLIM % Auto
"control deviation" 0.0 to 100.0
OFF
5O.i-,STRK Limit for stroke integral OFF
1 to 1.00E9
OFF
51.L,DCHG Limit for direction change OFF
1 to 1.00E9
OFF
52. L, ZERO Limit for end stop monitoring, bottom % OFF
0.0 to 100.0
OFF
53. h OPEN Limit for end stop monitoring, top % OFF
0.0 to 100.0
OFF
54.L,DEBA Limit for dead zone monitoring % OFF
0.0 to 100.0
Preset (factory setting)
"no" nothing activated no
"Strt" start of factory setting after pressing
55.PRST key for 5 sec. Strt
"oCAY" display following successful
factory setting oCAY
CAUTION: preset results in "NO INIT"
1}
If turn is selected it is not possible to set 33°.
2)
Parameter does not appear if l.YFCT = turn has been selected.
3)
Turning points only appear with selection 12.SFCT = FrEE.
4)
Alternatively "no" if initialisation has not yet been carried out
5)
NC contact means; action with opened switch or low level. NO contact means; action with closed switch or high level.
6)
Normal means: high level without fault. Inverted means: low level without fault.
Table 1

INDUSTRIES
Diagnosis
In the diagnostic mode the current operating data (such as number of strokes,
number of changes in direction, number of fault messages, etc.) can be displayed.
From the automatic or manual modes the diagnostic mode can be reached by
simultaneously pressing all three keys for at least 2 seconds.
Table 2 shows an overview of the displayable values. The diagnostic display has a
similar structure as the parameter menu displays. The respective next diagnostic
value can be selected with the hand symbol key. Certain values can be set to zero by
pressing the " | " key for at least 5 seconds. These are menu item line "1, 2, 3, and 4".
Some diagnostic values may be greater than 99999. In this case the display switches
to exponential display.
No.: Abbreviation Meaning Displayable Unit

value
STRKS Number of strokes 0 to 4.29E9
CHDIR Changes of direction 0 to 4.29E9
hCNT Fault counter 0 to 4.29E9
HOURS Operating hours 0 to 4.29E9 Hours
WAY Determined actuating path 0 to 130 mmor v
TUP Travel time up 0 to 1000
TDOWN Travel time down 0 to 1000
10 LEAK Leakage 0.0 to 100.0
11 P0 Potentiometer value below stop (0%) 0.0 to 100.0
12 P100 Potentiometer value bottom stop (100%) 0.0 to 100.0
13 IMPUP Impulse length up 2 to 100 ms
14 IMPDN Impulse length down 2 to 100 ms
15 DBOP Dead zone up 0.1 to 100.0
16 DBDN Dead zone down 0.1 to 100.0
17 SSUP Short step zone up 0.1 to 100.0
18 SSDN Short step zone down 0.1 to 100.0
19 TEMP Current temperature -45 to 85
20 TMIN Minimum temperature -45 to 85
21 TMAX Maximum temperature -45 to 85
22 Tl Number of operating hours in Temperature range 1 0to4.29E9 Hours
31 VENT1 Number of cycles pre-control valve 1 0 to 4.29E9
32 VENT2 Number of cycles pre-control valve 2 0 to 4.29E9
Store current values as "last maintenance"
33 STORE
Press the up key for at least 5 seconds (store)
Table 2

* f f 111 *

INDUSTRIES
Service and maintenance

The positioner is largely maintenance-free. The positioner is fitted with filters in the
pneumatic connection as protection against coarse particles of dirt. If the pneumatic
energy supply contains particles of dirt, the filters may be clog and impair the
function of the positioner. In this case the filters can be cleaned as follows:
Step A: Switch off the pneumatic power supply and remove the pipes.
Step B: Unscrew the cover.
Step C: Remove the three screws from the pneumatic connector strip.
Step D: Remove the filters and O-rings behind the connector strip.
Step E: Clean the filters (e.g. with compressed air).
Step F: After cleaning first insert the filters in the recesses in the housing and then
place the O-rings on the filters.
Step G: Align the pneumatic connector strip on the two lugs and screw tight with
the three self-tapping screws.
Note: Make sure that the same thread is used. To do this, turn the screws anti-
clockwise until they snap into the thread audibly. Only then should the
screws be tightened.

INDUSTRIES
Table of contents
Steam injection system

Steam injection system 64Z:027656a
Stop valve DN 80, PN 16 6010 000065
Cast iron strainer, DN 80, PN 16 7040 000026
Control valve, DN 80, PN 25 6000 000041
Temperature switch, 40-105°C •. 8070 000010
Water check valve, DN 80, PN 40 6020 000011
Vacuum breaker, BSP lA" 6000 000010
Steam injection, BSP 11/2" 7000 000014

Pipe dim. DN200
M87
VENT. TO DECK
OPEN AIR
Temp.switch+pocket+4m cap.tube
40-105 °C
Control valve
DN80 PN25
Counter flange (not shown)
Screw and nut (not shown)

M16
Gasket (not shown)
DN80
Stop valve DIN 1693
DN80 PN16 GGG-40.3
Steam injection system

for steam amount of 90 and 100 t/h
Steam pressure: 6 bar
(Type N)
AALBORG Article/Drawing No:
INDUSTtlES THIS DRAWING AND DESIGN SHOWN HEREIN IS THE PROPERTY OF AAIBORG INDUSTRI
AND MUST HOT BE USED BY OR REPRODUCED FOR THIRD PARTY 64Z: 027656
Version: B Date: 1998-11-10 Pos. M82
Description
A flanged bellows sealed stop valve, type BSA-1, for use on
steam, condensate and water systems.
Limiting conditions
Body design conditions PN16
Max. design temperature 300°C
Max. hydraulic test pressure 24 bar g
Size and pipe connection

DN80, Flanged DIN 2533/BS4504/ISO 7005 PN16.
Material specification
1 Body Cast iron DIN GG25
2 Bonnet SGiron DIN GGG 40.3
3 Seat Stainless steel AISI420
4 Disc Stainless steel DIN 17440 X30 Crl3
5 Bellows Stainless steel DIN 17440 X6
CrNiTil810
6 Stem Stainless steel AISI420
7 Handwheel Pressed steel BS 1449 CR4
8 Stem packing Graphite
9 Bonnet screw Steel DIN 931 Gr 5.6
10 Body/
Bonnet gasket Graphite laminate with
stainless steel insert
Dimensions in mm
DN 80
A 310
B 287
C 200
Weight, kg 21
Data Sheet
Stop Valve DN80, PN16 6010 000065
Page 1 of 1
AALBORG
INDUSTRIES
Version: A Date: 1998-11-10 Pos. M83
Description
Standard screen stainless steel 0.8 mm perforations,
type Fig. 33
Limiting conditions
Body design conditions PN 16
Max. hydraulic test pressure 24 bar g

DN80. Standard flange: DIN PN 16.
Materials
1 Body Cast iron DIN 1691 GG20
2 Cap Cast iron DIN 1691GG20
3 Cap gasket Reinforced exfoliated graphite
4 Strainer screen Stainless steel ASTMA240 316L
5 Cap studs Steel BS 4439 Gr 8.8
Cap nuts Steel BS 3692 Gr 8
Dimensions (approximate) in mm
DN 80
A 310
B 210
C 340
Screening area, cm2
Weight, kg
361
25.9 1
Installation Withdrawal
Distance i
The strainer should be installed in the direction of flow
as indicated on the body, in a vertical or horizontal
pipe line.
Data Sheet
Cast Iron Strainer, DN80, PN16 7040 000026
Page 1 of 1
AALBORG
INDUSTRIES
Description
Normally open, double seat control valve, type NS.
Limiting conditions
Max. differential pressure, DN 80 10 bar

Flanged BS 4504 PN 25.
1 Body Gun-metal BS 1400 LG2
2 Body gasket Semi-ridged graphite BS 2815 Gr.A
3 Valve closure
Member Gun-metal BS 1400 LG2
4 Plunger Brass BS 2874 CZ 121
5 Plunger guide Brass BS 2874 CZ 121
6 Return spring Stainless steel BS 2056 302 S 26
7 Spring housing Gun-metal BS 1400 LG 2
8 Bonnet Gun-metal BS1400LG2
9 Stem - Brass BS 2874 CZ 121
10 Body studs Steel BS 4439 Gr 8.8
Body nuts Steel BS 3692 Gr 8
DN 80 Ml6
DN 80
A 236
B 160
Weight, kg 22.7
Installation
The valve should be fitted in a horizontal line with the
actuator vertically below the line. Full details are supplied
with each valve.
Data Sheet
Control Valve, DN80, PN 25 6000 000041
Page 1 of 1
AALBORG
INDUSTRIES
Version: A Date: 2003-09-05
Description
A range of self powered control systems that
-Z
incorporate sensor, actuator, set point controller /
indicator, type 121. ©-Y
4
Temperature range 40 to 105°C
M"BSP
1 Sensor Brass
2 Actuator Brass
3 Capillary tube Copper PVC Covered
4 Adjustment head Polypropylene
5 Union kit Brass
6 Mounting bracket Steel
7 Clip Polypropylene
8 Adaptor plate Steel
9 Pocket Stainless steel
BS3605CFS316S18
Control system
A 271
B 148
C 424
D 25
3 4000
Weight, kg 2.0
Pocket
F 430
G 28
D G
Pocket
Data Sheet
Temperature switch, 40-105°C 8070 000010
Page 1 of 1
AALBORG
INDUSTRIES
Version: B Date: 2002-09-26
Description
DCV2 Water check valves are designed to be sandwiched between
flanges. They are suitable for use on a wide range of fluids for
applications in process lines, hot water systems, steam and
condensate systems etc.
1 Body Ferritic Stainless steel WS 1.4313
2 Disc Austenitic Stainless steel BS 1449 316 S 11
3 4 21
3 Spring retainer Austenitic Stainless steel BS 1449 316 S 11
4 Heavy duty spring Austenitic Stainless steel BS 2056 316 S 42
Dimensions in mm
DN 80
A 154
B 133
C 128
D 50
E 111.5
F 80
Weight, kg 2.42
Installation
DCV Water Check Valves must be fitted in accordance
with the direction of flow arrow indicating correct fluid
flow direction.
Flange Joint
When fitted with a spring they can be installed in any Gasket (Supplied
plate. When supplied without a spring these must be by Installer)
fitted in a vertical flow line with the flow from bottom

to top.
The "cam" design of the body allows the various flange
types to be accommodated. The body is rotated to touch
the flange joint bolts ensuring that the valve is centred in
the pipeline.
Note:
Dies Check valves are not suitable for use where heavily
pulsating flow exists, such as close to a compressor.
Data Sheet
6020 000011
Water Check Valve, DN80, PN40
Page 1 of 1
AALBORG
INDUSTRIES
Version: B Date: 1998-09-11 Pos. M87
Description
The VB14 is a small purpose designed vacuum breaker
for general purpose applications on condensing vapour
(steam) or liquid systems.
Limiting conditions
Body design conditions PN16
Max. cold hydraulic test pressure 24 bar g

1/2" (System connection) Screwed BSP or NPT.
1 Cap Brass CUZN39PB2
2 Valve Stainless steel Z 100 CD 17
3 Valve seat Stainless steel Z15CN16 02
4 Body Brass CUZN39PB2
5 Gasket Stainless steel AISI304
Size 1/2"
A 55
B (A/F) 34
C 39
Weight, kg 0.35
Installation
The VB14 Vacuum Breaker must be installed in a
vertical position with the system connection at the
bottom.
Data Sheet
6000 000010
Vacuum Breaker, BSP 1/2"
Page 1 of 1
AALBORG
INDUSTRIES
Description
• Steam injectors use steam to raise the
temperature of water or other liquids. They
work by using a jet of steam to draw in the
liquid through radial ports, mix it, and
distribute the heated liquid throughout the
tank or vessel. The circulation induced by
the injector ensures thorough mixing and
avoids temperature stratification.
Limiting conditions
• Body design rating: PN25
• Max. saturated steam condition: 17 bar g at
207°C
• Maximum heated liquid temperature 88
(tank/vessel vented to atmosphere): 90°C
• Weight: 1.6 kg
Materials
-115-
• Austenitic stainless steel grade 316L.
Installation Steam injector type IN40M

• Steam supply pipework must be firmly
anchored to prevent vibration and stress in
the tank wall. For more information, see
drawing "Steam injection system".
• • • • •
• • • • • Data Sheet
Steam Injector, BSP 7000 000014
Page 1 of 1
AALBORG
INDUSTRIES
INDUSTRIES
Table of contents
Soot-blower
Technical data for soot-blower
General data 1
Data for soot-blower 2
Soot-blower
Description 1
Soot-blower procedure 2
Soot-blower unit
General 1
Installation and mounting notes 2
Operation 3
Maintenance 4
Air scavenge valve
Description 1
Lubrication
Description 1

AALBORG SOOT-BLOWER OM8540#01.0
INDUSTRIES
Soot-blower
1 Description
The purpose of the soot-blower is to clean the heating surface for combustible
deposits. In order to clean the heating surface air is blown at high pressure through
the nozzles of the soot-blower element that extend and retract as well as rotate in the
heating surface of the boiler. The combustible deposits dislodged in the process get
removed via the exhaust gas system. The engine load should be at least 75% when
soot-blowing, to ensure that increased gas velocity through the boiler helps to carry
away the deposits dislodged by the soot-blowers.
Figure 1 illustrates the arrangement of the soot-blower system. The illustration is
shown with four manually operated soot-blowers, but the actual boiler can be
equipped with any number of soot-blowers.
Illustration of the soot-blower system
Air supply
1 Air supply valve

2 Soot-blower
3 Drain valve
The supply line must have a continuous

fall from supply to drain in order to ensure
adequate drainage. Branches should be
kept as short as possible.
I
Y
Figure 1 sb 9.cdr

AALBORG SOOT-BLOWER OM8540#01.0
INDUSTRIES
Soot-blowing procedure
To avoid damage of the heat surface and soot-blowers it is important that the air
supply is dry before soot-blowing is commenced.
Step A: Open the air supply valve and allow drainage of condensate through the
drain valve.
Step B: Operate the soot-blowers in the numerical order.
Step C: During soot-blower operation the air supply pressure must be kept
sufficiently high to ensure that the cleaning procedure is carried out
satisfactorily. The supply pressure should therefore be checked
continuously.
Step D: Turn the hand-wheel clockwise. The mechanical indicator will move
downwards. During the first turning, the element will be projected forward
into the heating surface of the boiler at which point the soot-blower valve
will be opened and admit air "Initial blow position". During the final
turning in the same direction, the element is projected further into the
heating surface emitting air for soot-blowing, in the pattern corresponding
to the blowing angle. When the hand-wheel cannot be turned further the
limit of the blowing angle has been reached.
Step E: Turn the hand-wheel counter-clockwise to return to the "Initial blow

position". The soot-blowing continues during this action.
Step F: Turn the hand-wheel clockwise again to the foil blowing angle limit and
then return to the "Initial blow position".
Step G: Repeat the soot-blowing operation once again. The total blowing time
should be carried out over a period of approximately 45 seconds.
Step H: When the soot-blowing is completed, return the blower to the "Full off
position by turning the hand-wheel counter-clockwise until the mechanical
indicator is pushed up.
Step I: Ensure that the soot-blower is left in the "Full off' position.
Step J: Repeat the same operation with all the equipped soot-blowers.
Step K: Close the air supply valve.
Step L: Open the drain valve when soot-blowing is finished and the air supply valve
is closed.

AALBORG SOOT-BLOWER UNIT OM8540#05.0
INDUSTRIES
Soot-blower unit
General
The soot-blower unit consists of a pressure chest including hand-wheel, mechanical
indicator, lubrication nipples and, scavenge air valve. The pressure chest is
connected to a soot-blower element with nozzle ports via a coupling. The soot-
blower unit is operated manually by means of the hand-wheel, thereby running in
and out as well as rotating the nozzle ports of the element inside the boiler.
Installation and mounting notes

During installation and mounting of the soot-blower the following should be
observed:
Step A: Pipe-lines for the soot-blower must be thoroughly purged with steam or air
to expel grit and metal cuttings prior to commissioning.
Step B: Drain pipes leading from the supply pipe-line should be arranged to permit
easy access.
Step C: The coupling and element are marked to give the correct setting for the
blowing angle. When assembling, those marked must be lined up before
locking in position.
Step D: The soot-blower should be carefully slung and the element carefully
inserted through the soot-blower socket and internal bearings of the boiler.
The blowing angle should be inspected from inside the boiler when
operating the soot-blower in manual operation.
Step E: Connection to the scavenge air supply should be minimum 025 mm piping.
To ensure a constant air flow, no other ancillary equipment should be
connected to this supply.
Operation
The frequency of the soot-blower operation depends on the operating conditions of
the boiler. Indicators of the need to soot-blow are boiler gas temperatures and boiler
slag inspections. As a general guideline the boiler should be cleaned shortly after
start up when full boiler working pressure is obtained and approximately 2 -3 times
per day. The engine load should be at least 75% when soot-blowing, to ensure that
increased gas velocity through the boiler helps to carry away the deposits dislodged
by the soot-blowers.

INDUSTRIES
Maintenance
4.1 Routine tests and checks
• Check by observation the effectiveness of seals, adjust if necessary.

• Check for build up of dust, clean as necessary.
• Check for exhaust/flue gas leakage, take necessary remedial action.
4.2 Lubrication
The efficiency, availability and reliability of a soot-blower are maintained by

adopting a recommended lubrication schedule which is detailed on the lube chart.
See the chapter "Lubrication". The soot-blowers should always be lubricated with
Clydspin® or similar, which is specially formulated for use on moving parts
exposed to high temperatures. On new equipment it is particularly important to
apply grease regularly, to create a long-lasting lubricating film on the surfaces.
Grease is applied from grease guns fitted with special adaptors. Please consult the
lube chart for identification of lubricating points.
4.3 Replacement of gland packing

When replacing the gland packing, it is not necessary to disconnect the supply inlet
flange or remove the soot-blower from the boiler. Proceed as follows when
replacing the gland packing. Please refer to Figure 2.
Step A: Ensure that the blowing medium has been safely isolated from the soot-
blower.
Step B: Remove the lubricating nipple plug (25).
Step C: Unscrew the guide pin (14) with an "Allen key".
Step D: Remove the four nuts (23) to detach the sleeve assembly from the pressure
chest.
Step E: Rotate the hand-wheel in a clockwise direction (looking from the hand-
wheel) to disengage the operating screw from the operating nut (7), which
will then be free and permit removal of the sleeve assembly.
Step F: Remove the operating nut (7), now loose in the ported spindle (4).
Step G: Remove all old gland packing (18).
Step H: Coat the new packing with Clydspin® lubricant or similar and insert
packing taking care not to damage the faces of the packing. Note the
position of the neck ring (19) in the bottom of the stuffing box and ensure
that it remains secure during replacement of the packing.

INDUSTRIES
4.4 Major overhaul

Proceed as follows for major overhaul of the soot-blower. Please refer to Figure 2
and Figure 4.
Step A: Disconnect the inlet flange connection and remove the soot-blower from the
boiler. If necessary, assist removal of the soot-blower element from inside
the boiler.
Step B: Dismantle as described in work step A to F (section 4.3).
Step C: Remove cap nut (13) at the boiler end of the soot-blower chest (1) and
withdraw the ported spindle (4), see Figure 2.
Step D: The liner (5) can now be inspected. If the liner is to be replaced, set the
soot-blower on to a solid foundation and drive the liner out with a suitable
drift. The new liner may then be pressed into the chest (1), see Figure 2.
Step E: Removal and fitting of the piston rings (20, Figure 2) is facilitated by the
use of circlip pliers.
Step F: The element (13) is attached to the spindle of the pressure chest by a fixed
coupling (2) and lock nut (12). To disconnect the element, remove grub
screws (8) and slacken back the lock nut, see Figure 4. The element can
then be disconnected by turning in anti-clockwise direction.
Step G: When re-assembling the soot-blower and reconnecting the element (13,
Figure 4), the setting marks on the spindle (4, Figure 2), coupling (2, Figure
4), and the element (13, Figure 4) must always be in line.
Illustration of the hand-wheel
Figure 1 sb 15.cdr

INDUSTRIES
Illustration of the pressure chest
Figure 2 sb 14.tif
Illustration of the mechanical indicator
Figure 3 sb 18.cdr

INDUSTRIES
Illustration of the soot-blower coupling
Figure 4 sb 6.cdr
Pos. Designation Pos. Designation Pos. Designation

Sleeve end cover Instruction plate Circlip
Hand-wheel Woodruff key 10 Socket head cap screw
Nut Bush 11 Operating screw
Distance piece Ball bearing
Chest 18 Packing 27 Non-return valve coupling

Inner sleeve 19 Neck ring 28 Non-return valve
Outer sleeve 20 Piston ring 29 Joint
Spindle 21 Bearing ring 33 Air scavenge valve
Liner 22 Stud 34 Joint
Operating nut 23 Nut 35 Mechanical indicator
10 Orifice plate 24 Sleeve pin 36 Plug
13 Cap nut 25 Plug 37 Joint
14 Guide pin 26 Lubricating nipple 39 Circlip
Plunger Spring Cover

O-ring Spring casing Grub screw
Pos. Designation Pos. Designation Pos. Designation

Coupling 12 Locknut 13 Nozzle element
Grub screw
Table 1

AALBORG AIR SCAVENGE VALVE OM8540#12.0
INDUSTRIES
Air scavenge valve

1 Description
The purpose of the air scavenge valve is to allow air to pass into the isolating valve
chest and expel any corrosive gases which may be present therein. This is achieved
by supplying moisture free air at 51 - 16 mm H2O above the exhaust/furnace
pressure. Figure 1 illustrates the air scavenge valve. The air supply pipe is 25mm o/d
and is sealed to the air scavenge valve by means of a compression fitting. The air
passes through the seat of the valve body, past the stainless steel ball then through
slots in the adaptor and into the isolating valve chest. Whenever the soot-blowing
pressure is achieved in the valve chest, the pressure causes the stainless steel ball to
seat tightly on the valve body seat and thereby prevents the air line from being
pressurised.
Illustration of the air scavenge valve
25 mm
O/D pipe
Figure 1 sb l.cdr

AALBORG LUBRICATION OM8540#13.0
INDUSTRIES
Lubrication
1 Description
The efficiency, availability and reliability of a soot-blower are maintained by
adopting the recommended lubrication schedule which is detailed in Table 1. The
identification of lubricating points can be found in Figure 1.
No. Item Recommended interval Lubricant

Chest liner Weekly*' Clydspin® or similar
Sleeve Weekly Clydspin® or similar
Gearbox Shell Tivela Compound A
*1) Please note that after replacing piston rings, lubricate daily for one week.
Table 1
Lubricating points
•—-—i
Figure 1 sb ll.cdr

AALBORG LUBRICATION OM8540#13.0
INDUSTRIES
1.1 Sleeve and liner lubrication

The sleeve and liner must be lubricated with Clydspin® or similar, which is
specially formulated for use on moving parts exposed to high temperatures. On new
equipment it is particularly important to apply grease regularly, to create a long-
lasting lubricating film on the surfaces. Grease is applied from grease guns fitted
with special adaptors. Below are some typical physical characteristics of the sleeve
and liner grease:
• Description graphite loaded, soap thickened lubricant
• General composition ....natural flake graphite, sodium soap, mineral base oil
• Consistency No. 2 grease
• Relative density IP59 0.89
• Drop point IP31 175°C
• Flash point IP34 180°C
• Un-worked penetration IP50 278/288
• Worked penetration IP50 290/300
• Acidity and alkalinity IP37 free acid 0.35%, free alkali 0.12%
• Solubility in water 20°C, 24 hours 0.1%
• Dynamic anti-rust IP220 1-2 grade
• Oxidised ash, 1 hour 800°C 1.9%
Note: It is recommended that the grease is not stored longer than three years.
1.2 Gearbox lubrication
The gearbox is factory filled with Shell Tivela Compound A, which is a specially
formulated non-tracking grease lubricant. The gearbox is pre-packed for life and it is
therefore not necessary to lubricate or change oil. However, in case of major
overhaul of the soot-blower an oil change is required. Below are some typical
physical characteristics of the gearbox oil:
• Penetration: 400-420
• Ash (sulphated): 0.5%
• Soap base: lithium
• Oil base: synthetic
• Oil viscosity: 128 cSt at 40°C
• Viscosity index >200
Note: It is not permitted to top up the gearbox with any other lubricant other
than specified.

INDUSTRIES
Table of contents
Drawings
General arrangement 05Y:029875g
2 boiler arrangement 05Y:029916d
Sketch of uptake 05K37:032015b

uisiance Detween small legs Is changed (ram 2925 to 2955. d 041216 LD PRu Date Appr.
Dimension added. e 050322 HeJ LD 04052S LD PTh
Dimension to pfting eye added. f 050412 HeJ LD Burner mirrored. b 041025 LD PTti
Design pressure changed from 2.2 MPa to 2.24 MPa. 9 051122 LD RT Smokg uptake and air Inlet on burner changed. c 041210 LD PRu
37.5
r—r View C-C
C17
Positive pressure
connection 1"BSPT-Mato
Air consumplfon=0.73
NM3MN
S1-76mmH"O Above
TufTtoco pressure*
1530 1875 1200
Alignment of foundation:
The tolerance between
the feet levels to be Weight of boiler unit, dry - 6 3 ton
+ 2 mm. Weight of boiler unit, operation ~ 74 ton
Weight of boiler unit, full with water ~ 80 ton
Centre of gravity based on operation condition.
Starboard boiler
Dalian New Shipyard Mission D-type RaS 020404

LRS LRS LRS LRS LRS LRS LD 020404
T3000-9 T3000-10 T3000-11 T3000-12 T3000-13 T3000-14 50000Kg/h 2.24 MPa Sato:
737697 737699 738154 738156 738158 738160 1:30

AALBORG General arrangement Artide/Dnwfogrto
14190 14193 14784 14787 14790 14793 IHOUSTtitS
14191 14194 14785 14788 14791 14794 05Y: 029875
Description Index
Internal drawing bed and new burner added.
Burner mirrored
Smoke uptake and air inlet on burner changed. 041210 PRu
Design pressure changed from 2.2 MPa to 2.24 MPa. 051122 RT
Forward ship
Port side boiler Starboard boiler
TsTl 1 r—= 'I n
Title: Date
Customer Dalian New Shipyard Mission D-type Appr.

LD
Date
040119
Society LRS LRS LRS LRS LRS LRS LRS PTH 040119
Newb. No. T3000-8 T3000-9 T3000-10 T3000-11 T3000-12 T3000-13 T3000-14 50000 Kg/h 2.24 Mpa Weight Scale: Size
Project No. 737695 737697 737699 738154 738156 738158 738160 iiiiiiiii 2 boiler arrangement Article/Drawing No:
1:25 A3
Port side boiler Boiler No. 14187 14190 14193 14784 14787 14790 14793 AALBORG THIS DRAWING AND DESIGN SHOWN HEREIN IS THE PROPERTY OF AALBORG INDUSTRIES
Starboard boiler Boiler No. 14188 14191 14194 14785 14788 14791 14794 INDUSTRIES AND MUST NOTBE USED BY OR REPRODUCED FOR THIRD PARTY 05Y:029916
Description Appf.
Drawing changed
Uptake changed from 2400 to 2070
700
1 1
28
All plates above 500mm

In width or length has to be
supported with angle Iron
50x50x5 or similar
500-1000mm
1410
Plate 6mm, RSt37.2 / Q235-A GB700

DN1300, DIN86044 Flange according to DIN86044
Starboard boiler
Customer Dalian New Shipyard Mission D-type LD 141209
Society LRS LRS LRS LRS LRS LRS LRS PTh 041209
Newb. No. T3000-8 T3000-9 T3000-10 T3000-11 T3000-12 T3000-13 T3000-14 50000 Kg/h 2.2 Mpa Seals:
Project No. 1:1

737695 737697 737699 738154 738156 738158 738160 AALBORG Sketch of uptake MidaJQmAngHo:
Boiler No. IHDUSTKIIS
Boiler No. 14188 14191 14194 14785 14788 14791 14794 05K37=032015
INDUSTRIES
Table of contents
Data sheets for boiler and steam/water system

Safety valve, DN 65/100, PN 40/16 . 261 1174
Stop valve, angle, DN 250, PN 25 , 6010 000085
Stop valve straight, DN 100, PN 40 ......6010 000092
Stop valve straight, non return DN 100, PN 40 6030 000032
Stop valve straight, DN 40, PN 40 , 6010 000037
Stop valve straight, DN 8, PN 160 6220 000002
Check valve, DN 250, PN 25 ..: .....6020 000023
Water level gauge left, 2 x 6 DN 25, PN 25 7010 000136
Water level gauge right, 2 x 6 DN 25, PN 25 ..7010 000135
Safety valve, DN 15, PN 40 261 1358
Stop valve, straight, DN 80, PN 25 250 1093
Soot blower with air scavenge valve for manual operation 8540 000009
Drain valve and strainer 6000 000012
Expansion joint for safety valve 85Y:013427
Remote'pull for safety valve K03:019136
Remote pull for water level gauge.... K03:019137
TD 32F Thermodynamic steam trap.. 7020 000001
Counter flange K16:004096
Ball valve (Item C227) balll 13fl
Actuator (Item 227) AT400da
EGO switchbox, type M (Item 227) BoxM
Solenoid valves (Item 227) solvalve230
Level float switch RBA 24, DN 25, PN 40 8100 000008
DP water level control unit .". 70Z:019540
Pressure transmitter 0- 25 bar ; 663 8233
Needle valve, straight, '/a" x '/2", PN 400 254 1002
Pressure gauge, 0 63 663 3122
Pressure gauge, 063 663 3118.
. ' ' Pressure switch 1 0 - 3 0 bar 6310303
Full bore ball valve DN 8, PN 64... 666 6006
Language tJK • . . Page 1/2

INDUSTRIES
Orifice DN 32/07,9 K18:035884

Remote start/stop box 8000 000036
Pneumatic control valve, DN 25, PN 25 with I/P positioner 6050 000239
Filter regulator with automatic drain 291 5101
LED indicator / limit switch 8000 000034
Temperature transmitter 8060 000026
Chemical dosing unit 9296 000002
Sample cooler 875 0005
Pneumatic control valve, DN 65, PN 40 with I/P positioner 6050 000220
Steam flow measuring equipment 88Y:036113
Steam flow measuring equipment 88Y:036114
Pressure transmitter, type 7MF4433 8020 000001
Pressure transmitter 0-25 bar 8010 000008
Pressure transmitter 0 - 4 0 bar :..663 8234
Water washing hose with nozzle 294 1001
Test cabinet for boiler water treatment 880 0001"
Ultrasonic sensor for oil detection equipment 8310 000005
Control unit for oil detection equipment 8210 000025
Conductive electrode, type SL 700E 8620 000082
Control device, type SL 700 8210 000032
T-piece for salinity alarm equipment 8500 000115

AALBORG DATA SHEET
INDUSTRIES
Type:
Y/////X
• Safety valve, full lift
• 25.912
Size:
• Nominal diameter: DN 65/100
Application:
• To blow off saturated steam, air or water
Material:
• Body: GGG 40.3
DIN-Material No.: 0.7043
• Seat: X6CrNi Mo Ti 17122
DIN-Material No.: 1.4571
• Disc:X35CrMo 17
DIN-Material No.: 1.4122.05
Technical data:
• Nominal pressure: PN 40/16
• Weight: 40 kg
• Flanges according to DIN
• Inlet: DN 65, PN40
• Outlet: DN 100, PN16
Type No.: 6040

Version: A Safety valve, DN 65/100, PN 40/16 261 1174

AALBORG DATASHEET
INDUSTRIES
Type: Material:
• Stop globe valve, angle • Body:GS-C25N
• 34.007 with stellited seat and cone DIN-Material No. 1.0619.1
• Seat: X5CrNiNb 19 9 with stellite
Size:
Din-Material No. 1.45 51
• Nominal diameter: DN 250 • Disc: P265 GH (Kbl. HE) - X 8 Cr Ti 18
Application: DIN Material No. 1.4025 - 1.4502
• For steam and/or water flow Technical data:
• Nominal pressure: PN25
• Weight: 170 kg
Disc
Seat
Body
Type No.: 6010

Version: B Stop valve, angle, DN 250, PN 25 6010 000085
V .
AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• Stop globe valve, straight • Body:GS-C25N
• Seat: X5CrNiNb 19 9 with stellited
Size: DIN-Material No. 1.4551
• Nominal diameter: DN 100 • Disc:X20Crl3
Application: DIN -Material No. 1.4021.05
• Nominal pressure: PN 40
• Weight: 39.5 kg
0 225
Body
Type No.: 6010

. Version: A Stop valve, straight, DN 100, PN 40 6010 000092

AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• Stop check globe valve, screw down non • Body:GS-C25N
return, straight DIN-Material No. 1.0619.01
• 3 5.006 R with stellited seat and cone • Seat: X5CrNiNb 19 9 with stellite
DIN-Material No. 1.4551
Size: • Disc:X20Crl3
• Nominal diameter: DN 100 DIN -Material No. 1.4021.05
Application: Technical data:
• For steam and/or water flow • Nominal pressure: PN 40
• Weight: 39.5 kg
0 225
Body
Type No.: 6030 Stop valve, straight, non return

Version: A DN 100, PN 40 6030 000032

AALBORG DATA SHEET
INDUSTRIES
Type: Material:
return DIN-Material No. 1.0619.01
• 3 5.006 R with stellited seat and cone • Seat: X5CrNiNbl9 9 with stellited
• Nominal diameter: DN 40 DIN-Material No. 1.4021.05
• Weight: 11.5 kg
0I6O
Body
Type No.: 6030 Stop valve, straight, non return 6030 000016
Version: A DN 40, PN 40

AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• Seat: X5CrNiNb 19 9 with stellited
Size: DIN-Material No. 1.4551
Application: DIN-Material No. 1.4021.05
• Weight: 11.5 kg
0 160
Body
Type No.: 6010

Version: A Stop valve, straight, DN 40, PN 40 6010 000037

DATA SHEET
Type: Material:
return DIN-Material No. 1.0619.01
• 35.006 R with stellited seat and cone • Seat: X5CrNiNbl9
DIN -Material No. 1.4551 with stellite
• Nominal diameter: DN 50 DIN-Material No. 1.4021.05
• Weight: 13.5 kg
0I6O
Body
Type No.: 6030 Stop valve, straight, non return

Version: A 6030 000035
DN 50, PN 40

AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• Seat: X5CrNiNbl9 9 with stellite
Size: DIN -Material No. 1.4551
• Weight: 13.5 kg
0 160
Body
Type No.: 6010


AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• Instrument stop cone valve, straight • Body: C 22.8
DIN- Material No. 1.0460
Size: • Seat:X20Crl3
• G I / 2 "x0l2 DIN- Material No. 1.4021
• Nominal diameter: DN 8 • Needletip:X35CrMol7
Application: DIN-Material No. 1.4122
• For steam, water and/or air Technical data:
• Inlet: GW male DIN
19207, form R
• Outlet: For steel tube 0 12
• Weight: 0.8 kg
0 80
Type No.: 6220

Version: D Stop valve, straight, DN 8, PN 160 6220 000002

AALBORG DATA SHEET
INDUSTRIES
Type:
• Opening pressure at horizontal flow (60°
• Wafer check valve, type WCV 6100 open): 19 mbar
Application: • Opening pressure at vertical flow
upwards: 22 mbar
• For steam and liquid media • Standard Kv value: 2200 m3/h
Design: • Operating temperature max.: 250°C
• The wafer check valve is designed to be • Operating temperature min.: -10°C
sandwiched between welding neck • Weight: 13.1 kg
flanges or slip-on flanges, with Installation:
horizontal flow or vertical flow • The check valve can be installed
upwards. The disc is eccentrically
sandwiched between welding neck
placed in relation to the body to obtain a
flanges or slip-on flanges
self-centring effect at installation
• Determine the correct installation
Size: situation and the direction of flow. It
• Nominal diameter: DN 250 must be installed either in a horizontal
flow or where the flow is vertically
Connection requirements: upwards
• Min. inline diameter of connection • The valve is self-centring. However, it
pipe/flange: 258.8 mm must always be ensured that it is
• Length of required min. inline diameter: completely centred in relation to the
200 mm connection pipe/flange. Use the body
rim (external) diameter for this purpose
Material: • The check valve can be installed directly
• Body: carbon steel on a valve, but a distance of 2-3 times
. Waferdisc:AISI316L the pipe diameter is preferable.
• Disc seating: metallic • In case of a steam system with vertical
installed check valve a steam trap should
Technical data: be installed for drainage of condensate
• Operating pressure max: 25 bar
• Max. cold hydraulic test pressure: 37.5
bar
Type No.: 6020

Version: B Check valve, DN 250, PN 25 6020 000023

AALBORG DATA SHEET
INDUSTRIES
Installation examples:
Welding neck flange Welding neck flange

installation installation with
recessed pipe
Slip-on flange Slip-on flange

installation installation with
recessed pipe
Type No.: 6020

Version: B Check valve, DN 250, PN 25 6020 000023

AALBORG DATA SHEET
INDUSTRIES
Type: Material:
• Stop globe valve, straight • Body: GGG 40.3
• 23.006 DIN-Material No. 0.7043
• Seat:X20Crl3
Size: DIN-Material No. 1.4021.05
Application: DIN -Material No. 1.4021.05
• Weight: 5.4 kg
0 140
Type No.: 6010


AALBORG DATA SHEET
INDUSTRIES
Type:
• Stop valve, gate straight
Size:
• Nominal diameter: DN 50
Application:
• Sea water, fresh water, oil, steam etc.
Material:
• Body: GG25
Technical data:
• Max. temperature: 150 °C
• Weight: 11.5 kg
120
Type No.: 6010


AALBORG DATA SHEET
INDUSTRIES
Material:
Type:
• Body: Carbon steel
• Reflective water level gauge, left
• Drain valve body: ASTMA105
• Model 26
Technical data:
Size:
• Weight: 22 kg
Application: • Connections between body and cocks are
• For boiler water level indicator made by end tubes and stuffing boxes
160
Drain connection a 10 x 2.5

mild steel
Type No: 7010 Water level gauge, left, model 26 7010 000136
Version: B DN 25, PN 25

AALBORG DATA SHEET
INDUSTRIES
Material:
Type:
• Body: Carbon steel
• Reflective water level gauge, right
• Drain valve body: ASTM A105
. Model 26
Technical data:
Size:
• Weight: 22 kg
Application: • Connections between body and cocks are
• For boiler water level indicator made by end tubes and stuffing boxes
160
Drain connection a 10 x 2.5

mild steel
Type No: 7010 Water level gauge, right, model 26,

Version: B DN25, PN25 7010 000135

AALBORG DATA SHEET
INDUSTRIES
Type:
• Safety valve, full lift
. 25.941
Size:
Application:
• To blow off steam and/or air.
Material:
. Body: GGG 40.3
• DIN-Material No.: 0.7043
Technical data:
• Weight: 3.5 kg
Body
Type No.: 6040

Version: A Safety valve, DN 15, PN 40 261 1358

• • • • •
• • • • •
AALBORG DATA SHEET

INDUSTRIES
Type: Material:
• Stop globe valve, straight • Body: GGG 40.3
• 23.006 DIN -Material No. 0.7043
• Seat:X20Crl3
Size: DIN-Material No. 1.4021.05
• Weight: 23 kg
0 200
Type No.: 6010

Version: B Stop valve, straight, DN 80, PN 25 250 1093

AALBORG DATA SHEET
INDUSTRIES
Type: Technical data

• Soot blower with air scavenge valve for • Nominal pressure: PN 40
manual operation • Flange nominal diameter inlet: DN 50
• MKSR/V/D according to DIN 2635
• Nominal diameter inlet: DN 50 • Rotation angle: 360° clockwise
• Element stroke: 137 mm
Application: • Medium: Steam / air
• For soot blowing with steam or air • Exhaust gas temperature: Max. 400°C
• Scavenge air connection: 25 mm O/D
• Weight: Approx. 100 kg
Air scavenge valve,

3/4" BSP
Hand-wheel
Inlet flange
Type No.: 8540 Soot blower with air scavenge valve for 8540 000009
Version: C manual operation

AALBORG DATA SHEET
INDUSTRIES
Material:
Type:
• Valve body: Forged carbon steel
• Mark 0 300
• Valve: Stainless steel
Size: • Seat: Stainless steel
• 3/4" BSP Technical data:
Application: • Steam pressures: Up to 21 bar
• The drain valve is designed to keep the • Temperature: Max. 3 50°C
soot blower pipeline free from • Weight: 8 kg
condensate. It employs a simple spring Installation:
loaded mechanism which can be pre-set
• The valve must be mounted vertical with
to suit the operating pressure of the
the inlet at the top
system and the valve is designed so that
it remains open when the blowers are
not in use. The valve closes during soot
blowing and automatically re-opens
when blowing is completed.
0 70
Seat
Strainer
Type No.: 6000

Version: B Drain valve and strainer 6000 000012

AALBORG DATA SHEET
INDUSTRIES
Method of operation:
• The valve may be opened manually with
the hand wheel provided while under
full boiler pressure, but it cannot be
closed by hand. This is an effective safe
guard against water accumulation in the
pipes.
• A fine mesh strainer is incorporated at
the valve inlet to prevent the valve from
becoming choked.
• Before using the blowers the master
steam supply valve is cracked. After a
pre-set time period the supply line to the
blowers will have warmed up and all
condensate removed from the pipes. As
the master supply valve is turned fully
open, the drain valve automatically
shuts, the blowers may be operated.
When the master supply valve is shut
the drain valve will open as the pressure
in the pipe line falls and any condensate
will be discharged.
Type No.: 6000

Version: B Drain valve and strainer 6000 000012

Drain connection changed to flange 020702 JNJ JA
Sealing ring added 041104 JA BZ
0219
Yard piping
oo
CO
co
o
<
Flange DN100-PN16
Flange DN25-PN16
Title: Drawn Date
Expansion joint with sealing ring Appr.

MRJ 20.09.2000
Date
STANDARD LD 30.11.2000
Weight Scale: Size
For safety valve DN65/100, PN16 outlet flange
52.5 kg 1:5 A4R
AALBORG General arrangement Article/Drawing No: Index
INDUSTRIES
Plot Date: AND MUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY 85Y:013427 b
^ ^ ^ Description Index D a ^ ^Drawn Appr.
Article no. for i t e ^ B ^ a n g e d a 97iH V JA TCG
Item 4 from 16 m. to 8 m. b 000518 JA BF
Detail of Item 1 removed c 030131 JA BZ
Item nos. changed d 040608 JA BZ
C186.2
Pulley Hot-dip galvanized 4337301

C186.5 050 mm vertical Steel
Wire stainless steel 4551052
C186.4 03 mm Specified in metre AISI 316
Wire clip Hot-dip galvanized 4576110
C186.3
3 mm Steel
Shackle Hot-dip galvanized 4573311
C186.2
3/16" Steel
Handle 6451004
C186.1
06x261
Designation Material code Article No.
Tag No.
Dimension Material type Detail drawing No.
Title: Drawn Date
AMF 961115
Appr. Date
STANDARD LD 961115
Weight Scale: Size
•1:1 A3
Remote pull for safety valve
INDUSTRIES THIS DRAWINQ AND OESIQN SHOWN HEREIN IS THE PROPERTY OF AALBORG INDUSTRIES
AND MUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY K03:019136
M | Description Index DaJÎ prawn Appr.
Item 5from40 n HWorn. a ooosw' JA BF
Item nos. changed b 040608 1 JA BZ
— • • • ' •
Approx.1500
-
Wire stainless steel 4551052

C187.5 03 mm Specified in metre 20 AISI 316
Wire clip Hot-dip galvanized 4576110
C187.4 3 mm Steel
Shackle Hot-dip galvanized 4573311
C187.3 3/16" Steel
Handle - "SHUT1 6451003
C187.2
Handle-"OPEN" 6451002
C187.1
Tag No. Material type Cert.
Dimension Detail drawing No.
Title: Date
JA 990113
Appr.
STANDARD BZ 990113
Weight Scale: Size
1:1 A3
Remote pull for water level gauge Affix
INDUSTRIES THB DRAWIN8 AND DESIGN SHOWN HEREIN IS THE PROPERTY OF AttBORG INDUSTRIES
AND MUST NOTSEUSED BY OR REPRODUCED FORTHIRD PARTY K03:019137 b
C
TD 32F Thermodynamic Steam Trap

Description
The TD 32F is a medium pressure flanged thermodynamic steam
trap with integral strainer screen suitable for mains drainage.
Sizes and pipe connections

DN15LC, 15, 20 and 25
Standard flange:- BS 4504 PN 40, BS 1560 Class 150 and 300
Limiting conditions
Maximum body design conditions PN 40
PMA — Max. allowable pressure 40 bar g
TMA — Max. allowable temperature 400°C
Cold hydraulic test 60 bar g
Operating range
10 20 30 32» 40
Pressure bar g
Note: Minimum operating pressure for satisfactory operation is 0.25 barg

PMOB — Max. operating back pressure is 80% of upstream pressure
Capacities
2 3 4 5 10 20 32
Differential Pressure bar (x 100 = kPa)
Materials
No Part Material
1 Body Stainless Steel
DIN 17445 G-X20 Cr14 Ws 1.4027
2 Cap Stainless Steel AISI416
3 Disc Stainless Steel BS 1449 420 S45
4 Strainer Screen Stainless Steel ASTMA240 316L
5 Strainer Cap Stainless Steel AISI416
B. Strainer Cap Gaske I Stainless Steel BS1449 304S16
7 Insulating Cover Aluminium
(optional extra. Not DN 25)
8 Flanges Steel DIN 17243 C22.8 Ws 1.0460
Aalborg Industries Data sheet No. 7020 000001 1/2

Withdrawal Withdrawal
distance distance for
Dimensions (approximate) in millimetres for cap insulating cover
Size - DN A B G L) E I- G H Weight
15 LC 150 55 41 40 80 57 38 55 2.3 kg
• 15 150 65 41 40 80 57 38 55 2.4 kg
20 150 60 47 40 95 57 38 61 3.1kg
25 160 65 53 40 100 — — — 4.2 kg
Installation
Preferably fitted in a horizontal pipe but can be fitted in other
positions.
Optional extras
Insulating cover:- to prevent the trap being unduly influenced by
excessive heat loss such as when subjected to low outside
temperatures, wind, rain etc. (Not available for DN 25)
Note: The internal blowdown valve is not available for the TD 32F
Spare parts
The spare parts available are shown in heavy outline. Parts drawn in
broken line are not supplied as spares.
AVAILABLE SPARE ITEM
Disc(Pktof3) 3
Strainer Screen and Gasket 4,6 Withdrawal
Strainer Cap Gasket (Pkt of 3) 6 distance
Insulating Cover (Not available for DN 25) 7 for Strainer
Maintenance
Before undertaking any maintenance on the trap it must be isolated
from both supply line and return line and any pressure allowed to
safely normalise to atmosphere. The trap should then be allowed to
cool.
How to service
Remove insulating cover if fitted and unscrew cap using spanner.
Do not use Stillsons or a wrench of similar type which may cause
distortion of the cap. If the disc and body seating faces are only
slightly worn they can be refaced by lapping individually on a flat
surface such as a surface plate. A figure of eight motion and a little
grinding compound such as the Carborundum Co's Compound I.F.
gives the best results.
If the wear is too great to be rectified by simple lapping, the seating
faces on the body must be ground flat and then lapped and the disc
replaced by a new one. The total amount of metal removed in this
way should not exceed 0.25 mm.
When re-assembling, the disc is normally placed in position with the
grooved side in contact with body seating face. Screw on cap, no
gasket is required but a suitable high temperature anti-seize grease
should be applied to the threads.
To clean or replace strainer
Unscrew strainer cap using spanner, withdraw screen and clean, or
if damaged replace with new one.
To re-assemble, insert screen into cap, then screw cap into place. A
fine smear of 'Molybdenum Disulphide' grease should be applied to
the first few threads. Care should be taken to ensure that the gasket
and gasket faces are clean. Tighten cap to the recommended torque.
Recommended Tightening Torques
Item DN or p Nm
mm | |
2 15LC 36 135-150
• 15 36 180-200
20 41 180-200
25 55 250-275
5 32 170-190

Description I Index I Date I Drawn | Appr.
Yard piping
Supplied loose
DN 0A 0D <*K 0B 0L C Bolt Number

15 21.3 95 65 22.0 14 14 4 / M12
20 26.9 105 75 27.5 14 16 4 / M12
25 33.7 115 85 34.5 14 16 4 / M12
32 42.4 140 100 43.5 18 18 4 / M16
40 48.3 150 110 49.5 18 18 4 / M16
50 60.3 165 125 61.5 18 20 4 / M16
65 76.1 185 145 77.5 18 22 8 / M16
80 88.9 200 160 90.5 18 24 8 / M16
100 114.3 235 190 116.0 22 26 8 / M20
125 139.7 270 220 141.5 26 28 8 / M24
150 168.3 300 250 170.5 26 30 8 / M24
200 219.1 360 310 221.5 26 32 12 / M24
250 273.0 • 425 370 276.5 30 35 12 / M24
300 323.9 485 430 327.5 30 38 16 / M28
Title: Drawn Date

MRJ 970910
Appr. Date
Counter Flanges MSO 981016
•• •• •• •• •• • Weight Scale: Size
DN15 - DN300 PN25
1:1 A4R
AALBORG BS4504 type B Article/Drawing No: Affix
INDUSTRIES THIS DRAWING AND DESIGN SHOWN HEREIN IS THE PROPERTY OF AALBORG INDUSTRIES
AND MUST NOT BE USED BT OR REPRODUCED FOR THIRD PARTY K16:004096
C ZZ?
BALL VALVE
Dimensions
DN25- 100
Full Reduced H 1 L M N O ISO
bore bore 5211
DN25 DN32 M12 x 1.25 7.5 20.0 10.0 42 M5 F04
DN32 DN40 M15x1.5 8.9 27.0 13.0 50 M6 F05
DN40 DN50 M15x1.5 8.9 28.0 14.0 50 M6 F05
DN50 DN65 M15x1,5 8.9 25.0 12.5 50 M6 F05
DN65 DN80 M22 x 1,5 16.0 3b.O r/,o 70 M8 F07
DN80 DN100 M24x1.5 18.0 37.5 15.0 70 M8 F07
DN 25 -100
Flanged connections - PN 16-40

Full bore
DN A B C D E F Weight
50 230 118 225 50 165 125 17.5

65 290 136 350 64 185 145 23.0
80 310 150 500 78 200 160 28.5
Reduced bore
DN A B C D E F Weight
65 290 118 225 50 185 145 14.0

80 310 136 350 64 200 160 20.0
100 350 150 500 78 235 190 24.5
Dimensions in mm. Weights in kg.
Flanged connections
Arrangement of bolts
4+4 bolts: ft Kv factor

DN 15-50 reduced bore (Kv = Water flow in m3/h at a pressure drop of
DN 8-40 full bore 1 bar and a temperature of 20°C)
DN Full Reduced
8 6.8
6+6 bolts: 10 6.8
DN 65-80 reduced bore
15 12.8 6.8
DN 50-65 full bore
20 29.1 12.8
25 50.0 29.1
32 72.6 50.0
40 106.8 72.6
8+8 bolts: 50 213.7 106.8
DN 100 reduced bore
65 275.0 213.7
»DN 80 full bore
_>80 500.0 275.0
Aalborg Industries Data sheet No. b a l l ! 13fl 1/2

ALL VALVE
Parts/Material specifications
Shown with encapsulated seat on the end piece
Standard versions
Item Quant. Part Body - Carbon steel Body - Stainless steel
1 1 Handle Galvanized and plastic- Galvanized and piastic-coated
coated carbon steel carbon steel (Stainless steel
A 316 to special order)
2" 1+1 Handle retaining nut (2A) Cadmium-plated Stainless steel A 316
Locknut(2B) carbon steel
3 1 Stem packing Graphite Graphite
4" 2 Spring washer Stainless steel A 302 Stainless steel A 302
5" 1 Antistatic stem Stainless steel A 316 Stainless steel A 316
« 1 Packing ring Stainless steel A 316 Stainless steel A 316
7* 1 Thrust washer PTFE PTFE
8' 1 O-ring Viton PTFE
9" 1 Ball Stainless steel A 316 Stainless steel A 316
10" 2 Seat seal PTFE + 20% carbon + PTFE + 20% carbon +
5% graphite 5% graphite
ir 2 Primary body seal PTFE + 20% carbon + PTFE + 20% carbon +
5% graphite 5% graphite
12 1 Body Carbon steel A 1 0 5 Stainless steel A 316
13 2 End piece Carbon steel A 1 0 5 Stainless steel A 316
14 1 Antistatic spring Stainless steel A 316 Stainless steel A 316
unit in stem
15* 4+4 or Body bolt (see "Arrange- Stainless steel A193 B7 Stainless steel A 1 9 3 B8
6+6 or ment of bolts")
8+8
16 4+4 or Bolts Carbon steel Carbon steel
6+6 or
8+8
17" 1 Lockwasher Stainless steel A 316 Stainless steel A 316
18" 2 Secondary body seal Graphite Graphite
19" 2 Seat seal PTFE or graphite PTFE or graphite
Recommended spare parts after 2 years of service

* Recommended spare parts after 5 years of service
Aalborg Industries Data sheet No. ball113fl 2/2

C ZZ7
Model AT401 DA and SR-9O0
Available Flange: F10

0ZStd. 56
F07-F1O
Flange Dimensions
ISO 5211 F07 F10
df8 55 70
Q1 70 102
W1 M8xl2 1/110x15
I 55 70
M5XS Square 22 22 27
PortT Port'4' Lmin. 24 24 29
hmin. 1,5 1.5
M 2,5 2
Position Indicator Z=65
tor Proximity
12 \ G1/4" ISO228 -1 Pressure connection B2
Ancillary Attachment AA2
345
Spigot optional
TYPE Output Torque for Double Acting a n d Spring Return in N m Spring
2,5 bar 3 bar 3,5 bar 4 bar 4,2 bar 4,5 bar 5 bar 5,5 bar 6 bar 7 bar 8 bar stroke Weight
0' 90° 0" 90° 0° 90° 0° 90° 0° 90° 0° 90" 0° 90° 0° 90° 0° 90° 0° 90° 0° 90° 90° 0° (Kg)
138 166 194 222 233 249 277 305 332 388 443 10,2
End Start
S05 86 56 114 84 141 111 169 139 180 150 197 167 224 195 82 53 11
S06 75 40 103 67 131 95 159 123 170 134 186 150 214 178 242 206 99 63 11,1
S07 93 51 120 79 148 106 159 117 176 134 203 162 231 189 259 217 115 74 11,3
S08 110 62 138 90 149 101 165 117 193 145 221 173 248 201 304 256 132 84 11,4
S09 127 73 138 84 155 101 182 129 210 156 238 184 293 239 349 295 148 95 11,6
S10 144 84 172 112 200 140 227 168 283 223 338 278 165 105 11.8
S11 161 96 189 123 217 151 272 206 328 262 181 116 11,9
•S12 179 107 206 135 262 190 317 245 198 126 12,1
Max. Rotation Screw stroke Chamber Air Volume (L) Moving Time (Sec.) (A) Operating Temperature (°C) (B)
Pressure Adjustment 0(mm) Opening Closing Opening Closing STD (standard) HT (high temp.) LT (low temp.)
90° ±4° For1° D 0,90 1.1 NBR "O"-Ring FPM "O'-Ring Silicon "O'-Ring
8 bar at 0° and 90' need 1/4 Turn 125 1,54 2,34 S 1,20 1,40 -20 to+80 -15 to+150 - 40 to +80
Notes: (A) The above indicated moving time of the actuator, are obtained in the following test conditions^"]) Room Temperature, (2) Actuator Stroke 90",
(3) Solenoid Valve with Orifice Of 4 mm and a flow capacity Qn 400 L/minC4) Inside pipe diameter 8 mm, (S) Medium clean air. (6) Air supply pressure
5.5 bar (79,75 Psi)(7) Actuator .without external resistance load.
Cautions: obviously on the field applications when one or more of the above parameter are different, the moving time will be different.
(B) For HT (high temperature) and LT (low temperature) services, a special Lubricant is requested. Please contact Air Torque factory.
Aalborg Industries Data sheet No. AT400da 1/1

EGO SWITCHBOX
TYPEM
Description:
EGO switchbox with integrated mikroswitches to be used

for remote as well as visual indication of valve position
The switchbox include bracket for mounting on a
pneumatic actuator. With use of a special bracket the box
can be mounted on a gearbox or directly on a valve.
Specifications
Box Poiycarbonat
Shaft POM
Cam plate Nylon
Ground plate Pertimax
Cam Brass
Protection IP 65
Position indicator POM
O-ring Viton
Aalborg Industries Data sheet name: BoxM 1/2

EGO SWITCHBOX
TYPE M
Technical data
EGO BOX M
No. of switches 1+1
Type of switch Mikroswitch
Manufacture Honeywell
Manufacture item No. V5C010TB1C
Voltage max. 250 VAC
Consumption -
Max. load 10 (3) A
Max. frequency -
Ambient temperature H- 55°C til +85°C
Dimensions 82x80x67
CONNECTION DIAGRAM
Mieroswitch Inductiv Nainur
EGO Box DWG NO: 04.98.06-EGO BOX
Aalborg Industries Data sheet name: BoxM 2/2

C ZZ?
SOLENOID VALVES
pilot operated, spool type
single/dual solenoid
aluminium body
FEATURES
. Solenoid valves comply with all applicable EC Directives
. The solenoid operated spool valves have threaded port connections and NAMUR
interface
. The same spool valve can be adapted for 3/2 NC or 5/2 functions for controlling
double-acting and single-acting actuators
. All the exhaust ports of this spool valve are pipable, providing better environmental
protection, particularly recommended for sensitive areas such as clean rooms, and
applications in the pharmaceutical and food processing sectors
. It is necessary to connect pipes orfittings to the exhaust ports toprotectthe internal
parts of the spool valve and its pneumatic operator if used outside or in harsh
environments (dust, liquids etc.)
, The return-spring chambers of the single-acting operators "breath" through the
spool valve, isolating them from the outside atmosphere
. Manual operator as standard
GENERAL
Differential pressure 2-10bar[1bar=100kPa]
Flow (Qv at 6 bar) 700 l/min (ANR)
fluids (*) temperature range (TS) sealings (*)
air, inert gas, filtered NBR (nitrile)
-25°C to +60°C
PUR (polyurethane)
MATERIALS IN CONTACT WITH FLUID

(*,) Ensure that the compatibility of the fluids in contact with the materials is verified
Body Aluminium, black anodized
End covers + interface plates Glass-filled polyamide (PA/FG)
Internal parts Zamak, stainless steel, acetal (POM), aluminium
Sealing NBR + PUR
Core and core tube Stainless steel
Shading coil Copper
ELECTRICAL CHARACTERISTICS
Coil insulation class F
Coil Epoxy resin
Spade plug connection coil 3 x DIN 46244
Connector Type 22, spade plug (Pg 9P)
Electrical safety VDE 0580
Standard voltages DC (=):24V
AC (~): 230V 7 60 Hz
power ratings ambient
coil inrush holding hot/cold temperature protection
type range (1) (TS)
(VA) (VA) (W) (W) (°C)
CM22-2.5W 6 3,5 2,5 2,5/3 -25 to +60 moulded IP65
SPECIFICATIONS
operating pressure
flow
operator
pipe orifice differential (bar)

exhaust
reducer
manual
coefficient coil
size size maximum (PS) type (C) catalogue number
Kv
min. air (*)
(G) (mm) (m3/h) | (l/min) ~/ =
Single solenoid pilot operated - spring return (monostable), with or without exhaust reducers
^QM2pi5W; : 1 • . ^ / ^ S C - G S M M O O I M S - G F ' ; .. >.
1/4 6 0,6 10 2 10
GM22'*2;5.W 1 • •> ., \ v ^caif!ApfigMs;if f: . : '„••
Dual solenoid pilot operated and air return (bistable), with or without exhaust reducers
• 6M22#5Vfr 2 • SG G5MA002JMS .. ' :
1/4 6 0,6 10 2 10
CM22-2.5W 2 • * '; •;. , Sfi/G|^jWJD2,MS;i-. ;,
(C) Construction type • : screw-type manual operator "0" : exhaust reducer
Aalborg Industries Data sheet name: solval230 1/2

SOLENOID OPERATED SPOOLVALVES • ALUMINIUM BODY
OPTIONS AND ACCESSORIES
Explosionproof enclosures according to "CENELEC" EEx d, m, em, i
Explosionproof and watertight enclosures according to "NEMA" standards
Coil comply with "UL" standard
Coil type CM25 with connector type 30 ISO 4400 (Pg 11P)
Polyamide coil
Versions : pneumatic operated, spring return: without exhaust reducer
Set of stainless steel mounting screws

Set of two exhaust reducers
1/8 exhaust fittings
Plug with visual indication and with peak voltage suppression or with cable length of 2m
INSTALLATION
The solenoid spool valves can be mounted in any position
Spool valve supplied with two interface plates with mating surfaces. Depending on function (NC 3/2 or 5/2),
position one of the two plates on the spool valve body before installing on actuator
Dowel pin (if necessary), bolts and gaskets are standard supplied
Connect or protect the exhaust ports to isolate the internal atmosphere of the internal parts of the spool valve.
Range of 1/8 fitting available
Pipe connections have standard thread according to ISO 228/1
The third digit in the catalogue number indicates the standard pipe connection
Other pipe threads are available on request
Installation/maintenance instructions are included with each solenoid spool valve
Replacement coils are available
DIMENSIONS (mm), WEIGHT (kg)
Port 1 : G1/4
Ports 3 and 5: G1/8
6)
ptz)
33.
kj 1
^
19J
| '—Ijl ET- 1 "-
139 (C)1 (C)1: monostable

192 (C)2 (C)2: bistable
(T) Interface plate Bistable version
© Mounting: 2 M5 x 35 screws
engaged lenght: 7 mm
weig ht(1)
® Connector rotatable 2 x 180°, CM8 (Pg 9P) catalogue number (C) 5/2
3/2
(4) 2 O-ring seals (supplied) SCG551A001 MS 1 0,339 0,339
(5) One 5 mm dia. hole for dowel pin SCG551A001 MSM 1 0,349 0,359
- in position A1: 3/2 function plate SCG551A002MS 2 0,457 0,457
- in position A2: 5/2 function plate
SC G551A002 MS M 2 0,467 0,477
© Manual operator screw-type
(C) Construction type (1) Incl. coil(s) and connector(s)
(7) Pilot exhaust connection port: 0 M5, equipped with drain protector
@ Exhaust reducers or protectors G1/8 adaptable on orifices 3 and 5 (on request)
* +15 mm for connector removal
Aalborg Industries Data sheet name: solva!230 2/2

AALBORG DATA SHEET
INDUSTRIES
Type:
• Level float switch
• RBA 24
Size:
• DN25 in
Application:
• Low water level switch rrm urn rrm mn
Material:
TWK
• St. 35.9
• C22.8
Technical data:
• Drain connection: 0 12 mm
• Cable connection: PG 11
• Max. working pressure: 32 bar
• Max. working temperature: 239°C
• Flanges according to DIN 263 5-C
• Magnetic switch: 2 x M130
• Switching voltage: 6-250V
• Switch current max: 1A ac; 0.5A dc
• Protection of switch housing: IP 54
Type No.: 8100

Version: C Level float switch RBA 24, DN 25, PN 40 8100 000008

Description Index DajB ^ Drawn Appr.
Item 3 c h a n g e d ^ ^ F a O2o!H* JA BZ
+ and - side reversed b 030326 JA BZ
Allen screw 3000000009

M10x55 A2
Washer 3090000004
M10 A 2-70
Gasket 3520000013
018.64x3.53 Rubber/viton
Diff. pressure transmitter 8020000001
2.5-250 mBar
Tube for upper level tube DIN 1629 4000000390
012 L=1446 St.37.4
Lower level tube DIN 17175
3.1C 70Z:012095
DN25 St.35.8 I
Upper level tube DIN 17175 70K02:012084
3.1C
DN25 St.35.8 I
Item Cert.
Title:
DP water level control unit Appr.
JA
Date
020117
Socket distance: BZ 020117

Note! - side to be connected to lower level tube
Weight Size
+ side to be connected to upper level tube 525-1300
1:5 A3
Assembly drawing
i f - Drain connection: 012 tube AALBORG Article/Drawing No:
INDUSTRIES THIS 0RAWN3 AND DESIGN SHOWN HEREIN IS THE PROPERTY OF AALBORG INDUSTRIES
AND MUST NOTBE USED BY OR REPRODUCED FOR THIRD PARTY 70Z:019540
AALBORG DATA SHEET
INDUSTRIES
Type:
• Pressure transmitter
• MBS 5100
Size:
• 0-25 bar
Application:
• The pressure transmitter converts pressure to an electric signal. This is proportional to, and linear
with, the value of the pressure to which the pressure-sensitive element is subjected by the
medium. The units are supplied as two wire transmitters with an output signal of 4-20 mA. The
transmitters have a zero-point displacement facility for equalizing static pressure.
Span adjustment is also possible.
Material:
• Housing material: Anodized AlMgSiPb
IS
D
m
m
o>
7 J I 1,
FTP • i
n
|
/
25.5
p g ' 11 in
0 5.8'
co III .
I
o
CM
>
l_ J I t
G 1/2" -m
15
4 30 , 30
73
84
Type No.: 8010

Version: A
0 - 2 5 bar

AALBORG DATA SHEET
INDUSTRIES
Technical data:
Performance:
• Accuracy (incl. non-linearity, hysteresis and repeatability): ±0.1% fs (typ.) / ±0.3% FS (max.)
• Non-linearity (best fit straight line): < ±0.2% FS
• Hysteresis and repeatability: < ±0.1% FS
• Thermal zero point shift: < ±0.1 % FS/1 OK (typ.) / < ±0.2% FS/1 OK (max.)
• Thermal sensitivity (span) shift: £ ±0.01% FS/K (typ.) / < ±0.02% FS/K (max.)
• Response time: < 4 rms
Electrical specification:
• Rated output signal: 4 to 20 mA
• Supply voltage, Vsuppiy (polarity protected): 10 to 32 Vd.c.
• Voltage dependency: < 0.01% FS/V
• Current limitation (linear output signal up to 1.5 x nom range): 28 mA (typ.)
• Max. load RL: RL < [(Vsuppiy -10V)/0.02A] - 10 D
Mechanical:
Connection: G 1/2" -m (EN 837-1-G XA A)
Max. operating pressure: 50 bar
Min. burst pressure: 100 bar
Operating temperature range: - 40 to 85°C
Compensated temperature range: 0 to 80°C
Transport temperature range: - 50 to 85°C
Cable entry: PG 11
Enclosure: IP 65
Weight: 0.4 kg
Type No.: 8010

Version: A Pressure transmitter 6638233
0 - 2 5 bar

AALBORG DATA SHEET
INDUSTRIES
Installation:
• There are facilities for adjusting zero point and span.
Zero point adjustments is necessary to equalise pressure arising from any differences in level
between the pressure transmitter and the medium being measured.
Zero point adjustment results in a parallel displacement of span.
Both zero point and span must be adjusted on the side of the unit with cover removed
-5 to > + 10% FS
4 - 2 0 mA
1. Supply*
2. Supply _
3. Function test
•4 Connected to MBS transmitter enclosure
Type No.: 8010

Version: A
0 - 2 5 bar

AALBORG DATA SHEET
INDUSTRIES
Type:
• Pressure gauge valve needle straight.
Size:
• 1/2" x 1/2"
Application:
• For instrument connections
Material:
• Body:C22.8
• DIN-material No. 1.0460
Technical data:
• Test connection: M20 x 1.5 mm threaded male
• Weight: 0.4 kg
Type No.: 6210

Version: F Needle valve, straight, 1/2" x 1/2", PN 400 2541002

AALBORG DATA SHEET
INDUSTRIES
Type:
• Pressure gauge, type P1116
Size:
• 0 63
Application:
• For all gaseous and liquid media
Material:
• Case: Stainless steel
• Socket: Cu-alloy
• Liquid filling: Glycerine
Technical data:
• Connection: G l/4"-m (1/4 BSP)
• Measuring unit: bar — Mpa - kg/cm2
• Measuring range: 0 - 40 / 4.0 / 40
• Pressure utilisation:
Static pressure: 75% of Pmax.
Dynamic pressure: 66% of Pmax.
• Operating temperature: -20 to +80°C
• Accuracy: EN 837 Class 1,6
32
6.5 r _
0
\
00
co
0 \
X
1 1
G1/4"A
Type No.: 8050

Version: B Pressure gauge, 0 63 663 3122

AALBORG DATA SHEE1
INDUSTRIES
Type:
• Pressure gauge, type P1116
Size:
• 0 63
Application:
• For all gaseous and liquid media
Material:
• Case: Stainless steel
• Socket: Cu-alloy
• Liquid filling: Glycerine
Technical data:
• Connection: G l/4"-m
• Measuring unit: bar - Mpa - kg/cm2
• Measuring range: -1 to +5 / - 0.1 to +0.5 / -1 to +5
• Pressure utilisation:
Static pressure: 75% of Pmax.
Dynamic pressure: 66% of Pmax.
• Operating temperature: -20 to +80°C
• Accuracy: EN 837 Class 1,6
32
6.5r _
0
\
CO
CD
Q
0 \
X
. G1/4"A
1 t
•m •
Type No.: 8050

Version: B Pressure gauge, 0 63 663 3118

AALBORG DATA SHEET
INDUSTRIES
Type:
Material:
• Bellows: Stainless steel 18/8
• Pressure switch
• Spring: Stainless steel 17/7
• RT117
• Housing: Brass
Size: • Bellows ring: Brass
• 10-30bar
Application:
• The pressure switch is a single-pole
changeover switch where the contact
position depends on the pressure in the
connection port and the set value.
83
. 28,
Type No.: 8030 Pressure switch

Version: A 631 0303
10-30 bar

AALBORG DATA SHEET
INDUSTRIES
Technical data:
Electrical switch contact load:
• Alternating current:
AC-l(ohmic): 10 A, 400 V
AC-3 (motor): 4 A, 400 V
AC-14/15 (coil transformer): 3A, 400V
Blocked rotor, 28 A, 400V
• Direct current:
DC- 13/14: 12 W, 230 V
Mechanical-
Connection: G 3/8", -m
Ambient temperature: - 50°C to + 70°C
Medium temperature: max. 150°C
Operating pressure: Max. 22 bar
Test pressure: Max. 47 bar
Adjustable/fixed mechanical differential:
1 to 4 bar
• Enclosure: IP 66
The pressure control housing is made of
bakelite to DIN 53470 while the cover is
powder painted deep-drawn steel plate.
To ensure the IP 66 degree of enclosure
is obtained, the front cover and screwed
cable entries must be correctly
tightened.
• Cable entry: Two Pg 13.5 for cable from
6 to 14 mm
Installation:
• The range is set by using the knob (5)
while at the same time reading the scale
(9). The differential is set by rotating the
differential disc (19).
Type No.: 8030 Pressure switch

Version: A 631 0303
10-30 bar

AALBORG DATA SHEET
INDUSTRIES
Type
• Full Bore ball valve
• EURO-SFER 1720
Size:
• Nominal diameter: DN8
Application:
• Assembly in rigid pipe system
• Direction of low in both directions
Material:
• Body: CW617N UNI EN 12165
• Lever: aluminium handle UNI 5076
painted black with epoxy powder
Technical data:
• Thread ends: female - female UNI ISO
7/1
Type No.: 6000 Full bore ball valve 666 6006

Version: A DN 8, PN 64

R<R0.1
0.5x45c
\To be stamped: DN 32/07,9
082
Plate
082x3 AISi 316
Item Pcs. Cert.
Title: Drawn Date
LD 050216
Appr. Date
• • • • •
Orifice DN 32/07,9 PRu 050216
Weight Scale: Size
1:1 A4R
AALBORG Article/Drawing No: Index
INDUSTRIES
Plot Date: AND MUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY K18:035884
AALBORG DATA SHEET
INDUSTRIES
Type: Technical data:

• Nominal operating condition:
• Remote start/stop box
U = 600VandI=1.2Aor
Application: U = 240VandI = 3Aor
• For start/operation and stop of pumps U=120VandI = 6A
• Protection: IP 65
Material • Temperature: -25°C to +70°C
• House: Polycarbonate
• Colour: Grey
120
85
Start/operation
incl. lamp function
Stop
Cable glands M 32 (PG 29)
105
e-
. Type No.: 8000

Version: D Remote start/stop box 8000 000036

AALBORG DATA SHEET
INDUSTRIES
• Cable inlet: M20x 1.5

Type: • Input signal: 4-20 mA
• Control globe valve, straight with • Ambient temperature: -30°C to +80°C
pneumatic actuator and I/P positioner • Protection: IP 65
• 23.470, DP 32
Technical data unit:
Size: • Design closing pressure: 25 bar
• Nominal diameter: DN 25 • Weight: 23.5 kg
Application: Installation:
• For cooling, water, steam, brine and/or • Only as shown in the picture
gas flow
Material valve:
• Body: GGG 40.3
• Seat:X20Crl3
DIN-Material No. 1.4021.05
• Plug:X20Crl3
DIN -Material No. 1.4021.05
• Stuffing box: PTFE V-ring unit (-10°C to
+ 220°C)
Technical data, valve:
• Positioning ratio: 50:1
• Flow characteristic: Equal percentage
• Standard kv value: 4 m3/h
• Stroke: 20 mm
• Plug type: Parabolic shaft guided
Stuffing box
Technical data, actuator:

• Spring range: 0.4 - 1.2 bar
• Design closing pressure.: 25.8 bar
• Diaphragm area: 250 cm2
• Filling volume: 1.2 1
• Max air pressure: 6 bar
• Action: Normally closed valve on air
failure
Technical data, I/P positioner:
• Air connection: G /4"
• Inlet air supply: 1.4 to 7 bar, instrument
air
• Air inlet consumption in stable state:
< 3.6 x lO"2 NmVh
Pneumatic control valve DN 25, PN 25,

Type No.: 6050
Version: A
with DP actuator 6050 000239
and I/P positioner

AALBORC DATA SHEET
INDUSTRIES
Type:
30
• Filter regulator with automatic drain
Haidle r
Size: Body l
CD
• Connections ports 1/4" BSP
• Gauge ports 1/8" BSP
9 8
Application: ipn Fitting
• Instrument air for regulating pressure L£
Technical data: Q
0)
• Medium: instrument air only
• Max. inlet pressure: 17 bar s? s
• Operating temp.: -20 °C to + 65 °C
S
• Filter element: 5 jum
• Recommend pressure regulating range:
0.14-7.0 bar Bin
• Pressure gauge: 0 - 1 0 bar
• Weight: 0.4 kg Connections ports
Material:
• Body: Steel SWi9"f
• Bin: Steel 1
• Handle: Acetal 41
Flow characteristics
Ink; tprejssur e7 >ar
X
•
— .
tS
— - —
- - —
33
O 2 —==; •
\
V
1
— .
— _
— - — - .
1 • — .
• — • — .
—
—
— - —
~ — — - — • —
— —
- —
1 2 3 4 5 6 7 8 9 10
îr flow [dm7s]
Type No.: 8000

Version: A Filter regulator with automatic drain 291 5101

AALBORG DATA SHEET
INDUSTRIES
• EMC immunity influence: < ± 0.5% of

Type
span
• LED indicator / limit switch • Max. wire size: 1 x 2.5 mm2
• 5514 A2 • Screw terminal torque: 0.5 Nm
• Relative air humidity: < 95% RH (non
condensing)
• Tightness (mounted in a panel): IP65
Voltage input:
• Measurement range: 0 .... 250 VDc
• Min. measurement range (span):
V A
50 mVDc
• Max. offset: 50% of selection max. value
• Input resistance:
96
< 2.5 VDC: nominal 10 Mfl
> 2.5 VDC: nominal 5 Mfi
Application: Current input:
• The 5514 with 2 relay outputs is • Measurement range: 0 .... 100 mA
designed for digital readout of current / • Min. measurement range (span): 4 mA
voltage or temperature signals. • Max. offset: 50% of selection max. value
• Input resistance:
Relay outputs: Powered unit: 10 Q + PTC (10 Q)
• Are selected as either a make or a break Non-powered unit: Rshunt= °°,
function. The relays can be used as a trip V d r o p <6V
amplifier.
• Two yellow front LEDs indicate the Display:
relay status. The relays can be set up • Display readout: + 9999 (4 digits)
with either delayed on or off. Active • Min. display readout (span): 0 counts
relay can be selected for either an • Decimal point: programmable
increasing or decreasing signal. The • Digit height: 14.2 mm
arrow keys can be used for fast change • Display updating: 2.5 times/s
of the set point. • Input outside input range is indicated by:
Nominal min. - 7% of span: In.LO
Technical data: Nominal max. + 3.5% of span: In.HI
• Panel cut out: 44.5 x 91.5 mm • Sensor error is indicated in display by:
• Weight: 330 g SEnS
• Readout > 9999 is indicated by:
Electrical specifications:
Flashing 9999
Common specifications: Relay outputs:
• Supply voltage: Max. voltage: 250 VRMS
Max. voltage: 24 VDC ± 20% Max. current: 2 A / AC
Internal consumption: < 3.5 W Max. AC power: 500 VA
Max. consumption: 4 W Max. current at 24 VDC: 1A
• Auxiliary voltages: Sensor error action: Make / break
2-wire supply: > 20 VDc / 20 mA
Type No.: 8000

Version: A LED indicator / limit switch 8000 000034

AALBORG DATASHEET
INDUSTRIES
Block Diagram:
Communication
2-wire Inputgnd.
transm. v> mA V < =
2.5 2.5
5514A2
Type No.: 8000

Version: A LED indicator/ limit switch 8000 000034

• • • ••
AALBORG DATA SHEET

INDUSTRIES
Type:
• Temperature transmitter
• PT100
Cable gland
Size: PG16
• 0 15x300
Range:
• 0-500°C
Application:
• For measuring temperatures in gases, 2. Cooling neck
vapours, and fluids
Material:
• Stainless steel:
Technical data:
• Housing: Form B, DIN 43729
• Connection at instrument: G 1/2" BSP
• Protection: IP65
• Cable gland: PG 16
• Response time (mean values) at
velocities in water at 0.4 m/s:
T0.5 = 29 sec.
• Response time (mean values) at
velocities in air at 3.0 m/s:
T0.5 = 120 sec.
• Recommended measuring current:
max. 2 mA 3. Sensor tube with
• Number of conductors: 4 PT 100 element
• Number of elements: 1 x PT 100
• Tolerance class, DIN C1JB: ± 0.3°C
• Resistance in Q at 0°C: 100
Electrical connection:
16 4 3
Type No.: 8060

Version: A Temperature transmitter 8060 000026

AALBORG DATA SHEET
INDUSTRIES
Technical data:
Type:
• Max pressure: 123 bar
• Dosing pump P.E. 100 with chemical
• Capacity: 2.5 1/h
tank
• Max pressure suction side: 35 bar
Application: • Max operating temperature: 50°C
• For chemical dosing • Enclosure rating: IP 44
• Insulation class: F
Material: • Chemical tank volume: 100 1
• Pump • Colour: RAL 1028
• Liquid end: PVC • Weight: 28 kg
• Check valve cartridge: PVC
• Seats: PVC
• Balls: Glass
• Contour plate: PVC
• Seals: Viton
• Chemical tank: Polyethylene
• Dosing head: Stainless steel
Chemical dosing unit item 9296 000002
Feed water line to boiler

Fittings, item 246 2707
Max 4.0 m from dosing pump
to feed water line
Manual stirrer -Tank ventilation
Fittings, item 246 2707-
Dosing valve, item 257 3307- Riling connection DN 15, PN 16, DIN 2633
Fittings, item 246 2707
Dosing line a12 x 1.5 mm
stainless steel
or steel pipe
Yard supply
Chemical tank
Dosing pump
Rttings, item 246 2707
Pressure valve
Suction valve
Filter
Foundation
680
Type No.: 9296

Version: A Chemical dosing unit 9296 000002

AALBORG DATA SHEET
INDUSTRIES
Dosing valve item 257 3307

Fitting item 246 2707
12 ... 12.5
c
..._.j
Performance curves
CO
O
20--
10 l/h
10-
8 l/h
10 20 40 80 Pressure (bar)
Type No.: 9296

Version: A Chemical dosing unit 9296 000002

AALBORG DATA SHEET
INDUSTRIES
Material:
Type:
• Sample cooler: austenitic stainless steel
• Sample cooler
grade316L
Size: • Cooling water inlet valve: stainless steel
• SCS20 • Sample inlet valve: stainless steel.
• Compression fitting: carbon steel
Application:
Technical data:
• The sample cooler is designed for taking
manual samples of boiler water for • Coil design pressure: 32 bar g
analysis. The cooling water is turned on • Coil design temperature: 300°C
and the sample inlet valve is adjusted • Body design pressure: 10 bar g
until a sample of boiler water is obtained • Body design temperature: 100°C
at a suitable temperature. For manual
sampling it is not normally necessary to
measure sample or cooling water flow
rates.
Sample in a 6 mm O/D
Customer supply
2. Sample inlet valve

1/4" BSP (each ends)
3. Compression fittings
for sample in 1/4" BSP
Cooling water out 1/2" BSP

Customer supply
. 1. Sample cooler
4. Cooling water Sample out

inlet valve 1/2" BSP
Cooling water in1/2" BSP
Customer supply
Type No.: 7050

Version: A Sample cooler 875 0005

AALBORG DATA SHEET
INDUSTRIES
• Allow the sample to run for a while

Installation: before collection. This will ensure that a
• Fit the SCS 20 so that the bottom of the true sample is collected for analysis.
unit is accessible for the collection of • When enough liquid has been collected
the cooled sample. close the sample inlet valve first and
• Connect the cooling water inlet in V2" then the cooling water inlet valve.
nominal bore pipe via an inlet valve. • After closing the sample inlet valve the
• The cooling water outlet should be piped sample out connection may drip for a
to an open drain or tundish. few minutes while the coil drains.
• The sample inlet pipe should be in 6 mm
O/D tubes. Performance:
• The sample inlet to the cooler can be • When it is required to predict the
taken direct from a boiler or steam line performance of the sample cooler
isolating valve. system, the table below gives the sample
outlet temperature to be expected for
Operation:
two boiler pressures an for two cooling
• Sample pipe work will become very hot water flow rates.
under normal working conditions, and
will cause burns if touched. Example
• Open the cooling water inlet valve first • A sample flow rate of 30 1/h is required
and ensure that a flow can be seen at the from a boiler operating at 10 barg. For a
cooling water outlet. cooling water flow rate of 0.4 1/s, from
• It is essential that cooling water is the table the sample outlet temperature
flowing before opening the sample inlet would be 4K (4°C) above the cooling
valve. water inlet temperature. If the cooling
• Gradually open the samples inlet valve water is 15°C, the sample temperatures
and regulate the flow to achieve a would be 19°C.
cooled sample at about 25°C.
Cooling water flow rate Cooling water flow rate

0.251/s (900 l/h) 0.41/s (1440 l/h)
Sample 1low rate Boiler pressure
10 barg 20 barg 10 barg 20 barg
l/h 1/min Sample outlet temperature above cooling water inlet temperature K (°C)
10 0.17 3 3 1 1
20 0.33 5 5 2 '3
30 0.50 7 9 4 5
40 0.67 8 10 5 7
50 0.83 10 12 6 8
60 1.00 11 13 7 10
80 1.33 12 16 8 12
100 1.67 15 19 9 14
120 2.00 17 22 10 16
Type No.: 7050

Version: A Sample cooler 875 0005

AALBORG DATA SHEET
INDUSTRIES
• Input signal: 4-20 mA

Type: • Ambient temperature: -30°C to +80°C
• Control globe valve, straight with • Protection: IP 65
pneumatic actuator and I/P positioner
• 35.470, DP 34 Technical data unit:
• Design closing pressure: 30 bar
Size:
• Weight: 70 kg
Installation:
Application:
• Only as shown in the picture
• For cooling, water, steam, brine and/or
gas flow
Material valve:
• Body:CS-C25N
DIN-Material No. 1.0619+ N
• Seat:X20Crl3
DIN -Material No. 1.4021.05
• Plug:X20Crl3
DIN-Material No. 1.4021.05
• Stuffing box: PTFE V-ring unit (-10°C to
+ 220°C)
Technical data, valve:
• Positioning ratio: 50:1
• Flow characteristic: Equal percentage
• Standard kv value: 63 mVh
• Stroke: 30 mm
• Plug type: Parabolic shaft guided
Technical data, actuator: Stuffing box
• Spring range: 2.1-3.0 bar
• Diaphragm area: 800 cm2
• Filling volume: 3.7 1
• Max air pressure: 5 bar
• Action: Normally closed valve on air
failure
Technical data, I/P positioner:
• Air connection: G %"
• Inlet air supply: 1.4 to 7 bar, instrument
air
• Air inlet consumption in stable state:
<3.6xlO- 2 Nm 3 /h
• Cable inlet: M20x 1.5
Pneumatic control valve DN 65, PN 40,

Type No.: 6050
Version: A
with DP actuator 6050 000220
and I/P positioner

AALBORG DATA SHEET
INDUSTRIES
Type:
• Filter regulator with automatic drain
Handle 1 • •
Size:
• Connections ports 1/4" BSP
• Gauge ports 1/8" BSP
-CD- I
—9-
T 1
Application:
Fitting
• Instrument air for regulating pressure
Technical data:
• Medium: instrument air only
• Max. inlet pressure: 17 bar
• Operating temp.: -20 °C to + 65 °C
• Filter element: 5 pm
• Recommend pressure regulating range:
0.14-7.0 bar
• Pressure gauge: 0 - 1 0 bar
• Weight: 0.4 kg
Material:
• Body: Steel
• Bin: Steel
• Handle: Acetal
Flow characteristics
Inle tpre ssur e 7 Dar
3 - " - —
-^.
—
—
X
"3
O 2 1
\
— .
— — _
• — _
.
— — . — .
—-—.1
• - - —
— —
.
•
——_
2 3 4 5 6 7 8 9 10
A'r flow [dm7s]
Type No.: 8000

Version: A Filter regulator with automatic drain 291 5101

Description Index Drawn Appr.
Approx. 325
Steam flow ,APP"».3IO
Control device 8210000026
19
230 V - 50/60 Hz
18
0-25 (max. 40 bar) Bar G 1/2"
Gasket 2911602
17 0i8/06.5t=2 Copper
Pressure gauge valve DIN 17243 2541002
16 1/2" PN400 C22.8
15
2.5-250 mBar
/JIILQJJJQ 14
Gasket
018.64x3.53 Rubber/viton
3520000013
Valve manifold DIN 17440 6230000002

13 DN5 PN420 1.4404
1W51.1
Washer 3090000004
12 M10 A 2-70
11 M10x55 A2
Min. 975 Gasket 3520000020

10 023/0171=1.5 Copper
Coupling DIN 3859 2462707
G 3/8"-m, CR 012 Steel
Hexagon set screw DIN 267 3020000003
M10x16 Electro galvanized 8.8
Fixing bracket for valve block
Incl. in item 15
Hexagon bolt ISO 898-1 6636348
M10x75 8.8
Incl. in item 15
*1: Support: Max. 0 55, Yard supply. Socket for Steam flow meas. 4150000086
3.1B
*2: Impulse lines: 012, Yard supply. DN25 L=125
Gasket 3520000007
*3: Gooseneck incl. drain valve and 1/2" female B.S.P., Yard supply. 026/0211=1.5 Copper
G 1/2"-f, CR 012 Steel
Install equipment as shown.
Pitot tube f. steam flow meas. 3.1 B
8620000068
1/2W52 DF25DFSE-DN300E-P40-HR
Material code Article No.
Item 1 delivered with 3.1B certificate. Dimension
PCS.
Material type
Cert. Detail drawing No.
Title: Date
JA 050307
Steam flow measuring equipment Appr. Date
Horizontal flow from right, 230V LD 050307
Weight Scale: Size
E~~"11 11 11 i 1 1 ° Pipe size: > I.D. 200 up to I.D. 300
1:10 A3
AALBORG General arrangement Article/Drawing No:
INDUSTRIES
THIS DRAWING AND DESIGN SHOWN HEREIN IS THE PROPERTY OF AAIBORO INDUSTRIES
88Z10:036110 AND MUST NOT BE USED BY OR REPRODUCED FOR THIRD PARTY 88Y:036113
Description Index Drawn Appr.
Steam flow

18
0-25 (max. 40 bar) Bar G 1/2"
Gasket 2911602
17 0I8/06.51=2 Copper
Pressure gauge valve DIN 17243 2541002
16 C22.8
1/2" PN400
15
2.5-250 mBar
Gasket 3520000013
14 Rubber/viton
018.64x3.53
Valve manifold DIN 17440 6230000002
13 DN5 PN420 1.4404
Washer 3090000004
12 M10 A 2-70
11 M10x55 A2
Gasket 3520000020
10 Copper
023/0171=1.5
G 3/8"-m, CR 012 Steel
Hexagon set screw DIN 267 3020000003
M 10x16 Electro galvanized 8.8
Incl. in item 15
Hexagon bolt ISO 898-1 6636348
M10x75 8.8
Incl. in item 15
Socket for Steam flow meas. 4150000086
* 1 : Support: Max. 0 55, Yard supply. DN25 L=125
3.1 B
*2: Impulse lines: 012, Yard supply. Gasket 3520000007
026/0211=1.5 Copper
*3: Gooseneck incl. drain valve and 1/2" female B.S.P., Yard supply.
G 1/2"-f, CR 012 Steel
Install equipment as shown. Pitot tube f. steam flow meas. 3.1B
8620000069
DF25DFSE-DN300E-P40-HL
Item
Dimension Material type
Cert. Detail drawing No.
Item 1 delivered with 3.1 B certificate.
Title: Drawn ' Date
Steam flow measuring equipment JA 050307

• • • •• Appr. Date
• •• •• ••••••• Horizontal flow from left, 230V LD 050307
iiiiiiiii Pipe size: I.D> 200 up to I.D. 300 Weight Scale:
1:10
Size
A3
AALBORG General arrangement Article/Drawing No: Index
INDUSTRIES THIS DRAWING AND DESIGN SHOWN HEREIN IS THE PROPERTY OF AALBORG INDUSTRIES
88Z10:036111 Plot Date: ANDMUST NOTBE USED BY OR REPRODUCED FOR THIRD PARTY 88Y:036114
Technical data for differential pressure transmitter, type 7MF4433
Mode of operation
Measuring principle Piezo-resistive
nput
Measured variable Differential pressure and flow
Measuring range
• Span (continuously adjustable)
- Nominal pressure PN 32 1 mbar to 20 mbar

- Nominal pressure PN 160 1 mbar to 30 bar
- Nominal pressure PN 420 2.5 mbar to 30 bar
• Lower measuring limit
- Measuring cell with silicone oil filling -100 % of max. span or 30 mbar (absolute)
- Measuring cell with inert filling liquid
For process temperature
-20 "C •; fl < 60 °C 30 mbar (absolute)
For process temperature 30 mbar (abs.) + 20 mbar (abs.) • [•& - 60 °C)/°C
+60 °C < •&< 100 °C (max. +85 °C
for 30-bar measuring cell)
• Upper measuring limit 100 % of max. span (max. 160 bar with oxygen measurement
and inert filling liquid)
• Start-of-scale (continuously adjust.) Between the measuring limits
Output
Output signal 4 to 20 mA
• Lower limit (continuously adjustable) 3.55 mA, factory-set to 3.84 mA
• Upper limit (continuously adjustable) 23.0 mA, factory-set to 20.5 mA or optional 22.0 mA
• Ripple (without HART communication) IOD < 0.5 % of max. output current
• Electric damping
- Adjustable time constant (T63) 0 to 100 s in steps of 0.1 s, factory-set to 0.1 s
• Current transmitter Adjustable from 3.55 to 23 mA
• Signal on alarm Adjustable from 3.55 to 23 mA
Load
• Without HART communication RB <. {UH -10.5 V) / 0.023 A in Q, UH: power supply in V
Characteristic Linear rising or falling or square-rooted
Accuracy
Reference conditions Increasing characteristic, start-of-scale value 0 bar, stainless steel seal diaphragm (with level:
mounting flange without tube), silicone oil filling and room temperature (25 °C)
r = max. span/set span = span ratio
Error in measurement with fixed-point
setting (including hysteresis and
repeatability)
- Linear characteristic
r<10 <0.1 %
10<rS30 <0.2%
30<r<100 < (0.005 • r + 0.05 %)
- Square-root characteristic
Flow > 50 % <0.1 % a t r < 1 0
< 0.2 % at
10<rS30
Flow 25 to 50 % £0.2%atr<10
< 0.4 % at
10<r<30
• Repeatability Included in error in measurement

• Hysteresis Included in error in measurement
Response time Approx. 0.2 s, approx. 0.3 s with 20- and 60 mbar measuring cells
(T63, without electric damping)
Long-term drift per 12 months < (0.1 • r) %
- 20-mbar measuring cell < (0.2 • r) %
Ambient temperature effect
• At-10 to+60 °C < (0.1 • r + 0.2) %V
• At -40 to -10 °C and +60 to +85 °C £ (0.1 -r + 0.15)%/10K 1 >

1 lu |

Influence of static pressure
• On start-of-scale < (0.15-r)% per 100 bar
- 20-mbar measuring cell < (0.15 - r ) % per 100 bar
• On span < 0.2% per 100 bar
- 20-mbar measuring cell < 0.2 % per 32 bar
Influence of mounting position < 0.7 mbar per 10° inclination
Influence of power supply 0.005 % per 1 V change in voltage
?ated operating conditions
Installation conditions
• Installation instructions Any mounting position
Ambient conditions
• Ambient temperature
(observe temperature class in
potentially explosive atmospheres)
- Measuring cell with silicone oil filling -40 to +85 °C
30-bar measuring cell -20 to +85 °C
- Measuring cell with inert filling liquid -20 to +85 °C
- Digital display -30 to +85 °C
• Ambient temperature limits See ambient temperature
• Storage temperature -50 to +85 °C ' '
• Climate class
- Condensation Permissible
• Degree of protection (to EN 60 529) IP 65
• Electromagnetic compatibility
- Emitted interference To EN 50 081-1
- Noise immunity To EN 50 082-2 and NAMUR NE 21
Medium conditions
• Process temperature
- Measuring cell with silicone oil filling -40 to +100 °C
30-bar measuring cell -40 to +85 °C (-20 to +85 °C for 7MF4533)
- Measuring cell with inert filling liquid -20 to +100 °C
30-bar measuring cell -20 to +85 °C
• Process temperature limits See process temperature
• Process pressure limits Nominal pressure (PN)
Design
Weight (without options) Approx. 4.5 kg
Dimensions See drawing
Material
• Wetted parts materials
- Seal diaphragm Stainless steel, mat. No. 1.4404, Hastelloy C276, mat. No. 2.4819,
Monel, mat. No. 2.4360, tantalum or gold
- Process flanges and
sealing screw Stainless steel, mat. No. 1.4408, Hastelloy C4, mat. No. 2.4610 or Monel, mat. No. 2.4360
- O-ring
FPM (Viton) or as option: PTFE, FEP, FEPM and NBR
• Non-wetted parts materials
- Electronics housing Die-cast aluminium, low in copper, GD-ALSi 12, or stainless steel precision casting,
polyester-based lacquer, stainless steel rating plate
- Process flange screws Steel, galvanized and yellow-passivized, or stainless steel
- Mounting bracket (option) Steel, galvanized and yellow-passivized, or stainless steel
Measuring cell filling Silicone oil or inert filling liquid (max. 160 bar with oxygen measurement)
Process connection Female thread VA -18 NPT and flange connection to DIN 19 213 with
mounting thread M10 (M12 for PN 420) or 7/16-20 UNF
Electrical connection Screw terminals, cable inlet via screwed gland Pg 13.5 (adapter),
M20 x 1.5 or Vz -14 NPT, or Han 7D/Han 8U pluq
Displays and controls
Input keys 3 for local programming directly on transmitter
Digital display Built-in, cover with window (option)
Power supply (U H)
Terminal voltage on transmitter DC 10.5 to 45 V and DC 10.5 to 30 V in intrinsically-safe mode
Ripple UppS 0.2 V (47 to 125 Hz)
Noise U r m s £1.2mV(0.5to10kHz)

Certificates and approvals Exclusively decisive are the data in the official EU prototype test certificate
and the respectively valid supplements
CENELEC To DIN EN 50 014:1997, EN 50 020:1994 and EN 50 284:1999
• Intrinsic safety ©H1/2GEExiallCT4/T5/T6
- EU prototype test certificate TUV99ATEX1494
- Max. ambient temperature +85 °C temperature class T4
+70 °C temperature class T5
+60 °C temperature class T6
- Connection to certified intrinsically- Ui = 30V./; = 100 mA,
safe circuits with maximum values Pi = 750mW, R; = 300fi
- Effective internal inductance l i = 0.25mH
- Effective internal capacitance q = 6nF
• Explosion-proof © 111/2 GEExd IIC T4/T6
- Conformity certificate PTB99ATEX1160
- Max. ambient temperature +85 °C temperature class T4
+60 "C temperature class T6
* 45 for Pg 13.5
1 a Process connection of low-pressure side VA - 1 8 NPT 5 Terminal side
1 b Process connection of high-pressure side Y« - 1 8 NPT 6 Electronics side, digital display
2 Mounting thread M10, M12 or 7/16 - 20 UNF 7 Protective cover over keys
3 Blanking plug 8 Sealing screw with valve
4 Electrical connection: 9 Vent on side for liquid measurements
screwed gland Pg 13.5 (adapter), M20 x 1.5 or 10 Vent on side for gas measurement (suffix H02)
14-14 NPT or Han 7D/Han 8U plug 11 Mounting bracket (option)

AALBORG DATA SHEET
INDUSTRIES
• Cable entry: Pg 9 (cable diameter 5 to 9

Type:
mm)
• Pressure transmitter • Screw terminals; Max. cross-section area
• VEGABAR14 of conductor 2.5 mm2
Range: • Process connection: G lA"A
• 0-25 bar
Application:
• The pressure transmitter converts
pressure to an electrical signal. This is
proportional to, and linear with, the 56
value of the pressure to which the
pressure-sensitive element is subjected
II II II II
by the medium. The units are supplied
as two wire transmitters with an output
signal of 4-20 mA. The transmitters
have a zero-point displacement facility
for equalizing static pressure
Material:
• Wetted parts: 1.4301 / A12O3 (ceramic
measurement cell)
• Housing: brass nickel-plated CM"
Technical data:
Performance:
• Average temperature coefficient of the
zero signal: < 0.15% / 10 K
• Deviation in characteristics relating to
measuring range:: < 0.5%
• Hysteresis relating to measuring range:
<0.1%
• Longterm stability: < 0.15% / year ZEJ
IO
• Supply voltage: 12 to 30 VDC G Vik
• Current limitation: to approx. 23 mA 0 38
• Interference: > 21.6 mA
Mechanical
• Ambient temperature: -20 to 85°C
• Product. Temperature: -20 to 100°C
• Storage and transport temperature:
-50tol00°C
• Protection: IP 65
• Connection plug / cable outlet: PA
Type No.: 8010 Pressure transmitter 8010 000008

Version: A 0 - 25 bar

AALBORG DATA SHEET
INDUSTRIES
Installation:
• The pressure transmitter can be mounted
in any individual position. For mounting
please use an appropriate process seal
(copper, Aluminium, steel-Viton etc.)
• Remove the plug from the sensor and
1. Supply +
push / pull the plug screw out of the 2. Supply-
plug. Remove the plug insert with a i Connected to Vegabar transmitter enclosure
small screwdriver out of the plug
housing. Hence the screw terminals of
the plug are accessible for cable
connection.
• The zero point can be modified in the
range of approx. 3 to 5 mA. If necessary
adjust the zero point to a 4 mA. Hence
pull out the plug and remove the plug
screws. Now insert the plug again to the
sensor and insert the 2 mm-screwdriver
(attached to the instrument) approx. 45
mm into the hole of the plug screw.
Then a small potentiometer is reached
by which the zero point can be adjusted.
Type No.: 8010 Pressure transmitter

Version: A 8010 000008
0 - 25 bar

AALBORG DATA SHEET
INDUSTRIES
Type:
• Pressure transmitter
• MBS 5100
Size:
• 0 - 40 bar
Application:
• The pressure transmitter converts pressure to an electric signal. This is proportional to, and linear
with, the value of the pressure to which the pressure-sensitive element is subjected by the
medium. The units are supplied as two wire transmitters with an output signal of 4-20 mA. The
transmitters have a zero-point displacement facility for equalizing static pressure.
Span adjustment is also possible.
Material:
• Housing material: Anodized AlMgSiPb
0 5.5'
Type No.: 8010

0 - 4 0 bar

AALBORG DATA SHEET
INDUSTRIES
Technical data:
Performance:
• Accuracy (incl. non-linearity, hysteresis and repeatability): +0.1% fs (typ.) / +0.3% FS (max.)
• Non-linearity (best fit straight line): < +0.2% FS
• Hysteresis and repeatability: < +0.1% FS
• Thermal zero point shift: < ±0.1% FS/10K (typ.) / < ±0.2% FS/10K (max.)
• Thermal sensitivity (span) shift: < ±0.01% FS/K (typ.) / < ±0.02% FS/K (max.)
• Response time: < 4 rms
• Rated output signal: 4 to 20 mA
• Supply voltage, Vsuppiy (polarity protected): 10 to 32 V d.c.
• Voltage dependency: < 0.01 % FS/V
• Current limitation (linear output signal up to 1.5 x nom range): 28 mA (typ.)
. Max. load RL: RL < [(Vsuppiy -10V)/0.02A] - 10 Q.
Mechanical:
Connection: G 1/2" -m (EN 837-1-G XA A)
Max. operating pressure: 80 bar
Min. burst pressure: 800 bar
Operating temperature range: - 40 to 85°C
Compensated temperature range: 0 to 80°C
Transport temperature range: - 50 to 85°C
Cable entry: PG 11
Enclosure: IP 65
Weight: 0.4 kg
Type No.: 8010

0 - 4 0 bar

AALBORG DATA SHEET
INDUSTRIES
Installation:
• There are facilities for adjusting zero point and span.
Zero point adjustments is necessary to equalise pressure arising from any differences in level
between the pressure transmitter and the medium being measured.
Zero point adjustment results in a parallel displacement of span.
Both zero point and span must be adjusted on the side of the unit with cover removed
-5to> + 10%FS
4-20 mA
1. Supply+
2. Supply -
3. Function test
i Connected to MBS transmitter enclosure
Type No.: 8010

0 - 4 0 bar

AALBORG DATA SHEET
INDUSTRIES
Type:
Nozzle, Couplings (2" Storz) Hose,
• Water washing hose with nozzle item No. 29,4 1101 \ item No. 294 1001
Size:
• V-nozzle: 12 mm
• Length: 15 metre (hose)
• Inner diameter: 52 mm (hose)
Application:
• For spraying of water
Material:
• Hose: full-synthetic material (polyester)
woven in 1/1 binding, with inner rubber
lining 2" BSP connection Couplings (2" Storz),
(male) item No. 294 1201
Technical data:
• Max allowable working pressure: 20 bar
• Water temperature area: -3 0°C-+60°C
• Weight: 5.5 kg
Water flow
l/min
210
200
190
180
170
160
150
140
130
120
/
110 /
100 /
90 /
80
70 t
60
50
40
30
20
10
1 8 9 10 Bar
Type No.: 8615

Version: A Water washing hose with nozzle 2941001

AALBORG DATA SHEET
INDUSTRIES
Type Technical data:

• Test cabinet Drew M4 Adjunct B incl. • Power supply: 220VAc for inside lamp
reagents • Cable length: 2 m with Euro plug
• Test cabinet: 1 Cabinet
Application: • Weight: 22 kg
• Test cabinet for boiler water treatment.
Alkalinity glassware set:
Material: 2 Bottle, 30 ml with dropper
• Steel 1 Bottle, 480 ml
1 Burette, 10 ml
Reagents:
1 Cylinder, 50 ml (Glass)
Alkalinity reagent set 1 Dish, evaporating
• 2Sulfuricacid,N/10 3 Stirring rod
• 1 Phenolphthalein Phosphate glassware set:
• 1 Alkalinity indicator, GP • 1 Bottle, molybdate Squeeze w/
Chloride reagent set Gooseneck
2 Chloride LMP test kit, each containing • 1 Comparator, Phosphate range 20 to 60
2 Silver nitrate, N/10 ppm
1 SuIfuricacid,N/10 • 1 Funnel, plastic
1 Phenolphthalein • 1 Measuring spoon, 0.2 mg
1 Potassium chromate • 1 Paper, filter 12.5 cm diameter box of
1 Plastic vial 10 ml mark 100
1 Glass tube vial 2 ml mark • 2 Mixing test tube marked at 5 ml and
17.5 ml
Phosphate Reagent set
Amerzine test kit:
• 4 Molybdate R
• 2 Stannous chloride powder • 1 Cylindrical comparator, Amerzine
• 1 Sample cup
• 30 Ampoules
PHtest:
• 1 PH paper wide range, 10 rolls
765 4 x 6 mm holes
410
610
f
r
A
Type No.: 8500

Version: C Test cabinet for boiler water treatment 880 0001
Language U K ' Page 1/1

AALBORG DATA SHEET
INDUSTRIES
Type:
• Ultrasonic sensor for oil detection
equipment
Application:
• The ultrasonic sensor is operated
together with a control unit.
• The equipment provides for oil detection
in feed/make-up water.
Material:
• Sensor: Stainless steel
Technical data:
• Temperature: -70°C to 150°C
• Design of duty: Chemical interface
• Liquid type: Clean, viscous with solids
• Cable: 6 metre
258
10 20 ,.25 152 .26
Type No.: 8310 Ultrasonic sensor

Version: A 8310 000005
for oil detection equipment

AALBORG DATA SHEET
INDUSTRIES
Type:
• Control unit for oil detection equipment
Application:
• The control unit is operated together with
an ultrasonic sensor.
• The equipment provides for oil detection
in feed/make-up water.
Material:
• Control device cabinet: Polycarbonate
Technical data:
• Power supply (selector switch):
110/120Vor220/240VAC
• Relay output: DPCO
• Enclosure: IP 65
• Holes for glands 3 of 0 16
•0 O Normal c
O Alarm
00
O Fault
OO
•0
188 —^ Holes for mounting
Holes for glands
- 40 ,
130
160
200
Type No.: 8210

Version: A Control unit for oil detection equipment 8210 000025

• • • • I
AALBORG DATA SHEET

INDUSTRIES
Type:
• Conductive electrode, type SL 700 E Electrical:
• Total cable length: max. 200 m
Application: • Connection to control device via junction
• The conductive electrode is used in box:
combination with a control device to Sensor pin 1 to pin 11 (white)
measure and supervise the salinity of Sensor pin 2 to pin 12 (black, white)
feed water. Sensor pin 3 to pin 13 (red)
Sensor pin 4 to pin 14 (shield)
Technical data:
Sensor pin 5 to pin 15 (black, red)
Instrument: Installation:
• Salinity range: 0 - 2 0 ppm (sea salt) • The conductive electrode must be
• Accuracy: +/-10% installed in the supplied T-piece (item
8500 000115). The cable must be
connected to the control device via a
junction box (not AI supply).
•u Cable lenght:
Y[/2.5 metre
Connector
plug:
6 pol GLC •
Packing
Gold-plated
electrodes
Type No.: 8620

Version: B Conductive electrode, type SL 700 E 8620 000082

AALBORG DATASHEET
INDUSTRIES
Type:
• Control device for salinometer, type SL Electrical:
700 • Mains supply: 90 - 115 VAC or
190-230 VAC, 5 0 - 6 0 Hz
Application: • Mains current: mains supply must be
• The control device is used in secured against over current externally
combination with a conductive electrode by using a fuse (max. 100 mA)
to measure and supervise the salinity of • Power: max. 3.5 W
feed water. • Cable connections:
Terminal 1-4: mains supply
Technical data:
Terminal 5-10: relay contacts for alarm
Instrument: and solenoid
• Salinity range: 0 - 2 0 ppm (sea salt) Terminal 11-16: electrode unit
• Accuracy: +/- 10% of displayed value Terminal 17 - 18: 4 - 20 mA current
• Adjustable alarm range: 1-20 ppm loop (I = 0.8 x (ppm) + 4 mA)
• Display: LED indication bar • Relay contacts: 8 A / 24 VDC
0 1 2 3 4 5 6 7 8 9 10 12 14 16 18 20
86
Alarm ; ilili: Alarm set |
liiiiijli
AALBORG - I
' " • " " " Salinometer type SL 700
105
Type No.: 8210

Version: A Control device, 8210 000032

AALBORG DATA SHEET
INDUSTRIES
Material:
Type:
• Housing: RG 5
• T-piece for salinity alarm equipment
• Nut for electrode: RG 5
Size:
Technical data:
• DN25
Application: • Flanges according to DIN 2501
• Housing for salinity electrode
110
Type No.: 8500

Version: A T-piece for salinity alarm equipment 8500 000115

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Iriitruction manual for boiler plant, volume 1

: 2 x MISSION™ D4ypo model 55000

System concept (vol. 1)

MISSION™ D-type boiler/accessories (vol. 1)

KBSD burner/accessories (vol. 2)

Language UK Page 1/2

Control system/electrical equipment (vol. 3)

Spare parts (vol. 3)

Language UK Page 2/2

Technical data for boiler unit

Language UK Page 1/1

Technical data for boiler unit

2 Dimensions for boiler unit

3 Water/steam process data

• Steam output: 50,000 kg/h

4 Combustion process data

Language UK Page 1/3

• Min. calorific value of fuel oil: 40,200 kJ/kg

Data for atomising steam

• Atomising steam pressure at burner, max.: 6.0 Bar g

Data for electric systems

• Power supply: 3 x 440V, 60Hz

Data for pressure part

• Boiler type: Large oil fired boiler

Language UK Page 2/3

8 Data for burner

• Burner type: Steam atomising, modulating

Data for water level operation

• Too high water level alarm +200 mm

10 Data for steam pressure operation

• Safety valve: 22.0 Bar g

• Language for manuals: UK

Language UK Page 3/3

Language UK Page 1/1

V:\Marine\Order\737xxx\737695~700\0800 Documentation\0810 Flow diagrams - steam water\737695.doc737695.doc

V:\Marine\Order\737xxx\737695~700\0800 Documentation\0810 Flow diagrams - steam water\737695.doc737695.doc

V:\Marine\Order\737xxx\737695~700\0800 Documentation\0810 Flow diagrams - steam water\737695.doc737695.doc

• 4 / 8 " - ' . ; . - ••• ••• •- <- ' •

List of Parts for AQ-2 Rev: g Class.:

V:\Marine\Order\737xxx\737695~700\0800 Documentation\0810 Flow diagrams - steam water\737695.doc737695.doc

List of Parts for MISSION D-type & AQ-2 Rev: g Class.:

V:\Marine\Order\737xxx\737695~700\0800 Documentation\0810 Flow diagrams - steam water\737695.doc737695.doc

List of Parts for MISSION D-type & AQ-2 Rev: g Class.:

V:\Marine\Order\737xxxY737695~700\0800 Documentation\0810 Flow diagrams - steam Water\737695.d6c737695.doc

List of Parts for MISSION D-type & AQ-2 Rev: g Class.:

V:\Marine\Order\737xxxV737695~700\0800 Documentation\0810 Flow diagrams - steam water\737695.doc737695.doc

Heavy fuel oil Heavy fuel oil

Mk For 2 x steam atomising burner size 4150

Title Drawn Date

C331 & C431 new no. b 030207 KTN STh

P a r t list u p d a t e d c 02MAJ2005 UMD

Aux. atomising steam supply from

Title Drawn Date

Language UK Page 1/1

N..e: MISSION™ D-type Boiler

1.1 Boiler Pressure Part

Language UK Page 1/2

AALBORG MISSION™ D-TYPE BOILER 737695#02.0

Principal drawing of MISSION™ D-type boiler

Inspection door J^ Inspection hole

Figure 1 Miss D9.cdr

Language UK Page 2/2

Language UK Page 1/2

Language UK Page 2/2