Thermopac / Deltatherm Revomax / Revomax Plus

REVOMAX / REVOMAX PLUS ( RXA , RXD )
TM
REVOMAX / REVOMAX PLUS

N-IBR Instant Steam Generator
Installation , Operation & Maintenance Manual
___________________________________________________________________
INSTRUCTION MANUAL
FOR
REVOMAX BOILER
REVOMAX PLUS BOILER
(NON IBR)
MODEL : RXA – 02,03,04,05,06
RXD – 04, 06, 850
(FUEL : OIL / GAS FIRED)
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COOLING & HEATING DIVISION CD 34/177

MULTISTAR – IFBD
_____________________________________________________________________________________________
INSTRUCTION MANUAL
FOR
MULTISTAR
MODELS: IFB – 06D, 10D, 15D, 20D, 30D, 40D & 50D
PRESSURE: 10.54 & 17.5 KG/CM2G
FUEL: COAL (INDIAN, IMPORTED) / WOOD / LIGNITE /

HUSK BRIQUITTE
PUBLICATION NO. : PIFDCM0035 REV : 01
JANUARY 2013
NOTE : The Unit looks different than that shown on cover page of
this manual.
ADDRESS TEL NO. FAX NO.

THERMAX LIMITED, 020-27475941 020-27472049/
TECHNICAL SERVICES, (5 LINES)/ 020-27475679
(COOLING & HEATING DIVISION) 020-27470346
D-13, MIDC INDUSTRIAL AREA,
R.D. AGA ROAD,
CHINCHWAD,
PUNE 411 019 (INDIA)
_____________________________________________________________________________________________
COOLING & HEATING DIVISION CD-34/177
___________________________________________________________________
THERMAX LIMITED
INDIA
Dhanraj Mahal,2nd Floor, Chatrapati
Shivaji Marg, Near Regal Cinema, (022) 67542222 (022) 22040859
Gateway of India, Colaba (022) 22852058
Mumbai. 400 039.
GARIAHAT MALL , 5TH FLOOR , 13 (033) 66070800 033-66070999
JAMIR LANE , (033) 66070900
KOLKATA 700019
14TH FLOOR, BEST SKY TOWER,
NETAJI SUBHASH PLACE, 011-46087200 011-27355211
PITAMPURA, 011-45019846
NEW DELHI 110 034 (INDIA)
FATHIMA AKHTAR COURT,
III FLOOR, 453, ANNA SALAI, 044-24303400 044-24353841
TEYNAMPET,
CHENNAI 600 018 (INDIA)
PUNE AREA OFFICE
D-13, MIDC AREA, 020-27475941 / 2 020-27472049
R D AGA ROAD,CHINCHWAD, 020-27470436 020-27475676
PUNE 411 019 (INDIA) (10 LINES) 020-27477066
409-411, MAHAKANT,
OPP. V S HOSPITAL, 079-26577073 079-26577270
ASHRAM ROAD, 079-26575408
AHMEDABAD 380 006 (INDIA)
NO. 1, “RNG PALLAZZO”,
1ST Floor, South End Street, 080-22371721-25 080-22371726
Kumara park East,
(Behind Shivananda Stores),
BANGALORE 560 001 (INDIA)
SBR GATEWAY BLDG, 301,
3RD FLOOR, HITECH CITY, 040-23253700 040-23253799
MADHAPUR,
OPP. MOTOROLA,
HYDERABAD 500 081 (INDIA)
A / 144, Shaheed Nagar,
1st Floor 0674-3296360. 0674-3296360
BHUBANESHWAR - 751 007
ORISSA (INDIA)
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___________________________________________________________________
THERMAX LIMITED
(OVERSEAS OFFICES)
AVENUE CHARLES THIELEMANS, 32(0) -

109 B – 1150, 7369244/473450186
BRUSSELS,
BELGIUM
C/O. PT, MITRABINA REKANIAGA, +62-21-83787473

PERKANTORAN CROWN PALACE,
BLOCK B # 02-03,
JALAN PROF. SOEPOMO SH NO 231
TEBET, JAKARTA, 12870,
INDONESIA.
C/O, SPENOMATIC (K) LTD,
P.O.BOX NO. 39935, WAIYAKI WAY, 00-254-20-4440233/ .
CLOSE TO ABC PLACE, 206/207
NEXT TO HOPE HOUSE (BABY HOME) 00-254-72-6729812
WESTLANDS,
NAIROBI, KENYA
THERMAX LIMITED,
139, BUILDING NO:9, 26 BAKINSKIKH 007(495)434-30-41 007 (495) 434-46-58
COMISSAROV
(OPP. METRO SOUTH-WEST, 3 MIN.
WALK)
119571 MOSCOW, RUSSIA
(REPRESENTATIVE OFFICE),
4TH FLOOR, NAILERT TOWER, 00-66-2-6555790 00-66-2-6555791
2/4, WIRELESS ROAD,
BANGKOK 10330, THAILAND
P O BOX 17156, JEBEL ALI,

FREE ZONE, JAFJA, 00-971-4-8861424
SOUTH – BJ – 02,
DUBAI, U.A.E.
THERMAX EUROPE LTD

2, STUDIO COURT, QUEENSWAY 00-44-1908378914
BLETCHLEY, MILTON KEYNES,
MK2 2DG, UNITED KINGDOM
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___________________________________________________________________
BLDG. NO. 114, FLAT NO. 68 00-73-272-543582 00-73-272-543582

PROSPECT LENIN, ALMATY 480100,
KAZAKSTAN
THERMAX INC, Phone: +1 248 207 0541

21800, HAGGERTY ROAD, SUITE 112,
NORTHVILLE, MI 48167, U.S.A.
C/O, PRO-ACTIVE MH RESOURCES 00-60-3-21619801/03/04 00-60-3-21612685

SDN.BHD, 3RD FLOOR (SOUTH WING),
BANGUNAN GETAH ASLI,
P.O. BOX 18, 148, JALAN AMPANG 50450,
KUALA LUMPUR, MALAYSIA
C/O, MIZAMI NIGERIA LTD., 00-234-805-1992790 /

SUITE 21 B, 1ST FLOOR, 00-234-1-7652930 /
WEST PAVILION, TBS COMPLEX, 00-25473423492
VICTORIA ISLAND,LAGOS, NIGERIA
THERMAX LIAISON OFFICE

35, NEW ESKATON ROAD
SUFIA HOUSE, DHAKA - 1000,
BANGLADESH
C/o. GULF POWER INTERNATIONAL, 00966 55 391 5403

(DABBAGH GROUP), PO BOX 74426, 00966 3 8874557
AL-KHOBAR 31952,SAUDI ARABIA
C/O LALAN ENGINEERING LTD., 00 – 94716823020

344, GRANDPASS ROAD,
COLOMBO - 14, SRI LANKA
C/O. UNIMEX INTER-TRADE INC., 0062 24537851,

113, MINDANAO AVENUE, 0063 24128856
BAHAY TORO,
QUEZON CITY, MANILA, ZIP: 1106
PHILLIPPINES
THERMAX HONGKONG LIMITED 00-852 2961 4041 00-852 2961 4042

907, SILVERCORD TOWER 2,
30, CANTON ROAD, TSIM SHA TSUI,
KOWLOON, HONG KONG
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REVOMAX BOILER
REVOMAX PLUS BOILER
(NON IBR)
MODEL : RXA – 02,03,04,05,06

RXD – 04, 06, 850
CONTENTS
SECTION 1 INSTALLATION
SECTION 2 OPERATION
SECTION 3 MAINTENANCE
SECTION 4 ANNEXURE
SECTION 5 MANUALS & LEAFLETS
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SECTION 1
INSTALLATION MANUAL
FOR
REVOMAX BOILER
REVOMAX PLUS BOILER
(NON IBR)
MODEL : RXA – 02,03,04,05,06
RXD – 04, 06, 850
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REVOMAX / REVOMAX PLUS SECTION 1
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CONTENTS
CHAPTER 1 : PREFACE ................................................................................................................................ 2
CHAPTER 2 : TECHNICAL SPECIFICATIONS ........................................................................................ 3
CHAPTER 3 : REVOMAX / REVOMAX PLUS IN GENERAL.................................................................. 6
CHAPTER 4 : "DO"S AND "DON'T"S FOR REVOMAX / REVOMAX PLUS INSTALLATION ...... 7
CHAPTER 5 : TRANSPORTATION.............................................................................................................. 9
CHAPTER 6 : BOILER HOUSE................................................................................................................... 10
CHAPTER 7 : CERTIFICATE FOR NIBR (N0N IBR) BOILERS UNDER ‘SMALL INDUSTRIAL
BOILERS’ ........................................................................................................................................................... 11
CHAPTER 8 : FUEL STORAGE & HANDLING....................................................................................... 12

8.1 FUEL STORAGE FORMALITIES ( APPLICABLE FOR OIL FIRED UNITS ONLY) ........................................... 12
8.2 BOILERS WORKING ON LIGHT DIESEL OIL (LDO/HSD) ....................................................................... 13
8.3 DETAILS :........................................................................................................................................... 14
8.3.1 Electrical Heating. (applicable for RXD units).................................................................... 14
8.3.2 Steam Heating. (applicable for RXD units) ........................................................................ 15
CHAPTER 9 GAS TRAIN .............................................................................................................................. 17
CHAPTER 10 : WATER SUPPLY................................................................................................................ 22

10.1 FLOW SENSOR: (ONLY APPLICABLE FOR RXD 850)......................................................................... 23
CHAPTER 11 : CHIMNEY ........................................................................................................................... 24
CHAPTER 12 : ELECTRICAL POWER SUPPLY ..................................................................................... 26
CHAPTER 13 : DRAWINGS........................................................................................................................ 27
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COOLING & HEATING DIVISION 1 CD 34/177.

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CHAPTER 1: PREFACE
The REVOMAX / REVOMAX PLUS is the latest in oil and gas-fired, coil-type steam
generators. The three pass, reverse flue, membrane-coil design is a blend of proven
techniques in combustion and heat transfer technology, backed by three decades of
Thermax design experience. This is an automatic, fully-packaged steam generator.
This manual is prepared with a view to:
a. assist you in making a proper installation,
b. assist you in understanding the construction and operation of the boiler,
c. assist you in starting and stopping the boiler,
d. guide you on routine maintenance required, and,
e. help you in locating the exact fault, and setting it right.
The first part of this manual deals with operation and maintenance of the unit and the
second part giving you the instruction for proper installation.
Our Service Engineers are always available to help you in solving any operating or
maintenance problems.
We have a team of Service Engineers to guide you in proper installation of your

REVOMAX / REVOMAX PLUS boiler. Apart from them we have Service Franchises
across the country to be of assistance to you.
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CHAPTER 2: TECHNICAL SPECIFICATIONS

REVOMAX, THREE PASS, REVERSE FLUE, COIL TYPE STEAM BOILER
S.N Description Unit RXA-02 RXA-03 RXA-04 RXA-05 RXA-06

Steam output F&A
1 kg/h 200 300 400 500 600
100°C
2 Heat Output MW 0.126 0.188 0.251 0.314 0.377
Steam pressure and
3 - 10.54 & 17.5 kg/cm2, at 185°C and 207°C
temp.
4 Efficiency on NCV (Oil) - 88 ± 2%
5 Fuel consumption
- LDO, HSD
Kg/h 12.0 18.0 24.1 30.1 36.1
(NCV – 10200 Kcal/kg)
6. Efficiency on NCV (Gas) - 87.5 ± 2%
- Natural Gas
Nm3/h 14.5 21.78 29.04 36.37 43.56
(NCV – 8,500 Kcal/kg)
- LPG
Nm3/h 4.95 7.42 9.90 12.37 14.85
(NCV – 24940 Kcal/kg)
7. Heating surface
Boiler heating surface
M2 3.7 4.37 4.37 5.92 5.92
area
Economiser heating
M2 1.27 1.91 1.91 2.6 2.6
surface area
Total heating surface
M2 4.97 6.28 6.28 8.52 8.52
area
8. Burner control - ON/OFF
Time required to reach
9. - 3 to 5 minutes
full load after cold start
10. Pressure parts - Non IBR
11. Electric supply - 415 / 380 (± 6%)V , 50(± 3%)Hz,
Blower (3000 rpm) kW 0.75 0.75 0.75 1.5 1.5
Water pump motor

kW 0.55 0.55 0.55 0.75 0.75
(1000 rpm)
c) Fuel pump motor
kW 0.37 0.37 0.37 0.37 0.37
(3000 rpm)
Total connected load
kW 1.8 2.17 2.17 2.75 2.75
(LDO)
Total connected load
kW 1.80 1.80 1.80 2.75 2.75
(GAS)
12. Overall dimensions (w/o Seperator)
Length M 1.3 1.5 1.5 1.5 1.5
Width M 1.1 1.3 1.3 1.4 1.4
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Height M 1.7 2.15 2.15 2.34 2.34
13. Dry weight (approx.) Ton 0.950 1.1 1.1 1.2 1.5
14. Flue gas outlet dia. mm 150 200 200 250 250
REVOMAX PLUS, THREE PASS, REVERSE FLUE, COIL TYPE STEAM BOILER
S N. Description Unit RXD-04 RXD-06 RXD-850

1 Steam output F&A 100°C kg/h 400 600 850
2 Heat Output MW 0.25 0.377 0.534
2
10.54 & 17.5 kg/cm g, at 185°C & at
3 Steam pressure and temp. -
207°C
4 Efficiency on NCV (Oil) - 88 ± 2%
5 Fuel consumption
- LDO, HSD (NCV – 10200 Kcal/kg) Kg/h 24.00 36.0 50
- FO (NCV – 9650 Kcal/kg) Kg/h 25.44 38.0 54
6. Efficiency on NCV (Gas) - 87.5 ± 2%
- Natural Gas - (NCV–8500 Kcal/kg) Nm3/h 29.04 43.56 61.71
- LPG (NCV – 24940 Kcal/kg) Nm3/h 9.9 14.85 21.03
7. Heating surface
Boiler heating surface area M2 5.92 7.42 10.4
Economiser heating surface area M2 1.91 2.6 4.45
Total heating surface area M2 7.83 10.02 14.85
8. Burner control - ON/OFF
Time required to reach full load after
9. - 3 to 5 minutes
cold start
10. Pressure parts - Non IBR
11. Electric supply - 415(± 6%)V, 50(± 3%)Hz,
Blower (3000 rpm) kW 0.75 1.5 1.5
Water pump motor (1000 rpm) kW 0.55 0.75 1.5
OPH (Only for FO) kW 3 3 3
Total connected load (FO) kW 5.2 6.2 6.9
Total connected load (LDO) kW 2.2 3.2 3.5
Total connected load (GAS) kW 1.8 2.75 3.5
12. Overall dimensions (w/o separator)
Length M 1.2 1.4 1.8
Width M 1.5 1.5 1.5
Height M 2.6 2.5 2.9
13. Dry weight (approx.) Tons 1.1 1.2 1.5
14. Flue gas outlet dia. Mm 200 250 250
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NOTES: The efficiency is guaranteed with commercially clean (normal operating cleanliness) internal
and external heat transfer surfaces.
Fuel consumption is based on Net Calorific Value (NCV) of 8,500 kcal/Nm3 for Natural Gas and 24,940
kcal/Nm3 for LPG. Fuel consumption is based on Net Calorific Value (NCV) of 9,650 kcal/ kg for FO,
10,200 kcal/kg for HSD and 10,500 kcal/kg for LDO.
IN VIEW OF THE COMPANY'S ENDEAVOUR TO IMPROVE THE QUALITY OF PRODUCTS, THE SPECIFICATIONS LISTED
ABOVE ARE SUBJECT TO ALTERATIONS WITHOUT PRIOR NOTICE.
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CHAPTER 3: REVOMAX / REVOMAX PLUS IN GENERAL
REVOMAX / REVOMAX PLUS is a once through, coil type, instant steam generator. It is
a fully automatic packaged boiler with all the necessary accessories mounted on a
common chassis.
The furnace section of the boiler consists of a membrane coil (helical coil with in between
spacer strips) where fuel is burnt. This coil is housed in a jacket assembly consisting of
inner jacket and outer jacket. Refractory cover is mounted on the topside of the inner
and outer jacket. The bottom side of the coil is filled with refractory. Oil or Gas burner is
mounted on the top cover of the outer jacket. Aluminum radiators are provided in the
annular space between inner and outer jacket.
In case of RXD units to reduce outer skin temperature, third (outermost) jacket has been
provided. Glass wool insulation has been filled in annular space between third
(outermost) and middle jacket.
Apart from the main boiler section, Economiser and Heat optimiser are provided before
the feed water pump. Economiser is a jacket & tube heat exchanger and optimiser is
tube in tube type heat exchanger. The necessary fuel handling system is also provided -
along with the boiler.
Fuel is burnt in the membrane coil by the oil and gas burner using the air from
combustion air fan. Cold air from the combustion air fan is passed through the annular
space between inner and middle jacket to pre-heat and in turn recover heat from the flue
gas. Since the coil is blinded from the rear end, the flame reverses within this coil (first
and second pass) and takes a turn at the top and enters into the annular space between
the membrane coil and the inner jacket (third pass). While the heat transfer in the
membrane coil is by radiation, the heat transfer in the third pass is by convection. At the
outlet of the boiler, the flue gas is exhausted through the economiser to recover further
heat from the flue gas.
Water from the feed water tank enters the economiser through the optimiser before
entering the feed water pump. The economiser outlet is again connected to the
optimiser. By this water circuit, the temperature of water entering the feed water pump is
maintained below 80°C which is the maximum temperature the reciprocating pump can
withstand.
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CHAPTER 4: "DO"S AND "DON'T"S FOR REVOMAX / REVOMAX

PLUS INSTALLATION
1. All water, fuel and steam piping should be thoroughly flushed before being
connected to the boiler. This will prevent foreign matter blocking or damaging the
boiler piping system.
2. See that the feed water pressure available at the inlet of the water softener is
never less than what is required as laid down in the softener manual.
3. Never install the soft water service tank at less than recommended height from
the floor level as this will cause cavitation in the feed water pump. Do not use
smaller diameter pipes also for the same reason and use as few fittings as
possible to reduce pressure drop.
4. Select fuel oil storage and service tanks of adequate capacity. Consider delivery
schedule, price breaks and adequate oil reserve. Keep in mind the regulations -
involved. Keep the fuel oil service tanks at the height specified in the manual.
Otherwise, there will be improper flow of oil to the fuel pump. Use as few fittings
as possible in the fuel oil line.
5. Use outflow heaters and tracers for furnace oil lines wherever the ambient
temperature is below 25°C and lag the pipe lines to reduce heat loss.
6. Use MS Black Class "C" pipes and NEVER use GI pipes for fuel oil lines as the
pipes will get corroded due to the presence of Sulphur in fuel oil.
7. Use chimney of correct cross sectional area as specified in the manual. Never
reduce the diameter as this will pose combustion problems due to frictional
resistance offered. CONSULT SMOKE NUISANCE INSPECTOR WHEREVER
THE ACT IS IN FORCE.
8. Use correct diameter pipes for the steam service line, as reduced diameter will
increase steam pressure drop.
9. Use steam traps wherever water clogging of the system is likely to occur.
10. Take the steam safety valve, blowdown valve & auxiliary valve connections
outside the boiler house for safety. Use a minimum number of bends in these
lines to avoid back pressure.
11. Ensure that the discharge of the blowdown & auxiliary connections is visible to the
operator.
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12. Lag the steam lines after testing, to reduce heat losses.
13. Provide adequate space around the unit for easy movement and servicing.
14. A leaky gasket can cause unscheduled shut-down in boiler operation. It is

therefore, recommended that suitable gaskets are always kept handy in the boiler
house.
15. Economiser air vent line should be rising vertically up.
For gas fired unit
16. The main gas line should be brought to the unit through an isolating valve,
Oil/water separator, a filter and a drain line to remove any oil, water etc. which
may accumulate in the line. Also a pressure gauge should be connected to
indicate the main gas line pressure.
17. The maximum allowable working pressure of gas at inlet to the gas train is
between 1 bar to 2 bar & for low pressure gas train it’s 100 mBar to 500 mBar. If
the pressure is exceeded, it should be brought down by means of a pressure-
reducing valve.
18. The gas supplied should be free of dirt, oil, water etc.
19. Use MS Black Class "C" pipes and never GI pipes for gas lines and it should be
welded construction and have flanges for easy removal.
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CHAPTER 5: TRANSPORTATION
The REVOMAX / REVOMAX PLUS dispatched from our factory is normally packed in a
crate. During transportation, care should be taken to keep the unit always in vertical
position. The unit should never be turned to horizontal position.
The unit should be lifted for loading and unloading or shifting from one position to
another, by means of lifting hooks provided on the top plate of the unit only. If lifting
tackles are not available, rollers should be placed beneath the chassis of the unit and it
should be guided to the position of installation. Under no circumstances, should the
weight of the unit, be borne on the control panel, or other structural members.
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CHAPTER 6: BOILER HOUSE
The REVOMAX / REVOMAX PLUS is a compact and lightweight unit, it can be installed
anywhere in the plant. The minimum space required is indicated in drawing no.060400.
However, if a new boiler house is planned, drawing RXD 060600 indicates schematic
layout of the boiler house. Install the unit on a raised foundation of about 100 mm. The
raised foundation prevents any oil or water spillage remaining under the unit. The raised
foundation must be cast out of non-combustible material like concrete and properly
leveled. Also, refer the General Arrangement - Terminal points and Foundation Details
Drawing.
The front clearance is provided to allow adequate room for movement, operation and
maintenance. On one side, more space is provided for lowering the coil on the floor. The
I-Beam shown in the above mentioned drawing should be fixed exactly over the center of
the boiler shell. A hand operated chain pulley block with a travelling trolley of capacity
mentioned for various models should be mounted on the I-Beam. The size of the I-Beam
and capacity of the chain pulley block are indicated as a guide. If the span is longer,
structural engineers should be consulted. An electrical hoist with a travelling trolley is
recommended for quicker and easier operation.
The vertical clearance required above the boiler for coil removal is also indicated.
Distance "H" as indicated in the drawing depends on the type of the lifting device
proposed to install. If sufficient height in the boiler house is not available, shifting the
entire boiler to a place with adequate vertical clearance may be considered. Coil removal
in such a case can be done with the help of a tripod and chain pulley block. Alternatively,
a trap door can be provided in the roof and an I-Beam can be fixed above it for lifting the
coil. This however, is an exception. Generally, an I-Beam and a chain pulley, as shown
in the drawing, are preferred.
The boiler house should be properly ventilated, preferably by large windows on all
sides. It is to be noted that in case of artificial ventilation, extraction of air by
exhaust fans is not recommended as this creates negative pressure in the boiler -
house, which may be detrimental to the proper operation of the unit.
Make sure that while installing the boiler, regulations of Fire Insurance Association, etc.
are strictly adhered to.
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CHAPTER 7: CERTIFICATE FOR NIBR (NON – IBR) BOILERS UNDER

‘SMALL INDUSTRIAL BOILERS’
As per the Indian Boilers Act, 1923, and Indian Boilers Regulations, 1950 issued by
Government of India, Ministry of Works, Mines and Power-Central Boilers Board, as per
sub – section (2) of section 3 of Indian Boilers (Amendment) Act, 2007, definition of
boiler has been amended as under Dated 1st April 2010.
‘Boiler’ means a pressure vessel in which steam is generated for external use. NIBR
boilers include pressure vessels –
1) With capacity less than 25 liters (such capacity being measured from the feed
check to the main stop valve).
2) With less than 1 kg /cm2 design gauge pressure or working gauge pressure. OR
3) In which water is heated below 1000C.
Boiler Act clarifies that if a pressure vessel falls in any one of the clauses 1, 2 or 3 of sub
– section (2) of section 3 of Indian Boilers (Amendment) Act, 2007, then it is not to be
treated as an IBR Boiler.
The Revomax series boilers are ‘Non IBR Small Industrial Boiler’.
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CHAPTER 8: FUEL STORAGE & HANDLING
8.1 Fuel Storage Formalities (Applicable for OIL fired units only)
The Department of Explosive prohibits the storage of fuel oil inside the boiler house, if it
exceeds 1000 liters. The following procedures should be followed for storage of fuel oil:
A. Tank below 4546 Liters (1000 Gallons):
No formalities required, if the storage tank is erected outside.
B. For storage more than 4546 Liters but less than 45460 Liters (10000 Gallons).
No Storage license is required but prior approval of the Controller of Explosive

should be obtained. For this purpose, three copies of layout plan showing the
proposed plan should be sent to the Controller of Explosives of your area. They
will return one copy duly signed in token of approval and only then the installation
of the tank should be carried out as per the approved plan.
While preparing the plan for the installation of the tank, the following precautions
should be taken:
1. There should be no structure within 10 feet from the tank.
2. Entire area has to be fenced with 4 1/2 feet barbed wire.
3. The tank has to be installed in an earth pit and the top area should be covered
with 9" thick and 6" high kerbing.
4. There should be no structure within a radius of 15 feet from the fill point on tank
lorry unloading platform.
5. Fill pipeline, suction pipeline, rotary gear or hand operated pump, vent pipe, dip,
etc. should be clearly shown.
6. In one corner of the plan, the cross-section of the tank should be shown with
fabrication details.
7. In another corner, the site plan of the factory showing the tank and entire pipeline
should be shown.
8. In case a tank is proposed above ground, apart from the above regulations, the
following additional measures should be adopted:
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The tank should be fitted on a proper pedestal.
An enclosure wall has to be built around the tank which should not be less than 5
feet away from the tank. The height of such a wall will depend on the capacity of
the tank. It should be high enough to contain all the fuel in the tank in case it leaks
out of the tank.
There should not be any structure within 10 feet from the enclosure wall.
C. For storage over 45460 Liters (10000 Gallons)
A Storage License should be obtained from the Explosives Department. For this
purpose, an approval should be obtained from the Controller of Explosives as per
the details given above. Simultaneously, an application should be made to the
District Magistrate with five copies of the plan for "No Objection Certificate". Only
after this certificate is obtained, the installation should be carried out as per plan.
The Storage License will be issued after the application is submitted in "Form D"
along with the original No Objection Certificate, Safety Certificate from the
suppliers and the Storage License Fees.
For your guidance, a model layout plan for the installation of a tank has been
attached (Refer Model Drawing) which will be helpful in preparing the plan.
INSTALLATIONS CARRIED OUT WITHOUT OBSERVING THE FORMALITIES -

MENTIONED ABOVE ARE LIABLE FOR PROSECUTION.
Fuel suppliers should be consulted for the mode of installation and storage of the
fuel storage tank. Fuel from this tank should be pumped by a hand oil transfer
pump or by an electrically driven gear oil transfer pump into the fuel oil service
tank. The gear pump installed should have an output capacity of 2000 Liters/hr
against 50 psi delivery pressure.
The pump may be installed either inside or outside the boiler house. Oil
companies should be consulted for selection of the size of the pipe from storage
tank to the service tank. In any case, the diameter of this pipe should not be less
than 40 mm.
IT IS IMPORTANT THAT ALL OIL PIPES ARE OF M.S. BLACK CLASS "C"AND
NEVER OF G.I. The Sulphur in the oil corrodes the Zinc in the G.I. pipes.
8.2 Boilers Working on Light Diesel Oil (LDO/HSD)
A typical arrangement for fuel oil storage and supply to the unit is shown in Drawing No.
RX/060700. The fuel service tank should have a hinged or tight lid, a vent, a drain with a
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valve, an overflow and a calibrated level indicator. The outlet from the service tank
should be 100 mm (4") above the bottom level of the tank. One mesh type filter of 80 x
80 mesh must be provided just at the outlet of the main storage tank. A separate filter
has been provided at the inlet of the fuel pump. Recommended capacities of oil service
tanks are given in Table I.
Where the ambient temperature is below 20°C, an outflow heater should be provided in
the tank to heat the out flowing oil to about 30°C. For this heater, a pipe of about 150
mm (6" NB) is welded to the tank and the oil flows out from bottom of this heater pipe.
8.3 DETAILS:
A typical arrangement for FO storage and supply to the unit (applicable for RXD units)
is shown in Drawing No. RX/060700. A horizontal cylindrical furnace oil storage tank with
enclosure wall, etc. should be erected at a minimum distance of 6.1 meters (21 feet)
from the boiler house. The tank can be placed underground.
The FO service tank should have a hinged or tight lid, a vent, a drain with a valve, an
overflow and a calibrated level indicator. The outlet should be about 100 mm (4") above
the bottom level of the tank.
An outflow heater (in the service tank) and line heaters (or heating cords) should be used
to maintain a temperature of 40°C throughout the fuel line as shown in Drawing No. I-
V/010901. A strainer or mesh type filter of 80 mesh must be provided in the pipe line
near the outlet of storage tank. In the case of units operating continuously for 24 hours,
an additional filter may be provided in the line parallel to the one of the unit, with
necessary valves, so that one filter will always be in operation while the other one can be
cleaned and kept ready. A similar filter is also recommended at the filling point which can
prevent dirt being carried into the tank.
Two types of outflow heaters are shown:
8.3.1 Electrical Heating (applicable for RXD units)
A pipe of about 150 mm (6" NB) is welded to the tank and the oil supply pipe is taken at
the bottom of this pipe. An electric immersion type single phase heater with a thermostat
is inserted in the pipe. Capacity of this heater depends on the model of the unit and
should be at least 3 kW.
The thermostat is to be set to about 60°C. For details of this type of heating
arrangement, please refer Drawing No. I-V/011001. An electric heating cord should be
used to heat the oil in the pipe from the tank to the boiler. For pipe lengths of less than
20 feet, heating cords of 220 V AC, 2 kW capacity should be wound. For longer pipes,
the cords should be of 3 kW capacity.
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___________________________________________________________________
8.3.2 Steam Heating (applicable for RXD units)
In case steam is available, tap out a small amount of steam from the steam pipe line by
a 1/2" NB pipe. Connect the pipe to the heater steam inlet through a 1/2" solenoid valve.
Electric supply for the solenoid valve should be given through a thermostat fitted on the
heater. The solenoid valve will remain open as long as the temperature of outgoing fuel
is less than the present temperature, i.e. 45°C. The outlet of the steam heating coil
should be connected to a tracer pipe of 1/2" NB running along the pipe, touching the fuel
pipe lines from the service tank to the fuel filter on the unit. This will keep the fuel hot as
it flows to the unit. It will be especially useful in case the fuel in the pipeline becomes too
viscous to flow in periods of shut down in cold weather. A steam trap should be fitted at
the end of tracer pipe. The tracer pipe and the fuel pipe then may be lagged together for
better heat transfer. For details of this type of heating arrangement, please refer
Drawing. No.I-V/011101.
As the steam requirement is very small, a steam outflow heater is preferable to an

electric heater. The return line also has to be heated similarly to prevent the fuel from
cooling down. The recommended capacities of fuel storage tanks and service tanks are
shown in Table I.
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___________________________________________________________________
TABLE - I
Capacity of fuel oil storage tank should be sufficient to contain fuel requirement for 10
days.
Operation Fuel Consumption for 10 Days

RXA - 02 RXA - 03 RXA - 04 RXA - 05 RXA - 06
LDO LDO LDO LDO LDO
Lit. lit lit. lit lit.
8 hrs/day 1120 1650 2210 2760 3320
16 hr/day 2230 3310 4410 5530 6630
24 hr/day 3350 4970 6630 8290 9930
Operation Fuel Consumption for 10 days

RXD - 04 RXD - 06 RXD - 850
FO LDO FO LDO FO LDO
lit. lit lit. lit lit. lit
8 hrs/day 2200 1800 3300 2700 4550 3850
16 hr/day 4350 3600 6550 5400 9050 7650
24 hr/day 6550 5600 9800 8100 13550 11450
Capacity of fuel oil storage tank should be sufficient to contain fuel requirement.
Operation Daily Consumption

RXA - 02 RXA - 03 RXA - 04 RXA - 05 RXA - 06
LDO LDO LDO LDO LDO
lit. lit lit. lit lit.
8 hrs/day 112 165 221 276 332
16 hr/day 223 331 441 553 663
24 hr/day 335 497 663 829 993
Operation Daily Consumption

RXD - 04 RXD - 06 RXD - 850
FO LDO FO LDO FO LDO
lit. lit lit. lit lit. lit
8 hrs/day 220 180 330 270 455 385
16 hr/day 435 360 655 540 905 765
24 hr/day 655 560 980 810 1355 1145
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CHAPTER 9: GAS TRAIN

FUNCTION OF GAS TRAIN
1. Reducing the inlet pressure of the gas so that required amount of the gas is
allowed into the furnace at a pressure to ensure good quality of combustion.
2. To have control over the amount of fuel entering into the furnace.
To safeguard the downstream burner components that can only withstand lower
pressures of gas.
Following are the basic parameters required for selection of Gas Train.
A. Type of gas : Natural Gas / LPG
B. Flow rate : In Nm3/hr
C. Inlet gas pressure (Pe) : 1 – 2 bar (g) or 100 – 500 mbar (g)
D. Pressure at outlet of : Desired gas pressure (mbar)

gas train (Pa)
E. All gas train components are to be sized for 1 bar (g) operating pressure. Effect
of temperature variations is neglected while selecting the Gas Train. And pipe
lines to be designed for 10 kg/cm2 pressure.
References used for preparing guidelines.
a. BS 5885 – Part I : Automatic gas burner

b. Canadian gas association std (CGA)
c. Krom Schroder
1. Any Gas train composes of two sections.
A] Gas Pressure Reducing Station.

B] Gas Control Section.
A] Gas Pressure Reducing Station consist of
1. Manual Ball Valve – AKT

2. Gas Filter – GFK
3. Pressure Gauge (Inlet) – RFM
4. Safety Shut Off Valve – KSAV, VSAV
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___________________________________________________________________
5. Gas Governor – VGBF or J125-S5
6. Safety Relief Valve – VSBV
1. Pressure Switch – DG
2. Upstream Solenoid Valve – VG
3. Downstream Solenoid Valve – VG
4. Pressure Gauge (Outlet) – KFM
NOTE: Item no - 4 & 6 are not given, if Gas governor model is J125-S5.
2. PILOT GAS TRAIN (Wherever applicable to RXD 850)

2. Gas Governor – VGBF, GBF
3. Solenoid Valve – VG
Gas Pressure Reducing Station
Manual ball valve is used for isolation or shutting off gas supply to the gas train.
The ball valve size is selected on the basis of velocities in the range of 20 – 25
m/s through ball valve. Generally, size of ball valve, gas filter and gas governor
should be same. It is recommended to use threaded connections up to 25 NB and
flange connections from size 40 NB and onwards.
DIN Standard: DIN 3537 Part I.
2. Gas Filter – GFK
Gas filter is given for filtration of fuel gas supply to all gas consuming appliances.
It protects devices downstream of gas train against clogging / blocking. Selection
of gas filter is based on the maximum pressure drop across the filter at operating
flow rate. While reading the diagram, one must apply operating cubic meters.
Read the pressure drop from graph and multiply this by absolute pressure of inlet
gas. This pressure drop should not exceed 10 mbar but in boundary cases, it can
be extended up to 15 mbar.
3. Pressure Gauge (Inlet) – RFM
The pressure gauge should be selected suitable for indicating inlet operating
pressure. Isolation valve is to be provided for isolation of pressure gauge.
_______________________________________________________________

___________________________________________________________________
4. Safety Shut Off Valve – KSAV, VSAV
This valve is required for the protection of all supply and gas consuming devices
connected downstream of a governor against a too high or too low pressure. The
gas supply is cut off in case of unfavourable operating conditions. It is
recommended to install safety shut off valve for plants having inlet gas pressure
more than 100 mbar. Also, when the downstream components of the gas train are
sized for maximum inlet pressure, then shut off valve is not required.
Normally, safety shut off valve is set at 30% over the outlet gas pressure of gas
governor. The sensing line tapping for safety shut off valve is to be taken from a
point > 5 DN. Valves above size DN 80 are to be installed in horizontal position
only.
5. Gas Governor – VGBF or J125-S5
Gas governor maintains constant outlet pressure for any inlet pressure of gas. It
takes care of inlet pressure fluctuations while maintaining outlet pressure
constant.
The pressure reduction in Gas governor is accomplished by two simultaneous

activities viz. Permanent pressure drop across the governor and Regulation by
plunger movement of governor. Movement of plunger is governed by diaphragm
movement.
The recommended permanent pressure drop for a governor is 50% of inlet gas
pressure. However, when dealing with low-pressure gas services, permanent
pressure drop should be less and pressure reduction should be achieved by
regulation only. After arriving at a particular governor size, check that this line size
corresponds to the gas filter and ball valve size. This may not be the case when
we are dealing with low-pressure application. Add all the pressure drops on
downstream components of the governor viz. Solenoid valves, burner and
furnace. Select the spring so that the desired governor outlet pressure lies in this
spring range. The sensing line tapping for gas governor is to be taken from a point
> 5 DN. The fitting position for gas governor is irrelevant of position.
The model J125-S5 incorporates two safeties in built. OPSS i.e. over pressure
Slam Shut in which gas supply will be cut of to Gas governor in case inlet
pressure to gas governor exceeds its design pressure. This will ensure that PRV
& subsequently downstream components will not be damaged. This safety is
similar to Safety Shut off Valve – KSAV, VSAV.
The other safety is Limited Capacity relief which functions like Safety Relief Valve
VSBV.
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___________________________________________________________________
6. Safety Relief Valve - VSBV
This valve is used to reduce temporary pressure surges in the control system,
especially upstream of burner in order to avoid accidental operation of safety shut
off valve and also to avoid sudden pressure increase in the case of gas leakage
due to gas governor not closing tightly. This valve is recommended for all gas
pressure regulating plant with inlet pressure more than 100 mbar. When operating
pressure is upped 100 mbar, then the spring retaining dome must point up. Above
100 mbar, the fitting position is arbitrary. The normal setting of this valve is 15%
above the governor outlet pressure. This valve is available only in size DN 25 i.e.
AKT 25 is recommended for isolation of relief valve during annual testing.
1. Pressure Switch – DG
Pressure switch is provided to take care of high pressures in the downstream of
governor due to abnormal operation of regulator, relief valve. The pressure switch
setting can be typically 20% above the Gas Governor outlet pressure which is
used in the safety circuit of sequence controller.
2 Upstream Solenoid Valve – VG

This upstream solenoid valve along with downstream solenoid valve and relief
solenoid valve forms the Block & Bleed system. This system ensures that there is
no entrance of gas into burner when upstream solenoid valve is leaking. The relief
solenoid valve is normally open type, whereas upstream and downstream
solenoid valves are normally closed types. The two solenoid valves are provided
for avoiding the hazards when one fails to operate. Out of two main gas solenoid
valves, the upstream solenoid valve should be quick opening and quick closing
type.
3. Downstream Solenoid Valve – VG

This valve is similar to upstream solenoid valve but this valve is with damping
device, which means, slow opening and quick closing. During operation, when
upstream solenoid valve opens, gas rushes towards the burner at high speed and
if downstream solenoid valve is also of fast opening type, then there will be
sudden blast of gas on to the burner resulting in extinguishing the flame. To avoid
this, the downstream solenoid valve is slow opening and fast closing type.
4. Pressure Gauge (Outlet) – KFM

The pressure gauge should be selected suitable for indicating gas governor outlet
pressure.
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___________________________________________________________________
PILOT GAS TRAIN
(APPLICABLE FOR GAS BURNER OF CAPACITY HIGHER THEN 0.7 MW)
The pilot gas train is meant for ignition of main gas line. The criteria for giving pilot line
depend on burner design. The pilot gas train size should be maintained as DN 15. The
intake for pilot line can be from a point after the main gas governor.
Pilot Gas Train consists of:
i. Manual Ball Valve – AKT
ii. Gas Governor – VGBF, GBF
iii. Solenoid Valve – VG
The selection of above components is in line with Main gas line components.
For low pressure (100 - 500 mbar) gas train contains following main components:
1. Ball Valve
2. Gas Filter
3. Pressure Governor
4. Multi block
5. Pilot Gas Train.
Multiblock (Double Solenoid Valve):

Multiblock integrates two solenoid valves in one compact fitting. It is an automatic shut
off valve with double seat. Maximum operating pressure of multiblock is upto 0.5 mbar
depending on the model being selected.
Among the two valves, first solenoid valve is quick opening – quick closing which is
installed from gas supply side. Second valve installed after first one is slow opening –
quick closing. Dampening is provided in this valve, which allows slow opening.
Gas flow can be controlled or adjusted via slow opening solenoid valve. Flow is
increased or decreased by loosening the top cover screw and rotating the top cover
anticlockwise and clockwise direction respectively. Whenever the burner trips or shuts off
or power failure occurs, the spring provided inside both the valves immediately closes
them tightly and thus stops the gas flow and it’s accumulation into furnace. Both the
valves are of normally closed type.
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CHAPTER 10: WATER SUPPLY
A typical water supply arrangement to the boiler is shown in Drawing No RX/060500. A

suitable water treatment plant (with Softener and chemical doser) is required for
treatment of feed water to the boiler.
For the details of Water Softener and Doser, please refer the irrespective manuals.
It will be necessary to install a raw water storage tank at a suitable height. The
centrifugal water pump should have discharge capacity between the specified maximum
and minimum treatment flow and should be capable of developing the pressure specified
in the Water Softener manual. The pump will have to be run as and when required to fill
up the Soft Water Service tank.
The soft water service tank should be installed at an elevation of at least 4 meters and
should have a hinged or bolted cover, an air vent, a float valve, a water level gauge glass
(preferably calibrated). A drain is required at the bottom (with a valve). An overflow pipe
should be connected to the main drain. The outlet pipe from the soft water service tank
should be taken at a height of about 100 mm (4") from the bottom level of the tank so
that sediments collected at the tank bottom do not flow to the boiler.
A level switch is recommended on the soft water tank to regulate the pump operation, so
that it starts and stops automatically.
The elevated soft water service tank and correctly sized suction piping with a minimum of
pipe fittings will reduce the possibility of cavitation in the feed water pump. The minimum
sizes of suction piping are given in Table-I.
Cavitation is a destructive phenomenon which may occur in positive displacement

pumps during the suction stroke. The point at which water boils is determined by
combination of its temperature and absolute pressure. Feed water at a particular
temperature may flash into steam if the absolute pressure reduces too much. Minute
steam bubbles form and as they are carried to the pressure side of the pump, they
collapse. This produces a hammer effect which reflects through various pump parts and -
causes mechanical destruction of these parts. Pump operating with cavitation will show
reduced output and in severe conditions, will run dry. Because of its destructive effect
cavitation must be avoided. This is done by supplying feed water with sufficient suction
head.
WHEN USING CONDENSATE RETURN, IT IS ABSOLUTELY NECESSARY TO

ENSURE THAT IT IS AS PER THE FEED WATER SPECIFICATIONS. ALSO ENSURE
THAT FEED WATER TEMPERATURE DOES NOT EXCEED 40°C.
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___________________________________________________________________
10.1 Flow sensor: (Only applicable for RXD 850)
In view of increased possibility of tube choking because of less tube inner dia, a special
instrument called flow sensor has been added in water circuit. This has to be mounted
on softener outlet line which goes to soft water tank. Flow sensor keeps on sending
signals to control panel based on the volume of water passed through it. After preset
volume of soft water has been passed through flow sensor (FS), audio alarm (hooter) will
come. This is caution alarm which indicates that softener is due for regeneration. Two
set points can be set through flow sensor. One is at 80% it means after 80% volume
boiler will give visual indication as well as alarm, giving a message to recharge softener.
The other set point will be set at 100% which means after 100% volume is passed it will
trip the boiler. Unit of both set points is 1000 liters. After caution alarm, boiler will run for
some more time based on the difference in settings of trip & caution alarms. During this
period, if softener is not regenerated, boiler will trip and go into lockout and boiler will not
restart until flow sensor is reset.
In case of failure of flow sensor, after replacing new flow sensor, new scale factor in ml
per second to be keyed in flow sensor.
The capacity of the soft water storage tank should be selected such that about 3 hours is
required to regenerate the water softener. The capacity of the soft water tank should, -
therefore, be equivalent to the capacity of the boiler at full load for three hours at least.
Table I gives recommended capacities of soft water service tanks.
On sending two liters of raw water sample, analysis is carried out by THERMAX
LIMITED at nominal charges. Recommendations on water treatment are also given
along with the analysis report.
TABLE 1
Soft Water Storage Tank
Water consumption Recommended Nominal suction

Model Boiler for 2 hours tank capacities line size (mm)
operation LTRS LTRS
RXA-02 400 500 25
RXA-03 600 800 32
RXA / RXD -04 800 1000 32
RXA-05 1000 1200 40
RXA / RXD -06 1200 1600 40
RXD-850 1700 2100 40
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CHAPTER 11: CHIMNEY
In view of pollution hazards, a chimney to discharge the products of combustion is

required. The minimum height of the chimney should be above the highest point of the
building. Local Environmental Control Regulations must be observed in deciding upon
minimum height of chimney.
Three different arrangements for installation of the chimney are indicated in Drawing
Nos. RX/060800, RX/060900 and RX/061000. The inside diameters of the chimneys are
also indicated.
As shown in Drawing No. RX/060800, all the connections should be with flanges and
bolts. The short distance piece can be removed when required without disturbing the
main chimney, the boiler, the boiler house wall or neighboring machines. The piece
above it is supported from the wall with a conical hood to divert rainwater. Any other
suitable method of supporting the main weight of the chimney stack either on structure or
by stay rods fixed on the ceiling would be in order.
Drawing No. RX/060900 shows a chimney with an angle piece, across connection and a
main stack. The angle piece connections have the same diameter but the main stack has
to be of a larger diameter to enable proper welding of the cross- connection. The main
stack is shown erected on ground outside the boiler house with proper foundation bolts.
Guy ropes, not shown in the drawing, may be used, if required for structural design.
The cross-connection is shown at an angle of 45° which is strongly recommended. A

lower angle up to 30° may be accepted. An angle smaller than 30° would affect boiler
performance. Also note that cross-connection should not be very long.
Drawing No. RX/061000 shows the cross-connection and the rest of the chimney stack
clamped to the wall. In this arrangement, the flue gases have to flow through two angles,
each at 45° as shown.
Drawing No. I-V/010200 shows the top hood of the chimney. Note carefully the
dimensions specified. The vertical clearance of 2/3D ensures a free flow of flue gases.
The hood diameter of 2D prevents entry of rain water into the chimney.
Chimney of smaller diameter, chimney with more than two bends or chimney with long
cross-connections should not be used.
_______________________________________________________________

___________________________________________________________________
THE CHIMNEY DIAMETER SHOULD NOT BE LESS THAN STATED BELOW.
MIN. CHIMNEY TOP DIAMETER (ID)

(MM)
RXA-02 180
RXA-03 225
RXA / RXD -04 250
RXA-05 275
RXA / RXD -06 300
RXD - 850 350
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CHAPTER 12: ELECTRICAL POWER SUPPLY
Three phases, 415 volts and 50 cycles/second A.C. electric supply with neutral is
required for operating the boiler. Terminals 1, 2, 3, N on panel board terminal strip of the
boiler indicate the three phase supply and neutral connection points respectively. The
supply to the boiler should be given through a main switch having capacity matching the
total connected load given in the Technical specifications. The capacity of the back up
fuses should be as per the Table given.
No extra starters or switches are required for the motors in the boiler. The control panel
board is pre-wired. A four core copper conductor cable may be used as indicated in the
Table or any other suitable conductor may be used which is capable of with standing the
current.
Earthing of control panel and motors are absolutely necessary.
An earth wire of adequate cross section must be provided to connect the boiler to a
suitable earth-plate.
BACKUP FUSE CAPACITY INCOMING CABLE SIZE

MODEL
(AMP) (SQ. MM)
AL CU
RXA-02 20 2.5 2.5
RXA-03 20 2.5 2.5
RXA-04 20 2.5 2.5
RXA-05 25 2.5 2.5
RXA-06 25 2.5 2.5
BACKUP FUSE CAPACITY INCOMING CABLE SIZE

MODEL
(AMP) (SQ. MM)
AL CU
RXD-04 25 4.0 2.5
RXD-06 32 4.0 4.0
RXD-850 32 4.0 4.0
NOTE:
If there is a voltage fluctuation of more than 6%, install a voltage stabilizer of 1

kVA in the control circuit.
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CHAPTER 13: DRAWINGS
SR.NO. DESCRIPTION OF THE DRAWING
1. MINIMUM CLEARANCE AROUND UNIT AND HEIGHT REQUIRED TO

REMOVE COIL
2. SCHEMATIC INSTALLATION OF REVOMAX /REVOMAX PLUS BOILER
3. FUEL OIL STORAGE AND SUPPLY ARRANGEMENT
4. FEED WATER SUPPLY ARRANGEMENT FOR REVOMAX / REVOMAX

PLUS BOILER
5. CHIMNEY FOR REVOMAX/REVOMAX PLUS CONNECTED

VERTICALLY ON TOP
6. CHIMNEY WITH CROSS CONNECTION AND MAIN STACK WITH BASE

PLATE ON GROUND
7. CHIMNEY WITH CROSS CONNECTION AND MAIN STACK CLAMPED

TO WALL
8. CHIMNEY HOOD
9. OIL BURNER SETTING
10. SCHEMATIC ARRANGEMENT OF GAS BURNER
11. ELECTRIC / STEAM PRE-HEATER FOR HEATING OUTFLOW OF F.O.

SERVICE TANK
12. STEAM COIL HEATER FOR HEATING OUT FLOW OF F.O. SERVICE
TANK
13. DESCALING PROCEDURE
_______________________________________________________________

___________________________________________________________________
FIG. 1. MINIMUM CLEARANCE AROUND UNIT &

HEIGHT REQUIRED TO REMOVE COIL
_______________________________________________________________

___________________________________________________________________
FIG. 2. SCHEMATIC INSTALLATION OF REVOMAX / REVOMAX PLUS BOILER
_______________________________________________________________

___________________________________________________________________
FIG. 3. FUEL OIL STORAGE AND SUPPLY ARRANGEMENT
_______________________________________________________________

___________________________________________________________________
FIG. 4. FEED WATER SUPPLY ARRANGEMENT FOR REVOMAX / REVOMAX PLUS

BOILER
_______________________________________________________________

___________________________________________________________________
FIG. 5. CHIMNEY FOR REVOMAX / REVOMAX PLUS CONNECTED VERTICALLY

ON TOP
_______________________________________________________________

___________________________________________________________________
FIG. 6. CHIMNEY WITH CROSS CONNECTION AND

MAIN STACK WITH BASE PLATE ON GROUND
_______________________________________________________________

___________________________________________________________________
FIG. 7. CHIMNEY WITH CROSS CONNECTION AND

MAIN STACK CLAMPED TO WALL
_______________________________________________________________

___________________________________________________________________
FIG. 8. CHIMNEY HOOD
_______________________________________________________________

___________________________________________________________________
FIG. 9. OIL BURNER SETTING
_______________________________________________________________

___________________________________________________________________
FIG. 10. GAS BURNER
_______________________________________________________________

___________________________________________________________________
FIG. 11. ELECTRIC / STEAM PRE-HEATER FOR

HEATING OUTFLOW OF F.O. SERVICE TANK
_______________________________________________________________

___________________________________________________________________
FIG. 12. STEAM COIL HEATER FOR HEATING OUT FLOW OF F.O. SERVICE
TANK
_______________________________________________________________

___________________________________________________________________
FIG. 13. DESCALING PROCEDURE
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___________________________________________________________________
SECTION 2
OPERATION MANUAL
FOR
REVOMAX BOILER
REVOMAX PLUS BOILER
(NON IBR)
MODEL : RXA – 02,03,04,05,06
RXD – 04, 06, 850
___________________________________________________________________________

___________________________________________________________________
CONTENTS
CHAPTER 1 OPERATING INSTRUCTIONS ............................................................................................... 2

1.1 BEFORE STARTING .................................................................................................................................. 2
1.2 SEQUENCE OF OPERATIONS - STARTING .............................................................................................. 3
1.3 RUNNING ATTENTION ............................................................................................................................. 4
1.4 SEQUENCE OF OPERATIONS - STOPPING ............................................................................................... 4
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COOLING & HEATING DIVISION 1 CD 34/177

___________________________________________________________________
CHAPTER 1 OPERATING INSTRUCTIONS
1.1 Before starting
1. Ensure that instructions given in the maintenance schedule have been followed.
2. Make sure that the boiler feed water is:
a) hardness < 5 ppm

b) pH 8.5 to 9.5
c) O2 Nil
3 It is recommended that the water softening test to be carried out after every four
hours of operation. If results of softening test are unsatisfactory, regenerate the
water softener immediately.
4 (a) For GAS fired unit: Ensure that gas is available at correct pressure. After that
open all necessary valves in the gas train.
4. (b) For OIL fired unit: Ensure that fuel temperature controller setting in accordance
with the viscosity of 5 to 10 CST.
5. Ensure that steam temperature controller setting is not altered. The knob pointer
should be set 10°C above the saturation temperature of steam. (Saturation
temperature at 10.54 kg/cm2g is 185°C).
6. Ensure that the drain valve of economiser, fuel strainer drain valve and the coil
blow down valves are closed.
Before starting the unit ensure that soft water service tank and fuel service tank have
sufficient quantities of water and fuel. Also ensure that all electrical connections are in
proper condition and no safeties are short-circuited.
SHORT CIRCUITING OF ANY SAFETY DEVICE CAN CAUSE SEVERE DAMAGE TO

THE UNIT.
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___________________________________________________________________
1.2 Sequence of operations - STARTING
1. Open the valves on water, fuel or gas supply line.
2. Put the electric main switch ON. Observe that the display comes ON.
3. Press the OPH HEATING KEY to start fuel pre-heating. Press oil circulation key
to heat up and circulate the fuel till nozzle tip and fuel return line. Observe the
fuel temp indicator. This heating takes about 20-30 minutes. (Applicable for FO
fired units).
4. Close the main steam valve and open the auxiliary steam valve to prevent water
entering process steam lines initially.
5. Press the FILL key on, to fill up the coil.
6 When water starts coming out of the auxiliary steam valve and after fuel
temperature has crossed the minimum required temperature, the unit can be fired.
7 (a) For GAS fired unit
Put the fire switch ON. Blower and water pump starts. Sparking between burner
electrode begins and gas solenoid valve gets open after 6 – 10 sec. This pre-
purging is done to drive out any combustible gases that may be present in the
furnace.
7. (b) For OIL fired unit
Put the FIRE switch on. Blower, fuel pump and water pump will start. Sparking
between burner electrodes begins, and fuel is sprayed after prepurge timing. This
"pre-purging" is done to drive out any combustible gases that may be present in
the furnace.
8. Green lamp glows, indicating BURNER ON, fuel spray or gas flow starts and
flame is established. Sparking stops when flame is established and heating of
water in the coil starts.
9. In about 3 - 5 minutes steam is seen coming out of the auxiliary steam valve.
After pressure starts increasing, open the main steam stop valve gradually and
close the auxiliary steam valve simultaneously.
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___________________________________________________________________
1.3 Running attention
It is advisable to check the following points occasionally while the unit is running.
1. Water softness after every four hours of operation of the boiler or more frequently,
if required. If water in the soft water service tank is found to be hard at any time
during the operation of the boiler, stop the boiler immediately. Drain the soft water
service tank. Regenerate the water softener. Fill the tank with fresh soft water
and then restart the boiler. THE BOILER SHOULD NEVER BE WORKED WITH
HARD FEED WATER.
2. Whether any excessive sound is coming from the motors or elsewhere.
3. That all valves and joints are leak-tight.
4. That proper water flow and fuel flow or gas flow are maintained.
5. That the flame is steady and golden yellow in colour. Reddish flame indicates that
air supply is insufficient.
6. That the exhaust from the chimney is almost colourless.
7. That the boiler stops and starts smoothly without excessive vibrations or smoke.
8. That flue gases are not leaking through the sight glass or the soot cleaning
access door.
1.4 Sequence of operations - STOPPING
1. Close the steam stop valve fully. The pressure switch will cut off the burner due
to high steam pressure.
2. Switch the FIRE key to FILL mode.
3. Open the coil blow down valve fully and blow down the boiler. Measure blowdown
time. Close the blow off valve and open the auxiliary steam valve fully. Drain the
economiser by keeping its drain valve open till clear water starts coming out.
4. Fill up the coil with water for the next day's operation (filling the coil with soft and
treated water minimize oxidation and rusting). After fill up of coil or when steam
temperature indication falls below 90°C, press the FILL key to switch off. Close
the auxiliary steam valve.
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___________________________________________________________________
5. Put off the HEATER by pressing the key. (Applicable for FO fired untis).
6. Put off the electric main switch.
7. Clean any dripped oil, water, etc. from the unit.
8. Close the outlet valves of soft water service tank and fuel oil service tank or main
gas supply.
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___________________________________________________________________
SECTION 3
MAINTENANCE MANUAL
FOR
REVOMAX BOILER
REVOMAX PLUS BOILER
(NON IBR)
MODEL : RXA – 02,03,04,05,06
RXD – 04, 06, 850
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CONTENTS
CHAPTER 1: MAINTENANCE SCHEDULE............................................................................................... 2

1.1 MEASURING FUEL CONSUMPTION ............................................................................................ 2
1.2 MEASURING BLOW DOWN TIME ................................................................................................ 3
1.3 WATER.............................................................................................................................................. 3
1.4 FUEL ADDITIVES (APPLICABLE FOR FURNACE OIL) ....................................................................... 3
1.5 TRAINING......................................................................................................................................... 4
1.6 LOG BOOK........................................................................................................................................ 4
1.7 SPARE PARTS .................................................................................................................................. 4
1.8 ROUTINE MAINTENANCE SCHEDULE....................................................................................... 5
1.9 OVERHAULING CHECK LIST ....................................................................................................... 6
CHAPTER 2: SETTINGS AT THE TIME OF COMMISSIONING.......................................................... 7
CHAPTER 3: TROUBLE SHOOTING ........................................................................................................... 8

3.1 FUEL SYSTEM ................................................................................................................................. 8
3.2 WATER SYSTEM ............................................................................................................................. 9
3.3 ELECTRICAL SYSTEM: ................................................................................................................ 10
CHAPTER 4: DO'S AND DON'TS .............................................................................................................. 11
4. 1 WATER SYSTEM ........................................................................................................................... 11
4.2 FUEL SYSTEM ............................................................................................................................... 11
4.3 ELECTRICALS ............................................................................................................................... 11
4.4 UNIT ................................................................................................................................................ 12
4.5 GENERAL REQUIREMENT .......................................................................................................... 12
CHAPTER 5: MAINTENANCE OF BOILER AND ITS PARTS.............................................................. 13
5.0.1 Opening and cleaning the boiler ............................................................................................. 13
5.0.2 Removing the Coil..................................................................................................................... 13
5.0.3 Reassembly ............................................................................................................................... 13
5.1 FEED WATER PUMP ..................................................................................................................... 14
5.1.1 Construction............................................................................................................................... 14
5.1.2 Maintenance .............................................................................................................................. 14
5.2 FUEL PUMP .................................................................................................................................... 15
5.3 BURNER ASSEMBLY.................................................................................................................... 15
5.4 BLOWER ......................................................................................................................................... 16
5.5 OIL FILTER ..................................................................................................................................... 16
5.6 ECONOMISER ................................................................................................................................ 16
5.7 HEAT OPTIMISER ......................................................................................................................... 17
CHAPTER 6: DESCALING .......................................................................................................................... 18
6.1 SYMPTOMS OF A SCALED COIL ................................................................................................ 18
6.2 DESCALING PROCEDURE........................................................................................................... 18
CHAPTER 7: SPARE ITEM LIST .............................................................................................................. 21
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CHAPTER 1: MAINTENANCE SCHEDULE
The performance of a REVOMAX / REVOMAX PLUS depends greatly on the

maintenance carried out. The unit, fuel and water pipe lines, filters, etc. should be
kept clean. In the following pages, the list of maintenance activities with
cleaning/checking frequency and overhauling check list are explained.
1.1 MEASURING FUEL CONSUMPTION
For FO fired (RXD) unit
• Fuel consumption should be checked periodically, as it may change due to

change in properties of fuel, wear of the nozzle, etc.
• Take a metal tin of about 5 to 10 lit. capacity. Its opening at the top should
not be very large. Weigh it with minimum accuracy of 0.1 kg. Put it on the
boiler top plate.
• Ensure that fuel temperature of 115°C has been attained. Keep a stop-watch
ready. Remove the photo-cell from its socket and the burner rod from the
guide pipe and put it in the tin.
• Put the FIRE switch on while holding the photo-cell in your fist. (Sequence
Controller does not proceed with firing sequence if the photo-cell senses light
before putting the FIRE switch on.)
• Start the stop-watch as soon as the BURNER ON lamp lights up.

Simultaneously release the photo-cell, so that it can sense light in the room.
• Put the FIRE switch off exactly after six minutes. Put back the burner rod and
photo-cell in place. Weigh the tin again.
• The difference in weight of the tin, multiplied by ten will give the fuel
consumption in kg/hr. If it is more or less than the rated consumption, reduce
or increase the fuel pressure slightly and measure the consumption again.
For gas fired unit
• The gas consumption mentioned in Technical specifications is at standard

ambient condition of 0°C & 1 atm pressure. This may vary according to
ambient condition on site. To check the gas consumption, gas flow meter can
be installed at the inlet of the gas train. Gas flow meter will measure the
actual gas consumed by the unit.
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1.2 MEASURING BLOW DOWN TIME
Blow down time gives an indication of the extent to which the coil tubes are scaled
up on water side. When blow down time exceeds twice the blow down time
measured at time of commissioning, the coil should be descaled.
1. Blow down time should be measured when boiler is hot, i.e. has run for at
least 20 - 30 minutes.
2. When the boiler is running, close the main steam stop valve. Pressure switch
will cut off the boiler. Steam pressure will now be above the rated pressure of
boiler.
3. Put the Fill-O-Fire switch in OFF position.
4. Open the blow down valve fully. Measure the time required for steam
pressure to fall from 10 kg/cm² to 2 kg/cm²g. This is the blow down time.
5. Close the blow down valve and open the by pass valve and cool coil by
putting the switch in FILL position.
1.3 WATER
It is necessary that only soft feed water is fed to the boiler. In order to maintain
water quality, adequate care of water softener should be taken. The instructions
given in the water softener manual should be strictly followed. The timings given for
back-washing, salt injection and rinsing should be strictly followed. The quality of raw
water can vary due to seasonal variations and, therefore, it is advised that raw water
(2 litres) is analysed in various seasons. This can be done by Thermax Limited,
Pune, at a nominal charge.
1.4 FUEL ADDITIVES (Applicable for Furnace Oil)
One of the main cause of erratic burner operation is the flow of contaminated fuel
into the fuel feed pipes. This can lead to choked strainers, partially clogged pipe
lines, excessive wear of the burner nozzle and damage to the fuel pump resulting in
unsteady combustion, back firing or complete blockage of burner.
Although fuel has some content of sediments and water even when supplied fresh,
further contamination can be retarded, if not eliminated, and burner operation can be
made less troublesome.
Use of some fuel additives is recommended. When added to fuel in a certain

proportion, these additives
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a. act as an effective sludge remover,
b. aid combustion,
c. keep the fuel system clean, thereby reducing maintenance of filters, heater,
burner nozzle etc.
d. act as inhibitors as far as Sulphur corrosion is concerned.
THERMOSOL ranges of fuel additives are available from Thermax.
1.5 TRAINING
Training is important to understand the product and its functioning completely and to
be able to carry out routine maintenance. Brief instructions are given to you by our
Service Engineers / Thermax at the time of commissioning. Thermax Service
Franchisee Engineers.
1.6 LOG BOOK
Log book format is shown below. It is suggested that log books are maintained
regularly and readings are recorded on an hourly basis so that deviations from
normal readings can be noted and attended to immediately.
1.7 SPARE PARTS
It is strongly recommended that essential spares be kept in stock to avoid idle time
due to unpredictable breakdowns, particularly in places which are far away from our
branches and not easily accessible. If there is any breakdown, it is better to replace
the defective component and repair it, if possible, at leisure, as replacement is faster
and easier. The list included at the end, may be followed.
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1.8 ROUTINE MAINTENANCE SCHEDULE

Sr.No Component Period of Cleaning / Checking
Specifications
Half
Daily Weekly Monthly Quarterly Yearly
yearly
1. Photo resistor/UV cell *

2. Feed water hardness *
3. Blow down *
4. Nozzle *
5. Pressure switches *
6. Bolts of all components *
(Pump, Blower, Motors)
7. All controllers *
8. Overload relays *
9. Strainers/Filters *
(Fuel & Water line)
10. Burner assembly *
11. Clean Economiser *
12. Feed water pump valve *
assembly
13. Fuel pump Coupling & *
Alignment
14. All valves *
15. Gaskets **
16. Refractory **
17. Chimney & its ducting **
18. Feed water pump **
overhauling
19. Combustion chamber **
20. General (refer separate
Check sheet)
Note:
1. The star mark (*) indicates when maintenance of the said above component to be done.
2. Double star mark (**) indicates overhauling.
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1.9 OVERHAULING CHECK LIST
Sr. Not Action Action

Activity Observation OK Remarks
No. OK Taken Proposed
1. Cleaning of coil /
jacket
2. Descaling
3. Inner / Outer
Jacket
4. Al. Radiator
5. Top refractory
6. Bottom refractory
7. Burner Assembly
8. Air / Wegman
cone
9. Hydraulic Test
10. Water feed pump
11. Fuel pump
12. Mountings and
valves
13. Water treatment
plant, check
resin, filters,
valves, etc.
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CHAPTER 2: SETTINGS AT THE TIME OF COMMISSIONING
Sr. Description Unit Reading Setting

No.
1. Steam - temperature controller °C
2. Fuel – temperature °C
3. Steam safety valve kg/cm²
4. Steam pressure switch kg/cm²
5. Water pump relief valve kg/cm²
6. Fuel pump pressure kg/cm²
7. Blower motor overload relay Amp
8. Water pump motor overload Amp

relay
9. Fuel pump motor overload relay Amp
10. Fuel consumption kg/hr
11. Water consumption kg/hr
12. Distance between flame cone mm

neck - diffuser plate
13. Blow down time from 10 kg/cm2 sec.

to 2 kg/cm2
14. Oil nozzle GPH
15. Water pump RPM
16. Gas inlet pressure Bar
17. Gas outlet pressure mbar
18. Pressure switch settings mbar
16. Water pump Motor RPM
17. Fuel pump motor RPM
FILL APPLICABLE BLANKS FOR OIL OR GAS.

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CHAPTER 3: TROUBLE SHOOTING
3.1 FUEL SYSTEM
1. "Burner On" lamp does not light after "Fire" switch is turned on.
- Photo-cell may be sensing external light. Check that it is properly fitted

in its socket and that the cap on top is in place.
- One of the fault indicating lamps may be on. Rectify the fault.
2. Burner On lamp lights and flame catches but the unit stops giving alarm.
- Photo-Register glass may be dirty, so it does not sense light.
- Electrical contacts of the photo-Resistor may be loose.
- Burner setting and/or air damper may be disturbed, and flame does not
sustain.
- Check fuel pressure and temperature settings.
3. Flame does not establish, in spite of fuel being sprayed in furnace.
- Check that sparking is taking place between electrodes. Remove the

burner rod, put the FIRE switch ON & see sparking. Clean the
electrode tips if necessary. (Sparking should not take place between
an electrode and diffuser plate). If flame still does not establish, check
burner setting with the burner gauge.
- Check that air damper setting is not disturbed. In some instances it

may be necessary to close the damper slightly while starting. (Restore
its original setting after the flame is established).
4. Fuel is not sprayed after BURNER ON signal.
- Check fuel pressure.
- Check that the burner solenoid valve (Solenoid Coil) is functioning. A

faint metallic click is heard when it operates.
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5. Fuel pressure does not develop.
- Check fuel pump.
- Flushing valve of the fuel strainer may be open.
- Valves on fuel supply line may not be fully open or fuel filters may be
blocked.
- If the unit is being fired for the first time or if the fuel line between pump
and burner has been emptied of fuel, then air may need to be removed
from this line. Take out the burner rod and hold it upside down (nozzle
upward). Take care to contain the spray that would be coming out. Put
the FIRE switch on. Put it off as soon as fuel spray starts. Repeat this
two to three times
7. Fuel temperature falls during operation or doesn’t rise at all.
- One or more of the heater elements may be damaged.
- Temperature sensing element may be damaged.
6. Excessive black smokes.
- Check air damper setting. However do not open it too much (beyond
its normal setting) to reduce smoke, as it will result in reduced
efficiency.
- Check fuel pressure and spray from nozzle. It should be fine and
uniform in all directions. Oil should not drip from sides of the nozzle.
Clean the nozzle. Replace if necessary.
- Check burner setting with the burner gauge. See that nozzle and
diffuser plate are concentric. The electrodes should not come within
the oil spray zone.
3.2 WATER SYSTEM
1. WATER LEVEL LOW light remains on even after the pump start.
- Check that valves on water supply line are open & there is sufficient
water in the tank.
- Check strainer / filter on water suction side. Clean if found choked.
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- Close the main steam valve, open auxiliary steam valve. Put the FILL
switch on and see if water is coming out. Close the auxiliary valve
slowly till pressure builds up above 6 kg/cm². If water flow reduces
sharply, it indicates problem inside pump. If water flow is less even
without pressure, the problem may be with the pump or the suction
line. (Accurate measurement of water flow is preferable, but the flow
may also be estimated visually.)
- Remove piping near pumps suction. If water does not come out freely,
choking of piping of optimiser/economiser is indicated.
- If the problem is not with suction piping, check the pump.
2. STEAM TEMPERATURE HIGH alarm with boiler trip.
- Check setting of steam temperature controller. (200°C for 10.54

kg/cm², 220°C for 17.5 kg/cm² pressure).
- Check fuel pressure. Fuel consumption may change with fuel

properties hence ensure that consumption is correct.
- Observe the steam by opening the auxiliary valve. Spray of wet steam
should be visible. Superheated steam is practically invisible. If steam is
indeed superheated & fuel consumption is also correct then carry out
all the steps explained in (1) to ensure that water flow is not less than
normal.
3.3 ELECTRICAL SYSTEM:
1. CONTROL ON lamp does not come on after switching on the main switch.
- Check the fuse in the control panel and main fuses in the main switch.
- Check the bulb inside the lamp.
2. Fuse in the control panel blows as soon as supply is switched on.
- Check for short circuit in the control circuit.
3. Motors do not start or trip after some time.
- Check the setting of the overload relay on the contractor.
- Check currents in all phases.
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CHAPTER 4: DO'S AND DON'TS
4. 1 WATER SYSTEM
(a) Never operate the water softeners at a pressure other than that specified in
the manual.
(b) Ensure that the pressure at the inlet of the water softener is at least 25 psi
while doing the salt injection. Otherwise, the injector will not work.
(c) Do the back washing, salt injection and rinsing in the time specified while
regenerating the water softener. Otherwise, it will not give good quality of soft
water.
(d) Feed only soft and suitably dosed water to the boiler. Never feed hard water,
as this will result in scale formation and choking up of the coil.
(e) Never run the water pump with insufficient or incorrect lubricating oil.
4.2 FUEL SYSTEM
(a) Never run the fuel pump dry. It will get damaged.
(b) Use fuel oil additives to improve combustion and for trouble free operation of
the burner.
(c) Never set the point of the fuel temperature controller above 130°C. Higher
temperature causes higher pressure in the OPH tank, resulting in opening of
the relief valve. Frequent operation of the relief valve will reduce the water
level, requiring frequent topping up.
(d) Do not use the house of solenoid valve as a lever for tightening the valve.
(e) Ensure supply of clean filtered fuel to the unit. Filter the fuel through fine
mesh filter (size 120).
4.3 ELECTRICALS
(a) Check all the safeties and controls regularly as mentioned in the maintenance
schedule.
(b) Never short circuit safeties and work the boiler. Damage caused can be
costly.
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4.4 UNIT
(a) Generally avoid operating the boiler at steam pressure below 5 kg/sq.cm.
(b) Check the blow down timing regularly to estimate the extent of scaling in the
coil.
(c) Ensure that the isolating valves for steam and fuel pressure gauges are
always open.
4.5 GENERAL REQUIREMENT
(a) Maintain the log book supplied with the boiler. It helps in detecting faults at an
early stage.
(b) Keep spares in stock to minimise down time due to breakdowns.
(c) Send an operator for training to understand the product completely and
enable him to carry out routine maintenance.
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CHAPTER 5: MAINTENANCE OF BOILER AND ITS PARTS
5.0.1 Opening and cleaning the boiler
• Remove the burner rod, wiring to photo-cell and electrodes etc. from the top
plate.
• Remove the bolts on the periphery of the top plate and lift it.
• Remove the Outlet connector.
• Remove the nuts bolting the top refractory to the inner jacket and lift it. The
burner housing and the flame cone which are attached to it will also come out.
Take care not to damage the flame cone while putting the refractory down,
keep it upside down.
• At this stage, the coil, radiator, refractory, flame cone are accessible for
cleaning. Clean the inner surface of the coil with flat wire brush. Also clean
the outer surface to the extent possible. Compressed air may be also used.
• Wipe the aluminium cladding of top cover with kerosene/ thinner. Clean the
radiator (between inner & outer shells) to the extent possible.
• Clean the flame cone with kerosene/thinner. Emery paper may be used to
remove hard deposits, if any.
5.0.2 Removing the Coil
• Disconnect the flanged steam outlet connection. Remove the piping

connection coming out of the boiler using a pipe wrench.
• Disconnect the threaded water inlet connection to the coil. Remove the piping
connection going in the coil using a pipe wrench.
• Lift the coil using the hooks provided on it. Do not let it swing too much and
damage the shell.
5.0.3 Reassembly
• Put the coil back in the jacket assembly. Align the inlet and outlet elbows with
the openings in the jacket. For refitting of the threaded inlet piping, it is
necessary to remove the bolted covers on the inner and outer jackets. Clean
the threads before assembly and wrap teflon tape on the male threading.
__________________________________________________________________________

Refit the covers on the inner and outer jackets. Check and replace the
compressed asbestos fibre gaskets in the covers if necessary.
• Check and replace if necessary, the sealing rope on the top refractory. Lower
the top refractory in the inner jacket, with the sight glass port and the bolting
in proper positions.
• Clean and lubricate the bolts before tightening.
• Check and replace if necessary, the sealing rope on the top cover. Lower the
top cover on the outer jacket, with the sight glass port and the bolting in
proper positions. Clean and lubricate the bolts before tightening.
5.1 FEED WATER PUMP
Make: DAMPF & COLBEN
5.1.1 Construction
The pump is a reciprocating single acting pump. It is driven by a 3-phase electric

motor through pulleys and V-belt. Pump & motor are mounted on a platform.
Adjusting bolts on the platform allow adjustment of belt tension.
The pump has water chamber and crank case. The crankshaft mounted on ball
bearings drives the pistons. The pistons suck water during the return stroke & push
water during the forward stroke. Gland washers and oil seals prevent the
pressurised water from entering the crankcase. Control valves in the water chamber
prevent flow of water from pressure side to suction side.
A control valve consists of valve seat, valve disc, spring and valve cage, all held
together with the Teflon washers. Control valves are fitted between the suction and
valve chamber and between the valve and delivery chamber.
The surge suppresser is a pressure vessel mounted on the delivery chamber. It

serves to dampen the pressure fluctuations caused by the reciprocating pump.
5.1.2 Maintenance
To access the water chamber, open the two vertical bolts holding the suction, valve
and delivery chambers together. The control valves can be simply lifted from their
sockets. For dismantling the control valve, stretch the rubber washer gently and pull
out the valve cage with seat. Check for cracks in the washer. Check that the valve
disc & seat are not worn. They should seat on each other precisely. A leaky seat or
cracked washer or some foreign material between seat and disc will allow water flow
in reverse direction under pressure, resulting in reduced water supply to the boiler.
Replace if necessary.
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Remove the two horizontal bolts holding the crankcase & valve chamber together to
access the pistons, oil seals, gland washers etc. Examine the gland washers for
cracks & wear. Replace if necessary. While reassembling, tighten the oil ring (which
holds the gland washers) properly. On the water chamber side, carefully clean the
surfaces on which the control valves sit & then place the control valves in their
sockets.
The crankcase side usually does not require frequent maintenance. SAE-40 oil
should be used (up to the indicated level) for lubrication. Drain off the oil and fill new
after 3 months as indicated in the maintenance schedule.
Unscrew the surge suppresser, empty it of water and fit it back. If it is full of water
the pressure fluctuations will not be dampened properly.
5.2 FUEL PUMP
Make - Suntec
Installation:
This is gear type positive displacement pump and is driven by separate motor at
3000 RPM.
Adjustment:
To adjust set pressure, turn the pressure adjusting screw clockwise for increasing
the pressure & anticlockwise for reducing it. This should be done when the boiler is
firing. The adjusting screw is located opposite to the oil outlet connection.
5.3 BURNER ASSEMBLY
Construction:
The main components of burner assembly are the Burner rod, Flame cone, Diffuser
plate and the electrodes. The flame cone-diffuser plate cause the combustion air-
fuel mixing.
The flame cone is fitted on a cast iron housing bolted on boiler's top refractory. The
burner rod, electrodes and the diffuser plate are fitted on a Guide Pipe. The guide
pipe fits on the burner plate and can be moved up or down for adjustment.
The diffuser plate holder, mounted on the guide pipe holds the diffuser plate and the
electrodes. The burner rod fits inside the guide pipe.
Burner rod consists of inlet port at middle, circulation port at top and nozzle port at
bottom end. Fuel oil enters through inlet port and reaches up to the nozzle.
Flexible metallic hoses are used for burner fuel connections.

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Maintenance:
Maintenance of the burner involves cleaning the nozzle, diffuser plate, electrodes.
Sight glasses should be cleaned, including the glass inside the photocell mounting.
Burner setting should be done as shown in the figure with the help of burner gauge.
The distance between diffuser plate and flame cone neck should also be as per the
figure.
To access the nozzle, lift the burner rod from the guide pipe. The nozzle can be
removed by No.16 spanner while holding the burner rod tightly. For cleaning the
nozzle, hold its body and use a 4 MM Allen key to remove the inner piece. Below
this piece is the slotted swirler. Clean these parts carefully with thinner or kerosene.
Wires of soft metals like copper may be used for cleaning. Do not use hard metal
wires. Do not use excessive force for tightening the inner piece.
5.4 BLOWER
Connection:
This is a centrifugal fan having impeller directly coupled with motor shaft. The motor
is foot mounted type, bolted on the blower casing. The assembly is bolted on the
bottom chassis of the unit. The blower is bolted to the air supply duct of the boiler.
The air damper is provided to adjust the air flow for good combustion.
Maintenance:
To remove the impeller, remove the bolts on the casing on the motor side. Pull out
the motor with the impeller and casing plate. Clean the dirt on the impeller blades,
with emery paper if necessary. It is important that all the dirt deposits are removed
simultaneously, to avoid vibrations due to unbalancing.
5.5 OIL FILTER
This has a MS body and a filter element. For quick cleaning, open the drain plug
near the bottom. Fuel supply has to be shut off before cleaning the filter. Some fuel
will come out with dirt. Refit the plug. For thorough cleaning of the filter element,
remove the top cover. Clean the element with kerosene/thinner. Compressed air
may also be used. While refitting, check all gaskets. Replace if necessary.
5.6 ECONOMISER
It is a rectangular, shell and tube heat exchanger with water on shell and flue gas on
tube side. Carbon steel tubes are welded between MS tube plates. The air vent
connection comes out from the top. Drain is provided at the bottom. Inspection
window is on the rear side.
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After stopping the boiler at the end of day's operation, open the drain valve. Initially
dirty water will come out. Close the valve when clean water starts coming out.
Open the access door on top of the chimney duct and clean the soot inside the
tubes with a round wire brush. This should be done atleast once a week.
The tubes can be inspected through the inspection window. To check for a possible
leak in the tubes, open the bottom access door below the economiser (when the
boiler is cold) and see if any water is dripping.
If any water leakage is noticed, remove the chimney duct and then the economiser.
If the leak is in an accessible place, seal it with welding/brazing. Otherwise replace
the economiser.
For cleaning the rust on the water-side of the tubes, see the instructions given in
"Optimiser", as both are to be cleaned simultaneously.
5.7 HEAT OPTIMISER
This is a shell and tube heat exchanger with hot water on tube side and cold water
on the shell side.
During operation, the heat transfer surfaces get covered with rust and other deposits
which must be cleaned at least once a month. The economiser and the optimiser
can be cleaned together.
Maintenance:
Disconnect the water supply to the unit which is connected to the optimiser (point 1).
Disconnect the piping going to the feed water pump which is connected to the
optimiser (point 2). Plug the air vent connection on the economiser.
Blow the piping with compressed air or steam. Dirt will be blown with the air/steam
jet. Then blow in reverse direction also.
For better cleaning, use a descaling or derusting chemical. (Refer the chapter on
"Descaling"). Circulate the chemical solution through optimiser-economiser for about
10 minutes. Drain the solution, repeat this once more and then rinse with soft water.
Circulate alkaline water (water mixed with some caustic soda) and leave it for about
5 minutes. Rinse twice with soft water to remove all traces of any chemicals.
__________________________________________________________________________

CHAPTER 6: DESCALING
To avoid scaling, ensure that always soft and properly dosed water is fed to the
boiler. Descaling is not a part of routine maintenance, as descaling shortens the life
of coil. Before attempting descaling, make sure that boiler coil is really scaled up. If
descaling is found necessary, never do it when the coil is hot.
6.1 SYMPTOMS OF A SCALED COIL
a. Measure the blow down time and compare it with the blow down time
recorded at the time of commissioning. When blow down time goes beyond
twice the initial blow down time, it will be necessary to descale the coil.
b. When scaling occurs the pressure gauge at the inlet of the coil will indicate a
higher pressure than that observed during commissioning.
Make sure that the rate of pumping of the boiler feed water (water
consumption) is identical with that at the time of commissioning to ensure that
this does not mislead one regarding the coil pressure drop.
The blow down timings can vary considerably depending upon the resistance
to flow offered by the piping between the blow down valve to the point of
drain. Blow down timing for comparison should, therefore, be the one
recorded at the time of commissioning.
6.2 DESCALING PROCEDURE
Before descaling, please keep a record of the following:

a. Blow down time before and after descaling.
b. Pressure drop across the coil with boiler running at rated pressure.
c. Approximate number of hours the boiler has worked before descaling.
In the procedure described below a separate pump is to be used for descaling. This
is outlined below in three stages.
1. Connections
2. Descaling
3. Recommissioning
1. CONNECTIONS : - (See Fig. RX/060300)
a. Take a separate pump motor set consisting of an electric motor and a single
or multi-stage centrifugal pump (preferably acid proof) of 25 Litres/min to 50
Litres/min at a pressure at which water can flow through the coil. While the
ideal choice would be to employ an acid-proof pump, in view of its cost, a
__________________________________________________________________________

normal water pump will serve the purpose, provided it is carefully washed with
an alkaline solution after pumping the descaling compound.
b. Take an acid proof tank of a minimum 50 litres capacity. A large plastic

bucket will do.
c. Take polyethylene tubing and connect one end of the tube to the inlet of the
pump with worm clips, the other end being dipped to the bottom of the bucket.
d. Connect the delivery of the pump to inlet of the coil through the blow down
connection. Use MS pipes and fittings as pressure here will be more. Connect
a pressure gauge in this line.
e. Remove the copper piping connected to the steam pressure gauge and
steam temperature combistat bulb from the steam header. Remove the steam
safety valve also. Plug the openings.
f. Connect polyethylene tube of required length to the piping of auxiliary steam

valve and leave the other end free at the top of the bucket. Fix a filter mesh
just under this end of the tubing to collect scale and dirt that might otherwise
enter the bucket. Keep the main steam stop valve closed throughout the
descaling operation.
g. Make sure before starting that the non-return valve, connected between the
boiler feed pump outlet and steam coil inlet, is functioning properly and that
there is no danger of acid flowing back into the boiler feed pump, as it might
damage the pump.
2. DESCALING OPERATION:
a. Fill the bucket with soft warm water. Start the pumping set and fill the boiler
coil with soft water. After the coil is entirely filled with water, it will return to the
bucket through the polyethylene tube.
b. Take the mixture of descaling compound and water in the bucket. Dip a piece
of pH indicating paper which is yellow in colour, into the bucket. It should turn
red indicating acidity.
c. Hold another piece of pH paper in the water emerging from the tube just
above the bucket; it will normally show higher pH value (more greenish in
colour) indicating that the alkaline salts from the coil are being carried in the
flushing water. Continue the circulation for about 8 to 10 minutes, then add
another two litres of descaling compound to the bucket and continue for a
further 8 to 10 minutes checking periodically the change of colour with pH
paper.
__________________________________________________________________________

d. The process may have to be repeated until the return water has the same pH
as the water in the bucket.
e. During these operations the water pressure reading on the gauge fitted at the
inlet of the coil should be checked to ascertain the variation of pressure with
the progress of cleaning. As the coil is cleaned, this pressure comes down.
f. Now throw away the acidic water in the bucket and add soft water to it. Let
out the coming water from the coil to drain and not into the bucket.
Run the centrifugal pump to force all the contents out of the coil. Keep adding
soft water to the bucket and pump it through the coil. The colour of the
indicating paper when dipped in the water in the bucket will be slightly
GREENISH, showing a slight alkalinity of 8 to 9 pH. On the other hand, the
pH of the return water will be slightly acidic. Continue rinsing till the pH of the
return water is the same as that of the soft water.
g. Add about 1 kg of Caustic Soda or Caustic Potash to the soft water in the
bucket. Put the return water connection back into the bucket and circulate this
alkaline water through the boiler coil for 15 minutes to half an hour. This
caustic solution completely neutralises any acidic traces in the coil.
h. Once again rinse the boiler coil with soft water for about 15 minutes and again
check the pH of the water in the bucket and at the return outlet. A slight green
colour is to be expected. The coil is now descaled.
3. RECOMMISSIONING:
a. Disconnect the temporary connections and reconnect the boiler to its

permanent piping and tanks. Use the boiler feed pump to fill up the coil with
soft water. Fire the boiler with the main steam stop valve closed and auxiliary
steam valve open. Give a blow down. Carefully collect and examine the
condition of the blow down; some rusty water might come out of the boiler.
Continue steaming and blowing down till the blow down comes out clean.
b. Check and note the blow down time and pressure drop across the coil.
Descaling operation is complete and the boiler can be put back in service.
NOTE:
MAXCLEAN range of descaling compounds is available from Thermax. These are

hydrochloric acid or sulphuric acid based formulations containing corrosion
inhibitors. These compounds should be used as directed in MAXCLEAN manual.
Though it is not advisable, commercial hydrochloric acid or sulphuric acid may be

used in 5% to 25% concentration depending upon hardness of scales.
__________________________________________________________________________

CHAPTER 7: SPARE ITEM LIST
SPARE SPECIFIC TO MODELS

RXA-02 :
DESCRIPTION PART NO. QTY
NIBR-COIL 10.54 kg PRXCL10011 1
ECONOMISER RXA-02 PRXEC10016 1
HEAT OPTIMISER RXA-02 PRXEC10017 1
DIFFUSER PLATE- RXA-02 DIA. 94 (Light Oil) PBR5730000 1
DIFFUSER PLATE- DIA 92- RX-02 ( NG/LPG Gas) PBR5730154 1
WEGMAN CONE - DIA 106 x DIA 180 160H P22WC10090 1
NOZZLE- DANFOSS- 2.5 GPH, D45, S'PAT-B P22ND10090 1
VALVE, SAFETY- THD- GUNMETAL-1"BSP (M) x 1"BSP (F) ,100-
P36SS2023M 1
200 PSI, STEAM, MNFC For 10.54 kg/sq.cm(g)
P36SS2026M 1
300 PSI, STEAM, MNFC
PUMP- D' KOLB- SIMPLEX, 200 LPH (Feed Water Pump) P01RD10010 1
FILTER,OIL,SIMPLEX-FILTER-NAMI-1/4" BSP P260110030 1
PUMP,FUEL- SUNTEC- AN 67 B P01FS10020 1
BURNER ASSLY- GAS, W/O HSG & WEG- RX 02-TP 01/NG-LPG PBR2200014 1
PUMP,FUEL- SUNTEC- AJ 6 AC 1000 P01FS10030 1
RXA-03
ECONOMISER RX-03/04 PRXEC10015 1
HEAT OPTIMISER RX-03/06 PRXEC10014 1
DIFFUSER PLATE- RX-03/04 DIA 110 (Light Oil) PBR5730003 1
DIFFUSER PLATE- DIA 110 - RX03/04 (NG / LPG Gas) PBR5730146 1
WEGMAN CONE- DIA 124 x DIA 220- 185H P22WC10070 1
NOZZLE- DANFOSS- 3.75 GPH, D45, S'PAT-B P22ND10030 1
200 PSI, STEAM, MNFC P36SS2023M 1
SP-D'KOLB- WATER PUMP-TRIPLEX (Feed Water Pump) P01RDS0710 1
FILTER,OIL,SIMPLEX-1/2" BSP, 120 MESH P260110070 1
BURNER ASSLY- GAS, W/O HSG & WEG- RX 03/NG-LPG PBR2200017 1
__________________________________________________________________________

RXA-04 :
COIL 10.54 kg PRXCL10012 1
COIL 17.5 kg PRXCL10012 1
DIFFUSER PLATE- RX-03/04 DIA 110 PBR5730003 1
DIFFUSER PLATE- DIA 110 - RX03/04 PBR5730146 1
P36SS2023M
200 PSI, STEAM, MNFC 1
P36SS2026M
BURNER ASSLY- GAS, W/O HSG & WEG- RX 04-TP 02/NG-LPG PBR2200018 1
RXA-05 :
DIFFUSER PLATE- RX-05 DIA 120 PBR5730006 1
DIFFUSER PLATE- DIA. 122- RX-05 PBR5730155 1
P36SS2023M
P36SS2026M
BURNER ASSLY- GAS, W/O HSG & WEG- RX 05/NG-LPG PBR2200020 1
__________________________________________________________________________

RXA-06 :
WEGMAN CONE - DIA 150 X DIA 250 X H P22WC10100 1
BURNER ASSLY- GAS, W/O HSG & WEG- RX 06, RXD 04, RXD
06, SX 600/NG-LPG. PBR2200019 1
NOTE:
1. Please Indicate unit Serial Number while ordering Spares.
2. Please Order Burner Nozzle as per the make of the nozzle used in your boiler.
3. Before placing order for spare items kindly confirm the spare items part number
required
from Head Office.
__________________________________________________________________________

RXD-04 :
ECO.WITH H.OPTIMISER,RXD-03,04 PRXECO0019 1
DIFFUSER PLATE- RXD-06 DIA 132 PBR5730009 1
WEGMAN CONE- DIA 150 x DIA 250- H P22WC10100 1
P36SS2023M 1
P36SS2026M 1
FILTER,OIL,BASKET-25NB,120 MESH (FO) P260120030 1
PUMP,FUEL- SUNTEC- E6 NB 1001- 6P (FO) P01FS10070 1
PUMP,FUEL- SUNTEC- AJ 6 AC 1000 (LDO) P01FS10030 1
GAS BURNER ASSEMBLY RXD 04/NG+LPG/WO HSG+WEGMAN
PBR2200130 1
CONE
RXD-06 :
ECO.WITH HEAT OPTIMISER,RXD-06 PRXECO0018 1
WEGMAN CONE- DIA 150 x DIA 250- H P22WC10100 1
P36SS2023M 1
P36SS2026M 1
PUMP,FUEL- SUNTEC- E6 NB 1001- 6P P01FS10070 1
BURNER ASSLY- GAS, W/O HSG & WEG- RX 06, RXD 04, RXD
PBR2200019 1
06, SX 600/NG-LPG
__________________________________________________________________________

RXD-850 :
ECO. & HEAT OPTIMISER RXD-850 PRXECO0020 1
DIFFUSER PLATE ASSLY- DIA 150 (FO & LDO) PBR5740001 1
DIFFUSER PLATE- DIA 155 - TP-06/RXD-850/TP-10/SX-1000 &
PBR5730148 1
1250
WEGMAN CONE- DIA 180 x DIA 280- 210H P22WC10020 1
VALVE, SAFETY- THD- GUNMETAL-1 1/2"BSP (M) x 1 1/2"BSP
P36SS2024M 1
(F),100-200 PSI, STEAM, MNFC
VALVE, SAFETY- THD- GUNMETAL-1 1/2"BSP (M) x 1 1/2"BSP
P36SS2028M 1
(F),200-300 PSI, STEAM, MNFC
PUMP- D' KOLB- TRIPLEX- PLUNGER - BF- 4322, 893 LPH P01RD10140 1
PUMP,FUEL- SUNTEC- E6 NB 1001- 6P P01FS10070 1
GAS BURNER ASSEMBLY RXD 850/NG+LPG/WO
PBR2200131 1
HSG+WEGMAN CONE
NOTE:
1. Please Indicate unit Serial Number while ordering Spares.
2. Before placing order for spare items kindly confirm the spare items part number
required
from Head Office.
__________________________________________________________________________

________________________________________________________________
SECTION IV
ANNEXURE MANUAL
FOR
REVOMAX BOILER
REVOMAX PLUS BOILER
(NON IBR)
MODEL : RXA – 02,03,04,05,06
RXD – 04, 06, 850
___________________________________________________________________________

___________________________________________________________________
CONTENTS
APPENDIX A BOILER FEED WATER.................................................................................................... 2
APPENDIX B : CHEMICALS FOR CONSISTENT PERFORMANCE................................................ 19

B1. BOILER WATER TREATMENT CHEMICALS ............................................................................. 19
B2. FUEL ADDITIVES........................................................................................................................... 21
B3. FIRESIDE CHEMICALS.................................................................................................................. 21
B4. DESCALING CHEMICALS............................................................................................................. 22
APPENDIX C : ECONOMIX (FIRESIDE BOILER CLEANING COMPOUND) ..................................... 23
C1. APPLICATION INSTRUCTIONS .................................................................................................. 23
C2. A GUIDE TO THE ACTION OF ECONOMIX ................................................................................ 25
APPENDIX D : COMPLAINT INFORMATION FORM............................................................................ 28
__________________________________________________________________________

___________________________________________________________________
APPENDIX A BOILER FEED WATER
Boilers are used for converting water into steam by evaporation in the boiler. Only the
water gets evaporated and solids dissolved in the water remain in the residual water.
Apart from getting converted into steam, water has another very important function in the
boiler, which is to keep the heat exchanger portions cooled and healthy. To ensure that
the water behaves as a proper cooling medium it is essential to see that
1. The water continuously wets the heating surfaces.
2. The water does not corrode the heating surfaces.
3. The water does not erode the heating surfaces.
4. The water has necessary chemicals within it such that a protective oxide layer is
formed on the surfaces.
In the operation of the boiler it is of primary importance to have water in the proper
condition. Almost in all cases it is necessary to treat the water to obtain the correct
operating conditions as raw water almost always contains undesirable impurities.
IMPURITIES IN WATER
Impurities in water are found either in the form of dissolved salts and gases or as
undissolved suspensions. Undissolved suspensions usually lead to erosion and need to
be removed by proper filtration. The dissolved salts need chemical processing for
control. The dissolved gases may need thermal, mechanical or chemical treatment. The
treatment will depend on the extent of impurities present in the water.
The impurities are measured by evaluating the concentration of the various salts. While
expressing the concentration of the various salts it becomes necessary to use a unit of
measurement which is interchangeable between the various salts. Thus unless
specifically mentioned otherwise, the concentrations of boiler water impurities are taken
as milligrams of the salts expressed in terms of CaCO3 per litre of the solution. This also
approximately corresponds to ppm (parts per million) of CaCO3.
__________________________________________________________________________

___________________________________________________________________
Effect of various impurities in boiler water:
a) Hardness
Most of the calcium and magnesium salts present in the water are collectively called
hardness. Calcium carbonate, Magnesium silicate etc. are typical salts which create
problems in the boiler by forming sludge. Calcium sulphate, calcium silicate and calcium
carbonate form scales on the evaporating surfaces. Scales not only restrict heat transfer
but also prevent the cooling action of water, thus overheating the tubes. In serious
cases of scale formation the tubes can overheat to such an extent that these may burst
under steam pressure. Hardness is measured in terms of mg/l as CaCO3.
b) Acidity
Acidity in water induces corrosion of metallic surfaces. Highly acidic water dissolves
metals and causes general wastage of tubes. The consequent thinning of the tubes
eventually results in a tube burst under steam pressure. Mildly acidic water hastens
pitting and oxygen corrosion. Such tubes eventually puncture. Acidity is measured in
terms of pH value.
pH OF WATER
(ATMOSPHERIC PRESSURE)
EFFECT OF pH ON CORROSION
__________________________________________________________________________

___________________________________________________________________
c) Oxygen
Water at room temperature always contains oxygen dissolved from air. Oxygen
promotes corrosion. The rate of wastage and thinning of tubes in highly acidic water is
enhanced heavily by the presence of oxygen. Heavy pitting occurs in the presence of
oxygen in mildly acidic or even in mildly alkaline water, eventually puncturing the tube.
Oxygen is released from water on heating. The oxygen thus released may again
dissolve in the pipelines and other equipment inducing corrosion in those areas, unless it
is vented out. Oxygen is measured in terms of mg/l as O2.
d) Total dissolved solids (TDS)
All the salts dissolved in the water are together accounted against total dissolved solids.
The effect of the total dissolved solids in feed water depends on the type of salt and the
type of boiler. The effect is also complex due to the mutual action between the various
salts. Generally, presence of chlorides, iron salts, etc. accelerate corrosion. Presence
of other salts may increase foaming and priming resulting in expansion of water volume
and consequent carry-over. Such situations can also bring about heavy water level
fluctuations in the boiler aggravating the problem. A high TDS in the boiler water will
also increase steam contamination to the carry- over water having higher amount of
salts. The TDS is measured in terms of mg/l as CaCO3.
An approximate value of the TDS in mg/l can be obtained by measuring the electrical
conductivity in micro Siemens/cm.
e) Turbidity
Turbidity is an indicator of undissolved solids. Turbid water may induce erosion. The
undissolved solids also impair proper circulation of water on the heating surfaces which
in turn can reduce the cooling action of the water. The undissolved solids may deposit in
the low velocity regions impairing heat transfer and consequent overheating of the
surfaces. The turbidity is measured in mg/l.
f) Dissolved Carbon dioxide
Dissolved free carbon dioxide appears in the water in the form of carbonic acid. This is
corrosive. Often this is termed as free carbon di-oxide.
The bicarbonate salts present in the water is often considered as bound carbon dioxide
in the water. Carbon dioxide being a gas separates out of water on heating.
__________________________________________________________________________

___________________________________________________________________
The carbon dioxide released from the water gets carried away along with steam and
when the steam condenses the CO2 re-dissolves in the condensate forming carbonic
acid. This acid corrodes pipelines and other user equipment.
Carbon dioxide is measured as mg/l as CO2.
g) Organic matter
Usually the main source of organic matter in the boiler water is oil and grease within the
boiler, pipelines, pumps etc. Organic matter can also get into water from leaks in the
user equipment if condensate from heat exchangers having organic matter is returned.
It is difficult to predict the effect of organic matter in water as it depends on the exact
nature. Oils and greases induce foaming and priming and consequently water level
fluctuations and carry-over.
h) Silica
Silica is detrimental mainly due to carry-over along with steam in high pressure boilers.
The main problem being condensation and formation of silicates on turbine blades and
such other moving parts. In lower pressure boilers Silica does not present severe
problems except that it may induce the formation of sodium iron silicates and sodium
aluminium silicates which are hard scales.
ALLOWABLE LIMITS OF IMPURITIES
As seen above, impurities in the boiler water create problems in the operation and
reduce the life of the boiler as well as the connected equipment. Therefore, the
allowable limits of impurities will depend on what results we are looking for during the
operation. Taking into consideration the general operating conditions and requirements
of boiler operation and steam usage, various National Standards have been formulated
by various countries putting together the collective experience of boiler operation. The
feed water quality standards as well as the boiler water quality standards derived by all
countries are almost the same.
An extract of the Indian Standard IS 10392-1982 is given below for ready reference as
an example.
__________________________________________________________________________

___________________________________________________________________
Extract from IS 10392-1982, "Specification for feed water and Boiler water for low
and medium pressure land boilers."
CHARACTERISTIC REQUIREMENT FOR BOILER PRESSURE
Up to 2.0 2.1 to 3.9 4.0 to 5.9
MN/m2 MN/m2 MN/m2
Feed Water
a) Total hardness (as CaCO3) 10 1.0 0.5

mg/l, Max
b) pH value <-------- 8.5 to 9.5 -------->
c) Dissolved oxygen, mg/l, Max 0.1 0.02 0.01
d) Silica (as SiO2), mg/l, Max - 5 0.5
Boiler Water
a) Total hardness (of filtered <----------- Not detectable ----------->

sample)(as CaC03), mg l
b) Total alkalinity 700 500 300

*(as CaCO3), mg/l Max
c) Caustic alkalinity 350 200 60

(as CaCO3), mg/l, Max
d) pH value 11.0 to 12.0 11.0 to 12.0 10.5 to 11.0
e)** Residual sodium sulphite 30 to 50 20 to 30 -

(as Na2SO3), mg/l
f) Residual hydrazine 0.1 to 0.1 to 0.05 to

as N2H4), mg/l (if added) 1 0.5 0.3
g) Phosphates (as PO4) 20 to 40 15 to 30 5 to 20

mg/l (if added)
h) Total dissolved 3500 # 2500 1500

** solids mg/l, Max
i) Silica (as SiO2), mg/l Less than 0.4 of caustic alkalinity
__________________________________________________________________________

___________________________________________________________________
NOTE 1 :
Recovery Boilers - The boiler feed water used should be completely demineralised and
also the boiler feed water and boiler water should be conditioned in accordance with high
pressure boilers working at 5.9 MN/m2 (60 kg/cm2) and above (see IS : 43343 - 1967).
NOTE 2 :
When feed water heaters are of copper or copper alloy constructions, the pH of the feed
water should be maintained between 8.5 and 9.2 while when feed water heaters are of
iron construction, the pH of the feed may be maintained between 8.5 and 9.5.
NOTE 3 :
Silica in Boiler Water - Lower concentration of silica may be advisable for steam of
turbines, which generally require less than 0.02 mg/1 silica in steam.
* Total alkalinity should preferably be about 20% of total dissolved solids.
** Shall not apply if reducing agents other than sodium sulphite are used.
# For shell type boilers depending on parameters, the limits can be relaxed.
One MN/m2 is approximately 9.8 kg/cm2.
As the above standard is made considering the most usual situations in mind we can
expect a good life from the boiler if these specifications are met. However depending on
the specific needs of the user some modifications may be made. This depends entirely
on the specific experience of the user with respect to his specific circumstances. In
cases where it does not matter whether there is heavy water fluctuations or carry-over,
perhaps the TDS can be somewhat more than specified above provided the salts
contributing to the TDS are not corrosive.
Many shell boiler users operate with a boiler water TDS of 5000 mg/l without any
adverse effects. When the salts in the feed water are of non-corrosive and non-scale
forming nature, it may be possible to operate coil boilers even with 10,000 mg/l TDS in
the blow down water if carry-over & wetness are of no consequence to the user.
TREATMENT OF THE WATER

How do we get rid of the offending impurities in the water and ensure the quality
requirement as given by the standard specifications?
The tabulation below lists some of the possible methods.
__________________________________________________________________________

___________________________________________________________________
WATER SIDE PROBLEMS
PROBLEM ACTION METHOD
Hardness Soften Base Exchange
Acidity/pH Dose Phosphates & caustic soda
Oxygen Scavenge Sodium Sulphite or Hydrazine
TDS Reduce Blow down or De-alkalise

or De-mineralise
Turbidity Remove Filter
Organic Prevent Boil out
Silica (Not very critical Reduce De-mineralise

in low pressure boilers)
Hardness removal by softening
While there are methods like lime/soda treatment or treatment with some proprietary
chemicals the most popular and perhaps the best method to be adopted for softening is
the base exchange process using ion exchange resins. For this purpose filtered water is
passed through an ion exchange resin bed. The type of resin used is usually a strong
acid cation exchange resin in sodium form. It is specifically efficient for removing strong
metallic ions like calcium and magnesium from the water which impart hardness. When
the water passes through the bed, calcium and magnesium ions are exchanged by the
resin with sodium ions. Sodium salts do not impart hardness to water and thus the water
is effectively softened. The exchange process can continue until the sodium content in
the resin is depleted. The resin at this time can be regenerated to its original strength by
using a solution of sodium chloride (common salt) of appropriate concentration.
The details of the process and operational parameters are available in the instruction
manual of the water softener.
__________________________________________________________________________

___________________________________________________________________
SOFTENING
De-alkalisation
It is sometimes not sufficient to remove hardness from the water due to a high
concentration of total dissolved solids in the raw water. If a large portion of this TDS is
due to bicarbonates it is possible to reduce the TDS by a method called de-alkalisation.
For this purpose the water is first passed through a bed of a weak acid cation resin in the
hydrogen form. When the water passes through this bed the metallic ions associated
with bicarbonates are exchanged with hydrogen ions. Thus instead of bicarbonate salts
the water would now contain carbonic acid which is nothing but dissolved carbon dioxide.
This water containing dissolved carbon dioxide is then passed through a degasser tower
and air is blown through the water using a blower. The air current drives away carbon
dioxide from the water thus effectively removing the bicarbonate salts reducing the TDS.
This water is then passed through the strong acid cation exchange resin in the sodium
form as usual to remove the hardness.
For detailed operating parameters appropriate instruction manuals are to be referred to.
__________________________________________________________________________

___________________________________________________________________
DEALKALISATION
The de-alkaliser resins are regenerated usually using hydrochloric acid (Hydrogen
chloride) so that the regenerated resin comes back to hydrogen form.
Demineralisation
When water contains a large amount of TDS which cannot be treated by de-alkalisation
or when process requirement is for very low TDS, demineralisation needs to be resorted
to. The raw water after filteration is first passed through a strong acid cation exchange
resin bed in the hydrogen form. When the raw water passes through this bed the
metallic ions are exchanged with hydrogen ions. This water containing now the
corresponding acids instead of metallic salts is passed through a strong base anion resin
bed where the acid radicals are replaced by hydroxyl ions. Thus resin bed in the acid
content gets converted to water. The entire TDS is hence removed.
__________________________________________________________________________

___________________________________________________________________
DEMINERALISATION
C C
2 HR + Mg SO4 -----> Mg R2 + H2 SO4
A
R OH + H2 SO4 R H SO4 + H2 O
The cation resin is regenerated using hydrochloric acid to supply the hydrogen ions for
exchange and the anion resin is regenerated using sodium hydroxide to supply the
hydroxyl ions for exchange.
Depending on the raw water impurity levels and types, various combination of exchange
beds and degassers can be arranged to obtain control over impurities.
Dosing
To obtain the necessary quality of feed water and boiler water it is not sufficient to just
remove impurities. It is necessary to conditions the water by adding necessary
chemicals. The addition of necessary chemicals in the appropriate quantity is called
dosing.
__________________________________________________________________________

___________________________________________________________________
Phosphates
Various phosphate salts of sodium are used for dosing the feed water. Perhaps the
most common salt is trisodium phosphate. The advantage of using this salt is its ability
to hold residual hardness slipped out of the ion exchange column as a sludge within the
boiler thus effectively preventing adhering scales. Use of sodium hexameta phosphate
is preferred by some as this chemical chelates the calcium salts and holds the hardness
in solution without allowing these to precipitate. Sodium hexametaphosphate is however
more expensive. The phosphate salts increases alkalinity and increase the pH value.
The quntity of the phosphates is to be determined taking into consideration the ratio of
caustic alkalinity to total alkalinity needed as well as the minimum quantity required to
hold hardness without scaling.
Caustic Soda
To maintain the necessary pH in feed water and boiler water it may be necessary to add
caustic soda in addition to phosphate salts. The quantity of the caustic soda to be used
will depend upon the ratio of the caustic alkalinity to total alkalinity required and the
minimum quantity needed to maintain the specified pH.
Sodium sulphite
Oxygen scavenging is an essential requirement for boiler water conditioning. Either

sodium sulphite or hydrazina can be used. Hydrazine reacts with oxygen in water
forming ammonia and water. Ammonia being a gas is removed from the water. Thus
even though it may appear that hydrazine is better for scavenging oxygen (except for
high pressure boiler) sodium sulphite is always preferred, as hydrazine is toxic during
handling. Sodium sulphite combine with oxygen forming sodium sulphate, effectively
removing oxygen from the water. One important aspect of dosing sodium sulphite which
is always to be borne in mind is the reaction time required for conversion of the sulphite
to sulphate. A minimum of 30 minutes of residence time is required for this reaction.
Therefore, the dosing of the sodium sulphite is necessary to be arranged in such a way
that this residence time is available for the feed water before it enters the boiler. A
catalysed variety of sodium sulphite is available which does not require long residence
time for the reaction. However, due to the much higher cost of the catalyst generally it is
much cheaper to provide the residence time. It is also necessary to keep in mind that
the sulphite treated water should not be exposed to air before feeding into the boiler as
otherwise oxygen from the air can continuously dissolve and react with the sulphite
available thus depleting the sulphite content in the feed water. The quantity of the
dissolved oxygen depends on the temperature of water. At 30°C approx. 7.5 mg/l can
be expected in the water. At about 100°C the oxygen content at atmospheric pressure is
negligible.
__________________________________________________________________________

___________________________________________________________________
TEMP °C
NOTE : THIS CURVE RELATES TO WATER EXPOSED TO AIR SATURATED

WITH WATER VAPOUR AT ATMOSPHERIC PRESSURE.
The quantity of the sulphite to be dosed is to be determined according to the expected

level of dissolved oxygen in the feed water and the required residual sulphite content in
the boiler water. 9 mg Sulphite is required to remove one mg oxygen.
Proprietory feed water conditioning chemicals
There are many proprietory formulations for feed water conditioning combining the
effects of various chemicals explained above. Some of these formulations contain
components like ethylene diamine tetra-acetic acid (EDTA) and such other chelating
agents which may enhance the effectiveness of conditioning. While choosing such
formulations it is also necessary to bear in mind that sometimes some of the
components used in such formulation may be deterimental for use in a boiler in particular
situations. It is necessary to know the exact nature of the components in these
formulations and their effects before deciding the use. The Thermax service engineers
will be in a position to give assistance in this regard.
__________________________________________________________________________

___________________________________________________________________
Blowdown
It will be seen that inspite of all treatment boiler water will contain dissolved solids. In
order to keep the level of total dissolved solids in shell type and water tube-drum type
boilers within limits and to remove any sludge, loose scales and corrosion products a
certain quantity of boiler is to be regularly drained. This process is known as blowdown.
The blow down can be intermittent - say once a shift - or continuous. The quantity of
the water to be blown down will depend on the dissolved solids entering the boiler
through the feed water and the maximum tolerable levels of these salts in the boiler
water. While determining the dissolved solids content in the feed water it is necessary to
take into account not only the original dissolved solids but also the dissolved solids
added in the form of dosing.
Continuous blowdown
Continuous blowdown is a continuous removal of boiler water controlled by a specially

designed adjustable valve or by an orifice plate. The installation of heat recovery
equipment may be economically justified. Suspended solids may block or erode the
adjustable valve or orifice plate and continuous blowdown is therefore usually limited to
the control of dissolved solids. Additional manual blowdown is necessary to control
suspended solids and prevent the build-up of sludge.
Intermittent blowdown
Intermittent blowdown may be effected by specially designed valves either operated by

hand or automatically controlled, for example, by timers, feed water flow or conductivity.
Where automatic valves are installed the manual blowdown valve should be operated at
intervals to ensure that the latter is clear. It should be noted that the most effective and
economic use of all types of intermittent blowdown valves is achieved by frequent full-
open operation for short periods rather than extended use at infrequent intervals. It is
usually not practicable to recover waste heat from infrequent intermittent blowdown.
Calculation of blowdown
The formulae in this subclause may be used to estimate the minimum quantity of water
that should be removed from a boiler during blowdown as shown in figure, where
E is the evaporation rate (in 1000 kg/h*)
S is the impurity content of feed water (in g/m3)
V is the water content of boiler (in m3)
__________________________________________________________________________

___________________________________________________________________
C is the maximum permitted concentration of impurity in boiler water (in g/m3)
C1 is the concentration of impurity in boiler water on completion of intermittent

blowdown (in g/m3).
B is the actual intermittent or continuous blowdown rate as percentage of

evaporation rate.
BA is the average (intermittent) blowdown rate as percentage of evaporation rate.
d is the duration of intermittent blowdown operation (in hours).
t is the interval between completion of one blowdown operation and completion of

the next (in h).
Q is the quantity of boiler water discharge during each intermittent blowdown

operation (in m3).
For continuous blowdown - C1 = C, BA = B and d = t.

The formulae linking these variables are as follows:
(a) Continuous blowdown

S
B = 100 -----
C-S
(b) Intermittent blowdown
100 tSV
B = ------------------------------
d(CV - 0.5 SE (t - d) - VS)
EtSV
Q = ------------------------------
CV - 0.5 SE (t-d) - VS
SE
C1 = C - (t - d) ------
V
Q
BA = 100 ---
tE
(* 1000 kg of steam is equivalent to 1 m3 of water at 4°C)
__________________________________________________________________________

___________________________________________________________________
CONTINUOUS AND INTERMITENT BLOW DOWN
TIME (h)
These formulae are based on steady load conditions and on the assumption that priming
and carryover conditions are absent or negligible. It is also assumed that the feed water
treatment is such that all the dissolved solids in the feed water remain in solution in the
boiler and do not precipitate as scale or sludge. They may be applied only when the
solids content of the feed water is reasonably constant and is measurable by
conventional means.
NOTE 1
When calculating blowdown on the basis of dissolved solids it is essential to make

allowance for the effect of the addition of treatment chemicals to the water.
__________________________________________________________________________

___________________________________________________________________
NOTE 2
The amount of water required to be removed by intermittent blowdown is greater than

that necessary when continuous blowdown is used (see fig.)
NOTE 3
When considering new water treatment plant, or alternative feed waters, the blowdown
required should not exceed the allowance made for it in the boiler plant design.
Blow Down - Controlling factor :
The blowdown quantity required is determined by the proportion of various impurities in

the feedwater. For a certain composition of feedwater, blowdown has to be calculated
for all the impurities. The maximum of these valves should be the actual blowdown.
Example - 1
Feedwater has a TDS of 600 mg/l, total alkalinity of 80 mg/l and silica level of 20 mg/l.
a. Blow down required to limit the TDS :
S = 600
C = 10000 (From experience say, of a coil boiler)
600
Hence B = 100 ---------------- = 6.4%
10000 - 600
b. Blowdown required to limit total alkalinity :
S = 80
C = 700 (as per IS 10392)
80
Hence B = 100 x ----------- = 12.9%
700 - 80
__________________________________________________________________________

___________________________________________________________________
c. Blowdown required to limit silica :
S = 20
C = 140 (as per IS 10392)
20
Hence B = 100 x ----------- = 16.7%
140 - 20
Thus total silica in the boiler water will determine the blowdown quantity in this case, and
blowdown required will be 16.7%.
However, if it is desired that TDS should not exceed 3500 mg/l, (say as is required for a
water tube boiler), then
S = 600 C = 3500
600
Hence B = 100 x --------------- = 20.7%
3500 - 600
Thus TDS in boiler water will determine the blowdown quantity now, and blowdown
required will be 20.7%.
__________________________________________________________________________

___________________________________________________________________
Appendix B : CHEMICALS FOR CONSISTENT PERFORMANCE
After a prolonged running of the boiler or heater, heating surface fouling takes place due
to soot deposition on the flue gas side and scale formation on the water or heat carrier
side. The performance of the equipment can get severely affected if the heating surface
is not cleaned. Chemicals are available to remove scales as well as to prevent scale
formation. Chemical Division of Thermax Limited is in the business of manufacturing
these chemicals.
Chemicals manufactured by Thermax Limited are basically of four types:
1. Boiler Water Treatment chemicals

2. Fuel additives
3. Fireside chemicals
4. Descaling chemicals.
Application of each type is as given below:
B1. BOILER WATER TREATMENT CHEMICALS
Untreated boiler water contains several impurities such as lower solubility salts,
dissolved gases and suspended particulate matter. These result in scaling and corrosion
of boiler heating surface. Also formation of foam in the boiler drum and water carry over
is not uncommon. To counter these Thermax has 'Maxtreat' range of chemicals.
Product Application Function Remark
Maxtreat 3220 Coil type Boilers Corrosion inhibitor Liquid

Antiscalant
Oxygen Scavanging
Maxtreat 3220S Coil type Boilers Corrosion inhibitor Solid

Antiscalant
Oxygen Scavanging
Maxtreat 3221 Smoke Tube Boilers Corrosion inhibitor Liquid

Antiscalant
Sludge Conditioning
Maxtreat 3222 Water Tube Boilers Corrosion inhibitor Liquid

Antiscalant
Sludge Conditioning
__________________________________________________________________________

___________________________________________________________________
Product Application Function Remark
Maxtreat 3223 Smoke Tube Boiler Corrosion inhibitor Liquid

using hard water Antiscalant
Sludge Conditioning
Maxtreat 3100 Smoke Tube & Water Catalysed Oxygen Powder

Tube Boilers scavanger Catalysed
sulphite base
Maxtreat 3200 Smoke Tube & Water Catalysed Oxygen Liquid

Tube Boilers scavanger Catalysed
Hydrazine
base. No
addition
to TDS
Maxtreat 3001 All Boilers Sludge conditioner Synthetic

keeps precipitated Polymer Liquid
salts in suspension. Falicitates
sludge removal
through
blowdown.
Maxtreat 3002 All Boilers On line descalant Eliminates

Iron, Calcium and shutdown
Magnesium scale
remover
Maxtreat 3003 Shell/Drum Boilers Anti foam compound Reduces

carryover due
to foaming
Maxtreat 3004 All Boilers Increases alkalinity Liquid

in boiler feedwater
Maxtreat 3005 All Boilers Reduces alkalinity Reduces

blowdown
frequency
__________________________________________________________________________

___________________________________________________________________
B2. FUEL ADDITIVES
To improve fuel combustion, to minimise harmful side effects like corrosion, soot
formation, fuel needs proper treatment. Thermax offers a complete range of fuel
treatment products such as sludge dispersant, water emulsifier, pour point depressant,
oil based surfactant, viscosity improver, corrosion inhibitor etc. They improve
combustion and heat transfer for better equipment utilisation and increase life of the
boiler.
Product Application Function
Thermosol Fuel oil treatment Prevents fuel polymerisation.

Disperses sludge. Aids water
removal & prevents corrosion
of tanks/lines. Restricts
formation of waxy deposits.
Improves atomisation due to

reduction in surface tension.
Improves combustion and
minimises SO3 corrosion.
Thermomix Solid fuel treatment Binds dust & prevents

spreading. Reduces unburnt
carbon in ash. Reduces
fouling & slag deposition.
Increases ash fusion
temperature and reduces
clinker formation.
B3. FIRESIDE CHEMICALS
Sooting, clinker formation and other combustion deposits are common fireside
occurrences in boiler and thermal fluid installation. Such deposits have to be cleaned
manually by brushing, scouring or by chemical action. The adhesive properties of
unburnt carbon results in the build-up of incombustible solids on the heat transfer
surfaces. This carbon acts as a barrier to heat transfer resulting in higher stack
temperature and lower heater efficiency.
Economix is a chemical formulation from Thermax for fireside cleaning of combustion

deposits. It contains dispersants, chemicals and corrosion inhibitors. It can be directly
__________________________________________________________________________

___________________________________________________________________
fed into the furnace while the boiler is in operation. Economix gives complete removal
of fireside deposits.
B4. DESCALING CHEMICALS
Untreated water contains several impurities which deposit on the heating surface leading
to poor boiler output and efficiency. It can, in extreme cases, even lead to the failure of
the heating surface. Thermax has a range of descaling chemicals, which can effectively
remove the scales formed and make the surface clean. These chemicals are from
'Maxclean' range. The application of each of these chemicals is as given below:
MAXCLEAN - 05
An off line descalant. It is sulphamic acid based with a corrosion inhibitor.

MAXCLEAN - 06
An off line descalant for removing organic deposits and silica scales. It is a balanced
formulation of a caustic, wetting agent and a silica deposit penetrant.
MAXCLEAN - 07
An alkaline formulation designed for boil-out in the boilers. It removes organic foulants
like grease, oil etc. from the boilers and softens silica scales.
In addition to the chemicals mentioned above, Thermax also supplies Water Analysis Kit.
This test can be used for quick and reliable checks of boiler feedwater/boiler water.
Thermax offers 'Q-TEST KIT' which can be used for carrying out following test at the site.
Tablets Q-Test-4
(Portable water analysis kit)
Hardness 1. Hardness test

M. Alkalinity 2. Sulphite test
P. Alkalinity 3. P. Alkalinity test
Dissolved oxygen 4. M. Alkalinity test
pH test 5. pH test
6. Total dissolve solids
7. Chlorides
8. Phosphates
9. Silica
__________________________________________________________________________

___________________________________________________________________
For your requirements of the chemicals and expert advice, please contact any of the
branch offices/service franchisees or Thermax dealers. They will be in a position to
assess your requirements and arrange for the supply. Or you may directly contact:
Thermax Limited
Chemical Division
97-E, General Block, MIDC, Bhosari.
Pune - 411 026 (India)
Phone: 020 – 27120181 / 169,
Fax : (020) 27120206
Appendix C : ECONOMIX (FIRESIDE BOILER CLEANING COMPOUND)
GENERAL APPLICATION INFORMATION
ECONOMIX is a free flowing powder which is designed to function to the best effect
when sufficient heat is applied to it so that it sublimes directly from the solid to the gas
phase. ECONOMIX demands minimum gas temperature of approximately 350°C in
steam raising plant, or a hot water temperature of 85°C in lower temperature boilers.
A rule of thumb guide is to ensure that the boiler has been functioning continuously for a
minimum of one hour before application of ECONOMIX.
C1. APPLICATION INSTRUCTIONS
SECTIONAL BOILERS
Introduce ECONOMIX into the boiler whilst actually firing. Unit drums or slim-pack tubes
should be thrown 2/3 of the way along the combustion chamber. It is not necessary to
open either pack as packaging is completely combustible. Economix can be thrown into
the combustion chamber through all the doors of MT boilers in equal proportions.
Should the only access be via the flame inspection port, then the glass should be
swung/hinged out of the way, and ECONOMIX, in the slim-pack tubes, slid into the boiler
through the inspection port. Ensure that pack travels far enough into boiler to be in the
actual flame zone.
PACKAGE/SMOKE TUBE BOILERS
COAL/SOLID FUEL FIRED
In these applications, ECONOMIX is applied directly onto the fire- bed utilising any
suitable access point.
__________________________________________________________________________

___________________________________________________________________
It is important to ensure constant firing of the boiler for a minimum of one hour after
application of ECONOMIX.
A white/grey vapour will be evolved by the ECONOMIX upon re-firing the boiler after
application, and this will continue for 2 - 5 minutes. The vapour is harmless and is an
indication that the ECONOMIX is working correctly. After the second application of
ECONOMIX, cleaning will be found to be much easier, hard scale deposits having been
broken down. It is recommended that the boiler is then brushed or vacuumed through in
order to remove loose scale.
__________________________________________________________________________

___________________________________________________________________
C2. A GUIDE TO THE ACTION OF ECONOMIX
Combustion deposits in boilers are formed in two ways:

(a) by the incomplete combustion of carbon sulphur and their complex compounds in
the fuel, and
(b) by corrosion of the boiler material by products of combustion.
These deposits contain carbon (and higher molecular weight compounds rich in carbon)
together with quantities of inorganic materials, and in many instances, products such as
metallic sulphates and oxides which may retain corrosive products of combustion. There
is evidence that these deposits catalyse the reaction between sulphur dioxide and
molecular oxygen forming sulphur trioxide which, in the presence of water, can result in
sulphuric acid. This forms below the acid dew point causing further corrosion. If this
complex deposit is allowed to remain in the boiler, the soot composed of carbon and
other complexes will harden and become increasingly difficult to remove. The bond
formed between the deposit and the metal of the heat exchange surface may be so
strong that normal means of cleaning often will fail to prevent a considerable build-up of
this dry-side scale. Effective methods of treatment may be physical or chemical but the
traditional methods of brushing, scraping and blowing alone are unlikely to remove the
hard scale and deposits without dismantling the boiler.
In any case, to remove such deposits even in the normal inefficient way, the boiler must
be shut down and allowed to cool, with consequent loss of steam or hot water
availability. Wet methods are of course available but these are extremely messy,
sometimes inefficient, and may damage the boiler if applied without allowing the boiler to
cool thoroughly.
ECONOMIX is designed for use where the boiler is working and eliminates the need for
shut-down. At normal temperatures the action of ECONOMIX is to produce, within the
combustion chamber and on the heat exchange surfaces, large quantities of oxidising
gases which react with the deposit chemically by the action of oxygen in the presence of
catalysts. ECONOMIX also reduces the ignition temperature of the carbon in the sooty
deposit: thus it will burn easy and create a typical micro-cellular structure within the
deposit which is readily friable.
ECONOMIX consists of a sophisticated mixture of alkaline nitrates, alkaline earth

nitrates, propellent materials and catalysts in the appropriate physical form and carefully
balanced in both quantity and size. The product is free - flowing under most conditions
to ensure that the components may be readily available in finely divided solid form and
may be picked up by the combustion gas stream and distributed throughout the boiler.
This enables the reaction to take place in both the gaseous and the solid phase.
__________________________________________________________________________

___________________________________________________________________
In order that the chemical reaction take place in even the most inaccessible parts of the
boiler, both the oxygen-bearing material and the catalyst must be propelled there. This
is achieved by including in ECONOMIX ingredients to cause rapid evolution of gas which
propels the finely divided reactants into the boiler gas stream. At this stage some
oxidation reactions are involved and the oxygen overbalance of the mixture is carefully
controlled with adequate nascent oxygen available to oxidise the combustible matter in
the sooty deposit.
The reaction is highly complex and many intermediary products and by-products are
formed. Part of this complex of reactions is one which encourages the formation of
'reaction centres' on the solid deposit surfaces. These 'Centres' initiate reactions on the
surface and within the body of the deposit which both physically and chemically tend to
break down the deposit and break the bond between it and the metallic heat exchange
surface. The result of this is the break-away of the deposit and the formation of friable
pieces and granules of its incombustible parts. These may then be ìreadily removed
from the boiler by normal physical means such as vacuum cleaning or brushing.
Combustion of combustible parts of the deposit normally takes place in completion with
production mainly of carbon dioxide with a little water vapour and sulphur dioxide which
are carried out of the boiler. Alkalis present within the mixture tend to neutralise the
sulphur dioxide and sulphur trioxide in the presence of water and produce a desirable
alkaline residue. As will be seen from the above, ECONOMIX is a highly complex and
carefully devised formulation which is designed to take care of deposit problems in
boilers burning all liquid and solid fuels. It is a carefully balanced product containing both
organic and inorganic ingredients and obtains optimum results in most kinds of boilers.
However, there are certain problems of deposition specific to solid fuel boilers and others
to high pressure boilers burning both solid and liquid fuels. To assist with these
problems, there are two variations of ECONOMIX known as ECONOMIX HD and
ECONOMIX S. These contain certain components which have been proved to assist
with particularly stubborn problems of deposition. The following gives a summary of the
use of the various grades of ECONOMIX:
ECONOMIX -
For general use in all boilers burning fuel oil or solid fuel, whether hot water or process
steam plant. A regular and routine treatment should give maximum fuel economy and
reduce maintenance and labour requirements to a minimum.
__________________________________________________________________________

___________________________________________________________________
ECONOMIX HD -
Developed for use in high temperature boilers burning fuel oil, particularly heavy residual
fuel oils. Certain vanadium complexes form hard residues and these deposits may, in
certain cases, be broken down and eliminated by the use of ECONOMIX HD. This use
facilitates the rapid physical removal of this type of deposit and many others which will
not yield to normal treatment.
ECONOMIX S -
Designed specifically for use with solid fuel boilers. A result of original work which
indicates that deposits of both fly-ash and incomplete combustion of solid fuels may be
minimised by treatment affecting the ignition temperature of carbon. ECONOMIX S does
not replace the original ECONOMIX but in certain specific cases its use may be
indicated. It may be used for boilers burning wood, peat, rubber and waste materials
and also for waste- heat boilers.
ECONOMIX X SUPER, ECONOMIX HDG and ECONOMIX G - Full details of these

products are available on request.
__________________________________________________________________________

___________________________________________________________________
Appendix D : COMPLAINT INFORMATION FORM
In case of any complaints please furnish following information for arranging prompt
After-Sales-Service.
Name of the Company
Address
Phone No. Telex No. Fax No.
Unit Model Sr. No.
Design pressure Temp.
Year of Make
Defective equipment & Make
Model & Sr. No.
Date of Installation
Date of Commissioning
Contact Person
Plant / Department
Weekly Off
Nature of Complaint
Name of person :
Designation :
Date :
__________________________________________________________________________

___________________________________________________________________
APPLICATION FOR TRAINING COURSE
To, From :
The Training Officer, __________________________________

Customer Services Dept.,
Process Heating Division, __________________________________
Thermax Limited.,
MIDC, Chinchwad, __________________________________
Pune - 411 019
Dear Sirs,
We wish to send the following participants for the training course at your factory.
__________________________________________________________________
Training on Tick Model Sr. No.

__________________________________________________________________
1. Revomax
2. Thermopac Oil/Coal
___________________________________________________________________
Tick whichever is applicable.
___________________________________________________________________
Name Designation
___________________________________________________________________
Technical Qualifications
___________________________________________________________________
Present duties in the organisation
___________________________________________________________________
Practical experience in Boiler/ Period :
Thermopac maintenance Make :
___________________________________________________________________
Languages known Read Write Speak
English
Hindi
___________________________________________________________________
Yours faithfully,
Customer's Signature
IMPORTANT : Please go through the instructions given on the next page before filling
in the particulars.
__________________________________________________________________________

___________________________________________________________________
INSTRUCTIONS FOR APPLICATION FOR TRAINING COURSE
THERMAX LIMITED
CHINCHWAD, PUNE - 411 019
1. The course covers operation, maintenance, electrical circuits and trouble

shooting aspects of boilers/Thermopacs.
2. The course is generally conducted in English and hence we suggest that you
depute a person who knows English and has some electrical background.
3. The clients should send the detailed particulars of the participant as required
in the application form.
4. If you have any problem on operation and maintenance or any clarification

on your unit, please prepare a list and send it through your participant so that
the same can be discussed and a solution provided.
5. Training charges of Rs. 600/- per participant are required to be paid in

advance by a demand draft in favour of Thermax Limited, Pune. ( Please
check with our nearest office for present training charges.)
6. The duration of the course is three days.
7. The participants should contact our Training Officer at our Chinchwad

factory at 9.30 AM on the day of commencement of the course.
8. The participants shall make their own arrangement for lodging and boarding.
Decent hotel accommodation is readily available in Chinchwad / Pimpri area
within 3 to 4 kms from our factory. Some of the hotels are Prince, Mayur,
Casino, Suryakiran, Panchshil and Emerald Park.
9. Lunch and tea/coffee will be served during training sessions.
10. Our factory is located on the east of Bombay-Poona Road, and is about two
kms. from Chinchwad Railway Station, and about 23 kms. from Pune
Railway Station. Buses and auto rickshaws are available.
__________________________________________________________________________

___________________________________________________________________
SECTION 5
MANUALS & LEAFLETS

FOR
REVOMAX BOILER
REVOMAX PLUS BOILER
(NON IBR)
MODEL : RXA – 02,03,04,05,06
RXD – 04, 06, 850
___________________________________________________________________________

___________________________________________________________________
Contents
HANDBOOKS
NO. DESCRIPTION UNIT MAKE MODEL
DAMPF-
RXA-02 LH / GAS SIMPLEX
KOLBEN
1 WATER PUMP
RXA-03 TO 06 & RXD 04 TO DAMPF-
LH / GAS TRIPLEX
850 KOLBEN
RXA-02 to 06 & RXD-04 to

FO /LH PETERCEM MA 810
SEQUENCE RXD-850
2
CONTROLLER RXA-02 to 06 & RXD-04 to LANDIS /
GAS LFL 1.122
RXD-850 GYR
RXA-02 to 06 , RXD-04 to 850

DOM-415 SELECTRON DTC-503
TEMPERATURE LH, FO & GAS
3
SWITCH
RXA-02 to 06, RXD-04 to 850 EXP-380 & FUJI
PXZ4,NAY2-1VC75
LH & GAS EXP-415 ELECTRIC
KROM
RXA-02 1- 2 BAR RP 1/2'' x 1"
SCHRODER
KROM
RXA-03 to 06 & RXD-04, 06 1- 2 BAR RP 1'' x 1"
SCHRODER
4 GAS TRAIN KROM
RXD-850 1- 2 BAR RP 25 NB X 40 NB
SCHRODER
RXA-02 to 06 & RXD-04, 06,

500 MBAR DUNGS DN 25 X DN 25
850
RXA, RXD SERIES FO SUNTEC E6

5 FUEL PUMP
RXA, RXD SERIES LH / HSD SUNTEC AJ 6
PRESSURE
6 RXA, RXD SERIES FO/LH / GAS TRAFAG 940.0079
SWITCH
___________________________________________________________________________

DAMPF - KOLBEN
* LEAFLET DAMPF KOLBEN PUMPS*

INDEX.
Sr.No. Description. Page Number.
1. Introduction. 2
2. Pump Version. 3
3. Pump Selection. 5
4. Complaints and Remedies. 7
5. Fault Tree Analysis. 8
6. Installation, Commissioning and Maintenance. 9
__________________________________________________________________________
1
DAMPF - KOLBEN
1. INTRODUCTION :
A power pump is a constant speed, constant - torque, and nearly constant capacity
reciprocating machine whose plungers or pistons are driven through a crankshaft from an
external source.
Dampf – Kolben presently manufacture pumps which are horizontal, single acting,
reciprocating type piston pumps. These pumps are suitable especially for high pressure
and low flow duties and are designed as per the latest International Standards, to suit
various stringent applications. The designs are ideal for food, chemical, pharmaceutical,
process and service industry.
These are divided into three categories, depending on the number of pistons.
Simplex - Single Piston.
Duplex - Double Piston.
Triplex - Triple Piston.
__________________________________________________________________________
2
DAMPF - KOLBEN
1. PUMP VERSIONS:
The schematic sketches of the feed water pumps assembly are as shown below just to
give an overall idea regarding the construction of the feed water pump.
a. Vertical Stationery Version :
b. Horizontal Stationery Version.
__________________________________________________________________________
3
DAMPF - KOLBEN
c. Directly coupled units.
Directly Coupled Models

The new version offers:-
• Extremely easier online service. Valve assemblies can be removed/replaced without

opening suction & delivery piping.
• Greater safety. No rotating parts are exposed as there are no pulleys & belts.
• Better efficiency being coupled directly.
• Higher working life of essential components. Pistons are replaced by ceramic
plungers. Important machined components are replaced by forged components.
• Low noise and vibration levels. Extremely low pulsations.
• Extremely compact design. Consumes much lesser space.
__________________________________________________________________________
4
DAMPF - KOLBEN
3. PUMP SELECTION:
While selecting the pump for a suitable application following points are required to be
considered.
A] Pressure / Head:-
• Reciprocating pump theoretically can develop any pressure irrespective of the basic
pump design.
• The maximum operating pressure in case of such pumps is the maximum pressure
which the pump can mechanically withstand.
• Thus, any amount of pressure within the operating range can be developed by
increasing the resistance ( e.g. By throttling the delivery valve or by introducing an
orifice in the delivery line. )
B] Flow:-
• As per the affinity laws, the flow is directly proportional to the speed ( rpm ).
• The desired flow can be achieved by running the pump at a particular Speed.
• This speed can be known by calculating exact pulley ratio of the pump and the prime
mover.
• Theoretically, a reciprocating pump delivers constant flow, at a particular speed,

irrespective of the system head.
• Practically, a variation in flow to an extent of 2 to 10 percent is observed

which is termed as valve loss.
__________________________________________________________________________
5
DAMPF - KOLBEN
C] Performance Curve:-
The performance curves of the pump gives the complete idea regarding
behaviour of pump with respect to its capacity in terms of flow, head and speed as shown in
below graph which is attached for understanding purpose.
__________________________________________________________________________
6
DAMPF - KOLBEN
4. COMPLAINTS AND REMEDIES :
A] Variation in Flow:-
Sr.No. Complaint. Remedy.
1. Clogged suction strainer Clean the strainer.

2. Low pump speed Correct the speed.
3. Inadequate gland lubrication Lubricate glands.
4. Clogged valve assemblies Clean the valve
B] Undue Noise / Undue Vibration:-
1. Check pump mounting.
2. Check pulleys for proper fitment.
3. Check belt tension.
4. Check crank case oil level.
5. Check con-rod bearing for wear & tear.
6. Check ball bearings.
7. Check suction strainer.
C] Pump Leakages:-
1. Check teflon washers for distortion.
2. Tighten gland nuts or replace gland washers for leakage from valve box.
3. Check piston / bearing oil seals in case of oil leakages.
D] Bearing Failure:-
1. Check for improper pulley alignment & excessive belt tension.
2. Ensure proper quality & quantity of lube oil.
__________________________________________________________________________
7
DAMPF - KOLBEN
E] Pump Runs Hot:-
1. Check temperature of liquid handled.
2. Check fitment & quality of con-rod bearing as well as ball bearings.
5. FAULT TREE ANALYSIS :

The fault tree analysis serves as easy check point to determine the probable cause of the
defect causing the pump to operate abnormally.
The sketch as shown below will help in identifying the probable cause if the pump fuctions
abnormally,
__________________________________________________________________________
8
DAMPF - KOLBEN
6. INSTALLATION, COMMISSIONING AND MAINTENANCE.
Fill the pump crankcase with lube oil before starting the pump.
Use SAE 30 / 40 or equivalent grade oil for crankcase lubrication.
Use Castrol make CRD-40 extra or equivalent grade oil when the operating pressure is
more than 40 bar or when the pumpage temperature exceeds 85 deg.C.
Fill first 500 ml. of oil from the top through Breather Plug. Remove the transparent cup of
the Constant Level Oiler (CLO) and fill it with oil. Place the cup in position using the
threads provided. Repeat the procedure till the displacement of oil from the cup to the
crankcase stops.
Ensure that there is some oil in the oil cup. Do not fill oil in the stem provided below the
transparent cup. CLO automatically maintains the oil level inside the crankcase to the
desired level. Remember that irrespective of the level inside the oil cup, the level inside the
crankcase remains constant. Kindly remember that leakage of oil through CLO is only
because of excess of oil filling. Few models are provided with a circular transparent
window on the pump back cover. In such cases, oil should be filled from the top till half the
window is covered.
b) Check Grease Cups for grease. Fill, if necessary.

Ensure proper grade. (Castrol AP-3 or equivalent grade is recommended).
c) Check Pulleys for proper reduction ratio and alignment.
d) Check and ensure proper Belt Tension.
e) Check the pump operating pressure and ensure that it is within the stipulated limit.
f) Check the installation for excessive vibration and noise level.
(Note: Pump is likely to run hot during first 50 hrs of operation. This will slow down as all
the moving parts achieve their respective operating / running tolerances).
DAMPF -- KOLBEN
MAINTENANCE SCHEDULE.
a) Weekly Schedule :-
1. Gland Lubrication – Weekly greasing is recommended. Grease nipples are provided
on the pump. Clockwise rotation of the grease cap forces the grease in to the stuffing
__________________________________________________________________________
9
DAMPF - KOLBEN
box thereby ensuring a lubricating film between the piston and gland washers. Kindly
ensure use of high temperature grease. Pumpage Tempt. along with the heat generated
due to friction causes normal grease to melt down. It gets carried away with the
pumpage. This make the glands run dry and eventually cause gland failure. This
process is usually accelerated during summer season). Suction filter / strainer should
be maintained clean. Clogging of filter / strainer can cause flashing of pumpage
(cavitation). The latent heat generated being very high causes immediate failure of
glands. This also can result in undue noise level and vibrations in the pump.
2. Ensure that the pump is operating at the rated pressure. Use of pressure gauge on the
delivery side is highly recommended. Needle fluctuations shall indicate clogged
suction strainer, worn out glands or clogged valve assemblies.
b) Monthly Schedule:-
1. Check and verify the oil level in the crankcase. The crankcase is usually filled half
with the oil. Use CLO as explained above.
2. Check gland leakage. If this exceeds 15 / 20 drops per piston per minute, tighten gland
nut lightly. If the leakage is heavy, water jet can strike the piston oil seal with pressure
resulting in water getting mixed up with the crankcase oil.
3. Check and ensure that the oil cap vent hole is not clogged. This can prevent movement
of hot air from the crankcase to the atmosphere. This puts undue pressure on the oil
seals thereby causing leakage of oil.
c) Quarterly Schedule :-
1. Check glands for leakage. Glands have a normal operating life of 3 to 6 months
depending on various aspects like pumpage temperature, suspended solids in the
pumpage, proper / improper maintenance, suction conditions, pump speed etc.
Maximum life can be expected for pumpages like clear cold water. Glands are
normally tightened so that there is a drop by drop leakage of water which provides a
lubricating and cooling film between the piston and the gland packings.
(Leakage upto max. of 30 drops per piston per minute is allowed by Hydraulic
Institute Std.) Expectation of zero gland leakage is always at the cost of gland life.
To avoid breakdown maintenance, it is preferred to change glands every six months.
As explained above, there are various conditions affecting the exact gland life which
can change from installation to installation. The replacement schedule for a particular
site hence should be fixed based on the gland life of that typical installation during the
first year of operation.
d) Six Monthly Schedule:-

2. Change lubricating oil (for daily average running of more than 4 / 5 hrs.)
e) Annual Schedule:-
1. Clean valve seat assemblies. Check contact areas of valve and valve seat for wear and
tear. Light lapping of these areas shall ensure a better contact. Teflon washers act as
sealing gaskets and hence should be replaced when found deformed.
__________________________________________________________________________
10
DAMPF - KOLBEN
2. Check oil seals for leakages (piston oil seals and bearing oil seal). Change, if
necessary. The oil seal life depends on the type of application and other relevant field
conditions.
3. Check Connecting Rod Bearing Pieces for wear and tear (Big End). Replace, if
necessary. Check small end bush for wear.
4. Check Ball Bearings.
5. Check Crank Pins of the crankshaft for wear.
6. Check Back Cover Gasket for leakage.
7. Check Constant Level Oiler for cracks etc.
8. Check Breather Plug. Clean from inside.
9. Check Pistons for “Scratches”. Deep and long scratches will reduce the life of gland
washers significantly.
Dampf - Kolben
Unit No 04, Sharada Indl Estate,
Ajinkyanagar, Hingne ( K ),
Sinhagad Road,
Pune 411 051
Contact Persons :
Mr. Anand D. Bapat
Mr. Ratnakar Bagul ( M – 9822942245 )
Ms. Deepa
Phone : 91 - 020 - 24346064, 24348334

Mob. : 9623720264
E-mail : dkolben11@gmail.com
__________________________________________________________________________
11
7 451
ISO 9001
Gas Burner Controls LFL1...
Supplementary data sheet 7712
Gas burner controls for gas, oil or dual-fuel forced draught burners of medium to
high capacity. Multistage or modulating burners in intermittent operation *) with air
pressure for checked supervised air damper control.
The gas burner controls are tested to EN 298 and CE-certified in compliance with
the directives for gas-fired appliances and electromagnetic compatibility.
The LFL1... and this data sheet are intended for use by OEMs that integrate the
burner controls in their products.
*) For safety reasons, at least one controlled shutdown must take place every
24 hours!
Use The burner controls of the LFL1... range are designed for the control and supervision of
forced draught gas burners of both expanding flame and interrupted pilot construction of
medium to high capacity. They are universally applicable and can be used for both
multistage and modulating burners as well as for dual-fuel burners and for burners of
stationary air heaters (WLE to DIN 4794).
The difference between series 01 and 02 lies in the duration of the safety time for the
pilot burner of burners using pilot gas valves.
For atmospheric burners of high capacity, type LFL1.638 is available.
For burner controls used with burners in continuous operation, refer to data sheet
7785, types LGK16... .
Mechanical design The burner controls are of plug-in design. Housing and plug-in baseplate consist of
shock- and heat-resistant black plastic.
The lockout indicator, the fault signal lamp and the reset button are located in the viewing
window of the unit. The burner control is supplied with an exchangeable unit fuse and a
spare fuse.
Landis & Staefa CC1N7451E October 06, 1997 1/13

Functions
With regard to The following LFL1.... features exceed the relevant standards, thus offering a high
standards level of additional safety:
– Detector and extraneous light tests are restarted immediately after the tolerated after-
burn time. This means that open or not fully closed fuel valves initiate a lockout
immediately after this time has elapsed. The tests end only on completion of the pre-
purge time of the next burner startup
– The correct functioning of the flame supervision circuit is automatically checked during
each burner startup sequence
– The control contacts for the fuel release are checked for welding during the post-purge
time
– A built-in unit fuse protects the control contacts against overloads
With regard to the – The units permit burner operation with or without post-purging
control of the burner – Fan motors with a current draw of up to 4 A (starting current 20 A max.) can be directly
connected
– Separate control outputs for OPEN, CLOSE and MIN of the air damper actuator
– Checked air damper control to ensure pre-purging with the nominal amount of air.
Checked positions: CLOSED or MIN (low-flame position) at the start, OPEN at the
beginning, and MIN on completion of the pre-purge time. In case the actuator does not
drive the air damper to the required position, the burner startup sequence will be
interrupted
– Functional test of the air pressure monitor before the startup and supervision of the air
pressure from the beginning of the required pre-purge time until controlled shutdown
occurs
– Separate control output for a pilot gas valve which is closed after the 2nd safety time
has elapsed
– Two control outputs for the release of the 2nd and, if necessary, 3rd output stage (or
load control)
– With burner controls of series 01 and expanding flame, it is possible to increase the
safety time from 2.5 to 5 s by a very simple measure (refer to "Engineering Notes"),
provided the longer safety time complies with the local safety regulations
– When load control is enabled, the control outputs for the air damper actuator are
galvanically separated from the control section of the unit
– Connection facilities for remote lockout warning device, remote reset and remote
emergency shutdown
With regard to flame Methods of flame supervision:

supervision
a) With an ionization current detector electrode, in networks with earthed or unearthed
neutral. For this supervision method, the flame supervision circuit is designed such
that possible disturbances of the ionization current due to the ignition spark normally
cannot have any influence on the establishment of the flame signal. A short-circuit
between detector electrode and burner ground cannot simulate a flame signal
b) With UV detectors of the QRA... range (gas and oil burners).
Refer to data sheet 7712
c) With simultaneous use of ionization current detector electrode and UV detector (e.g.
with interrupted pilot burners or gas-electrically ignited oil burners)
With regard to mounting – Mounting location and position optional (degree of protection IP40)
and electrical
installation
Baseplate – 24 connection terminals

– 2 auxiliary terminals, galvanically separated, with the markings «31» and «32»
– 3 earth terminals in the form of a latch for earthing the burner
– 3 neutral terminals, pre-wired to terminal 2, which is the neutral input
– 14 knockout entries for the cable entry by means of cable glands, 8 of which at the
side and 6 in the bottom of the baseplate
– 6 lateral threaded knockout entries for cable entry glands Pg11
2/13 CC1N7451E October 06, 1997 Landis & Staefa

Connection diagram
A z m a
t7 t16
t10
t11
P
t1
t3´
t12
t3
t2´ t2
t4 1
t4´
t9
t5 2
t5
B
AS C
D t6 t13
A
1 2 21 3 13 12 14 4 5 6 7 16 17 18 19 20 9 11 10 8 22 23 24
LR
+
d1 d2 QRA...
bv... W GP
SB 1
SA v a z m
R N N
M
3)
EK2 22 23 24
H t2´, t3´, t4´, only with:
BV1 BV2 BV3 LFL1.335,
M1 M2 Z LFL1.635 and
LK FE
S AL LP LFL1.638
L ZBV BV1 BV2
N
2 3 4 5 7451a02e/0496 6
1 7
Control signals of burner control

Permissible input signals
Required input signals: if these signals are missing at the time marked by symbols or during the
shaded phases, the burner control interrupts the startup sequence or initiates lockout. Legend for the
symbols: see «Lockout indication»
Switches, fuses , earthing, etc., must be in compliance with the local regulations. For the connection of valves and
Engineering notes other components, refer to the diagram provided by the burner manufacturer.
① Phase and neutral may not be interchanged!

Safety limit thermostats (manual reset, e.g. STB) have to be connected in the line.
② Remote reset: when button «EK2» is connected to terminal 3, only remote reset is possible; when
connected to terminal 1, only emergency shutdown is possible.
③ Required switching capacity of the contacts between terminals 12 and 4 as well as between 4 and 14:
depending on the load on terminals 16 ... 19.
④ Air pressure supervision: if the air pressure is not monitored by means of an air pressure monitor «LP»,
terminal 4 must be connected to terminal 12 and terminal 6 to terminal 14. Terminal 13 remains unused!
Control contacts of other devices in the burner installation are to be connected in series as follows:
To terminal 12: contacts which must be closed only during startup (otherwise no start).
To terminal 4 or 5: contacts which must be closed from startup to the controlled shutdown (otherwise no
start or controlled shutdown).
To terminal 14: contacts which must be closed at the latest at the beginning of the pre-ignition time and
which must remain closed until controlled shutdown occurs (otherwise lockout). This is valid for both long
and short pre-ignition.
⑤ • Connection of fuel valves with expanding flame burners. With two-stage burners, BV2 is connected
instead of BV3.
•• Connection of fuel valves with interrupted pilot burners.
The direct connection of a fuel valve to terminal 20 is permitted only in
– installations with a main shutoff valve on the mains side (safety valve) which is controlled by
terminals 18 or 19, and
– if two-stages valves are used, provided they fully close when the 1st stage - which is controlled
by terminal 18 or 19 - is switched off.
⑥ For further examples of air damper control, refer to «Connection examples». In the case of air damper
actuators without limit switch «z» for the CLOSED position of the damper, terminal 11 must be connected
to terminal 10 (otherwise no burner start).
⑦ Simultaneous use of ionization and UV supervision is possible.

Connection diagram
L
LFL1... H
SB
1
AS FE
br1
a b 22 23 24
ar2
ar1 I a XV
a b b
4 12 6 7
QRA...
W +
LP d1 d2
GP
R 22 23 24
M1 M2
N
5 13 14 V
FR
fr1 fr3 fr2
a b b a
XI (1) (2)
XIII
b a a b XII NTC
XIV a b
AR IV
a b
VII
3) br2 a b
EK1 VI V III ar3
L1 II X VIII
E M a b a b M
BR b a a b a b SM
A
3 21 2 15 16 17 18 19 20 9 11 10 8
LR
1 SA v a z m
AL Z M LK
3) BV2 7451a12/0496
EK2 ZBV BV1 BV1
H
N BV2
For the connection of the safety valve, refer to the diagram provided by the burner
manufacturer.
Legend a Changeover limit switch for OPEN position m Auxiliary switch for the MIN position of the
for the entire data sheet of air damper air damper
AL Remote lockout warning device (alarm) M... Fan or burner motor
AR Main relay (working relay) with contacts «ar...» NTC NTC resistor
AS Unit fuse QRA... UV detector
BR Lockout relay with contacts «br...» R Control thermostat or pressurestat
BV... Fuel valve RV Continuously adjustable fuel valve
bv... Control contact for the CLOSED position of S Fuse
gas valves SA Air damper actuator
d... Contactor or relay SB Safety limiter (temperature, pressure, etc.)
EK... Lockout reset button SM Synchronous motor of the sequence
FE Ionization current detector electrode mechanism
FR Flame relay with contacts «fr...» v In the actuator: auxiliary changeover
GP Gas pressure monitor switch for the release of fuel according to
H Mains isolator the air damper position
L1 Fault signal lamp V Flame signal amplifier
L3 Operational readiness indication W Limit thermostat or pressure monitor
LK Air damper z In the actuator: limit switch for the
LP Air pressure monitor CLOSED position of the air damper
LR Load controller Z Ignition transformer
ZBV Pilot gas valve
• Valid for expanding flame burners

•• Valid for interrupted pilot burners
(1) Input for the increase in operating voltage for the UV detector (detector test)
(2) Input for forced energizing of the flame relay during functional test of the flame supervision circuit
(contact XIV) and during safety time t2 (contact IV)
3) Do not press EK for more than 10 seconds!

Notes on the
program sequence
Sequence diagram
t2´, t3´, t4´:

These times are valid only for the burner controls of series 01, i.e. LFL1.335, LFL1.635
and LFL1.638.
They do not apply to the units of series 02, as cams X and VIII of these types switch
simultaneously.
Mode of operation The diagrams above show both the connection circuit and the control program of the
sequence mechanism.
A Start command (given by the control thermostat or pressurestat «R» of the installation)
A-B Startup sequence
B-C Burner operation (heat generation according to the control commands of load
controller «LR»)
C Controlled shutdown through «R»
C-D Sequence mechanism runs into start position «A», post-purging
During burner off periods, only control outputs 11 and 12 are under voltage and the air
damper is in its CLOSED position which is determined by limit switch «z» of the damper
actuator. In order to carry out the detector and extraneous light test, the flame supervision
circuit is under voltage, too (terminals 22/23 and 22/24).
Prerequisites for burner – Burner control not interlocked in lockout position

startup – Air damper closed, limit switch «z» for the CLOSED position must supply voltage from
terminal 11 to terminal 8
– The control contacts for the CLOSED position of fuel valves (BV...) or other contacts
between terminal 12 and «LP» with similar control functions must be closed
– The N.C. contact of the air pressure monitor «LP» must be closed (LP test), that is,
terminal 4 must be under voltage
– The contacts of the gas pressure monitor «GP» and of the limit thermostat or pressure
monitor «W» must also be closed

Startup sequence
A Start command by «R»
(«R» closes the control loop between terminals 4 and 5).
The sequence mechanism starts to run. At the same time, the fan motor receives voltage
via terminal 6 (only pre-purging). After t7 has elapsed, the fan motor or the flue gas fan
also receives voltage via terminal 7 (pre- and post-purging).
On completion of t16, the control command to open the air damper is given. During the
actuator's running time, the sequence mechanism stops, as terminal 8 - via which the
sequence mechanism is at first supplied with voltage - does not receive any voltage
during this time. The sequence mechanism continues to run only after the air damper has
fully opened.
t1 Pre-purge time with air damper fully open
During the pre-purge time, the correct functioning of the flame supervision circuit is tested
(de-energizing of flame relay). The burner control goes into lockout position, if the relay
does not function correctly.
Shortly after the beginning of the pre-purge time, the air pressure monitor must change
over from terminal 13 to terminal 14, otherwise the burner control initiates lockout (start of
air pressure check). At the same time, terminal 14 must be under voltage, as the ignition
transformer and the fuel valves are supplied with voltage via this current path of the
circuit.
After completion of the pre-purge time, the burner control drives the air damper via
terminal 10 into the low-flame position which is determined by the changeover point of
the auxiliary switch «m». During the running time, the sequence mechanism stops again.
Shortly after that, the motor of the sequence mechanism is switched onto the control
section of the burner control. That is why position signals to terminal 8 as of now do not
affect the further startup of the burner (and the subsequent burner operation):
t5 Interval. After t5 has elapsed, load controller «LR» is released via terminal 20.
With that, the startup sequence of the burner control ends. The sequence mechanism
switches itself off, either immediately or after some so-called «idle steps»; these are
steps without change of the contact positions, depending on the time variant.
Expanding flame
burners
t3 Pre-ignition time, then release of fuel on terminal 18
t2 Safety time (start load)
On completion of the safety time, a flame signal must be present at input 22 of the flame
signal amplifier. It must be continuously present until controlled shutdown takes place,
otherwise the burner control goes into lockout position and interlocks itself in this position.
t4 Interval. On completion of t4, terminal 19 is under voltage. Thus the fuel valve at auxiliary
switch «v» of the air damper actuator is supplied with voltage.
Interrupted pilot burners
t3 Pre-ignition time, then release of fuel for the pilot burner at terminal 17.
t3´
t2 1st safety time (pilot load)
t2´ On completion of the safety time, a flame signal must be present at input 22 of the flame
signal amplifier. It must be continuously present until controlled shutdown takes place,
otherwise the burner control goes into lockout position and interlocks itself in this position.
t4 Interval up to the release of the fuel valve at terminal 19 for the start load of the main
t4´ burner.
t9 2nd safety time. On completion of the 2nd safety time, the main burner must have been
ignited by the pilot burner, since terminal 17 becomes idle as soon as this time has
elapsed, causing the closure of the pilot gas valve.
B Operating position of burner
B-C Burner operation
During burner operation, the load controller drives the air damper to the nominal load or
low-flame position, depending on the demand for heat. The release of the nominal load is
carried out by auxiliary switch «v» in the air damper actuator.

C Controlled shutdown
During controlled shutdown, the fuel valves are immediately closed. At the same time,
the sequence mechanism starts and programs the
t6 Post-purge time (fan M2 at terminal 7).

Shortly after the start of the post-purge time, terminal 10 receives voltage, so that the air
damper is driven to the MIN position.
The complete closing of the damper starts only shortly before the post-purge time has
elapsed, initiated by the control signal on terminal 11, which also remains under voltage
during the following burner off period.
t13 Permissible after-burn time. During this time, the flame supervision circuit may still
receive a flame signal without initiating burner lockout.
D-A End of control program (start position)

As soon as the sequence mechanism has reset the control contacts into their start
position - on completion of t6 - the detector and extraneous light test starts again. During
the burner off period, a faulty flame signal of a few seconds only initiates lockout. Short
ignition pulses of the UV tube, e.g. caused by cosmic radiation, do not initiate burner
lockout.
Times t2´, t3´ and t4´ are only valid for burner controls of series 01.
Warning notes • In the geographical areas where DIN standards are in use, the installation must
be in compliance with VDE requirements, particularly with the standards DIN /
VDE 0100 and 0722!
• All regulations and standards applicable to the particular application must be
observed!
• Installation and commissioning work must always be carried out by qualified
personnel!
• Condensation and ingress of humidity must be avoided!
• To protect the flame signal amplifier from electric overloads, both ignition and
detector electrode must be located such that the ignition spark cannot arc over
to the detector electrode!
• Ignition cables must always be laid separately, maintaining the greatest
possible distance to the unit and other cables!
• Observe the notes on the laying of detector cables (refer to «Technical data»)!
• The electrical wiring must be made in compliance with national and local
standards and regulations!
• LFL1... are safety devices. It is therefore not permitted to open, interfere with or
modify the units!
• Check wiring carefully before putting the burner control into operation!
• The LFL1... must be completely isolated from the mains before performing any
work on it!
• Check all safety functions when putting the burner control into operation or after
performing service work!
• Ensure protection against electric shock on the unit and on all electrical
connections through appropriate mounting!
• Electromagnetic emissions must be checked from an application point of view!
• When used in connection with QRA..., terminal 22 must be earthed!
• Supervision with both detector electrode and UV detector QRA... is possible, but
for safety reasons, only one flame detector may be active at a time, with the
exception of safety time t9. At the end of the 2nd safety time, one of the
detectors must be inactive, that is, the detected flame must have extinguished,
e.g. by shutting down the pilot valve at terminal 17!
• UV detectors QRA... can be connected in parallel!

Control program In case of any disturbance, the sequence mechanism stops and with it the lockout
under fault indicator. The symbol above the reading mark of the indicator gives the type of
conditions and disturbance:
lock-out indication
No start, e.g. because one contact is not closed (also refer to «Prerequisites for
burner startup»). Lockout during or after control program sequence due to
extraneous light (e.g. non-extinguished flames, leaking fuel valves, defects in the
flame supervision circuit, etc.)
Interruption of startup sequence, because the OPEN signal has not been
delivered to terminal 8 by limit switch «a». Terminals 6, 7 and 14 remain under
voltage until the fault has been corrected!
Lockout, because there is no air pressure indication at the beginning of air

pressure control.
Every air pressure failure after this moment in time leads to lockout, too!
Lockout due to a fault in the flame supervision circuit.
Interruption of startup sequence, because the position signal for the low-flame
position has not been delivered to terminal 8 by auxiliary switch «m». Terminals 6,
7 and 14 remain under voltage until the fault has been corrected!
Lockout, because no flame signal is present after completion of the (1st) safety
time.
Lockout, because no flame signal has been received on completion of the 2nd
safety time (flame signal of the main flame with interrupted pilot burners).
Lockout, because the flame signal has been lost during burner operation.
If lockout occurs at any other moment in time between the start and the pre-ignition which
is not marked by a symbol, this is usually caused by a premature, i.e. faulty flame signal,
e.g. caused by a self-igniting UV tube.
Lockout indication a-b Startup sequence
b-b' «Idle steps»

(without contact confirmation)
b(b')-a Post-purge program
LFL1..., series 01 LFL1..., series 02
• Duration of safety time with expanding flame burners

•• Duration of safety time with interrupted pilot burners
When lockout occurs, the burner control can immediately be reset. After resetting (as
well as after correction of a fault which resulted in a controlled shutdown or after each
mains failure), the sequence mechanism always returns to its start position, whereby only
terminals 7, 9, 10 and 11 receive voltage in accordance with the control program. It is
only then that the burner control begins with a new burner startup.

Connection
examples
Doubling of safety time 16 17 18 19 Only when a burner control of series 01 is used.

with expanding flame Due to these circuit measures (connection of
BV2
burners terminals 17 and 18), the pre-ignition time is
Z BV1 reduced to 50 %.
N
7451a10/1295
Extension of the safety time is permitted only if this is in compliance with the standards of
the respective country.
Burner without air 6 11 10 8 In case of burners without air damper (or with an
damper air damper not controlled and supervised by the
burner control unit), terminal 8 must be connected
M to terminal 6, as otherwise the burner control
N 7451a11/0396 cannot carry out the burner startup.
Two-stage expanding Load control with an ON/OFF controller. The air damper is closed during burner off
flame burner periods.
16 17 18 19 9 20 11 10 8
LR L...
11 7 1 6 5 2 10 8 LR
SA
SA
IV I M II III
BV1/BV2
13 12 N 3 4 9
Z BV1 BV2 7451a03/0396 LK

N
A B C D
T P R
t7 t1 t6
M
M1
~ M2
t3
Z
t2
BV1
t4
R LR t5
100%
M
min.
LK 0...
BV2 t11 t12
t13
FS
7451a06/0396
Control of actuator «SA» according to the single-wire control principle (actuator «SA»:
e.g. type SQN3... according to data sheet 7808). For other connections, refer to
«Connection diagrams».

Modulating expanding Load control with a modulating controller with galvanically separated control contacts for
flame burner OPEN and CLOSED positions.
16 17 18 19 20 9 11 10 8
L...
LR LR
N SA SA RV
a z m BV1
M
Z BV1 RV LK
N
7451a04/1295
A B C D
T
P R
t7 t1 t6
M
~
M1
M2
t3
Z
t2
BV1
t4
R LR
t11 t12 t5
100%
M
min.
LK 0...
RV
t13
FS
7451a07/1295
The air damper is closed during burner off periods. For other connections, refer to
Two-stage interrupted Controlled and supervised by a burner control of series 01.

pilot burner
16 1 7 18 1 9 20 9 11 10 8
L...
LR
LR
ZBV SA v a z m SA
M
BV1/BV2
ZBV
Z BV1 BV2 LK
N 7451a05/0496
A B C D
T
P R
t7 t1 t6
M
M1
~
M2
t3´
Z
t2´
ZBV
t4´ t9
BV1
R LR
t5
M 100%
min.
LK 0...
BV2 t11 t12
t13
FS
7451a08/1295
The air damper is closed during burner off periods. For other connections, refer to

Mains voltage AC 220 V - 15 % ... 240 V + 10 % Required switching capacity of switching devices
Technical data AC 100 V - 15 % ... 110 V + 10% – Between terminals 4 and 5 1 A, AC 250 V
– Between terminals 4 and 12 1 A, AC 250 V
Mains frequency 50 Hz - 6 % ... 60 Hz + 6 % – Between terminals 4 and 14
Power consumption 3 VA depending on load on terminals 16 to 19,
1 A min., AC 250 V
Unit fuse,
built-in T6, 3H 250 V to IEC 127 Permissible mounting position optional
Degree of protection IP40
Unit fuse, external 16 A max., slow
Weight
Radio interference – Burner control approx. 1000 g
protection N to VDE 0875 – Baseplate approx. 165 g
Permissible input current

at terminal 1 5 A to VDE 0660 AC 3
Perm. loading of control

terminals 4 A to VDE 0660 AC 3
Environmental conditions CE conformity

- Transport IEC 721-3-2 According to the directives of the European
Community
Climatic conditions class 2K2 Electromagnetic compatibility EMC
Temperature -50...+70 °C 89/336 EEC incl. 92/31 EEC
Humidity < 95 % r.h. Gas appliance directive 90/396 EEC
Mechanical conditions class 2M2 Emissions EN 50081-1
- Operation IEC 721-3-3 Immunity EN 50082-2
Climatic conditions class 3K5
Temperature -20...+60 °C
Humidity < 95 % r.h.
Condensation, formation of ice and ingress of water are not permitted.
Ionization current supervision Voltage at detector electrode Maximum permissible length of detector cable
– Operation AC 330 V ± 10 % – Normal cable, laid separately ²) 80 m
– Test AC 380 V ± 10 % – Shielded cable, 140 m
e.g. high frequency cable; shielding connected to
Short-circuit current 0.5 mA max. terminal 22
Minimum ionization current required 6 µA
Recom. range of measuring instrument 0 ... 50 µA
UV supervision Supply voltage Weight

– Operation AC 330 V ± 10 % – QRA2 60 g
– Test AC 380 V ± 10 % – QRA10 450 g
Minimum detector current required ³) 70 µA Identification code to EN298:

all types (except LFL1.148) FBLLXN
Maximum detector current
– Operation 680 µA
– Test 1000 µA ¹)
Max. perm. length of detector cable

– Normal cable, laid separately ²) 100 m
– Shielded cable, 200 m
e.g. high frequency cable; shielding connected to
terminal 22
¹) During the pre-purge time with increased test voltage: self-ignition and extraneous light test
²) Laying in multi-core is not permitted
³) For better reading, connect an electrolytic capacitor of 100 µF, DC 10 V, parallel to the measuring
instrument, +pole of the instrument connected to terminal 23

Ordering
Available types Switching times are given in seconds, in the burner startup sequence, valid for a frequency of 50 Hz. In case of 60
Hz, the times are reduced by approx. 20 %.
LFL1.122 ¹) LFL1.133 ¹) LFL1.322 ¹) LFL1.333 ¹) LFL1.335 ¹)

Series 02 Series 02 Series 02 Series 02 Series 01
Preferred types for / in:

Flash Flash D (also A GB
steam steam for WLE) D
generator generator F
t1 10 9 36 31.5 37.5
t2 2 3 2 3 2.5
t2´ − 3 − − 5
t3 4 3 4 6 5
t3´ − − − − 2.5
t4 6 6 10 12 12.5
t4´ − − − − 15
t5 4 3 10 12 12.5
t6 10 14.5 12 18 15
t7 2 3 2 3 2.5
t8 30 29 60 72 78
t9 2 3 2 3 5
t10 6 6 8 12 10
t11 optional
t12 optional
t16 4 3 4 6 5
t13 10 14.5 12 18 15
t20 32 60 − 27 22.5
LFL1.622 ¹) LFL1.635 ¹) LFL1.638

Series 02 Series 01 Series 01
F B Large atmospheric
I NL ²) burner
t1 66 67.5 67.5
t2 2 2.5 2.5
t2´ − 5 5
t3 4 5 5
t3´ − 2.5 2.5
t4 10 12.5 12.5
t4´ − 15 15
t5 10 12.5 12.5
t6 12 15 15
t7 2 2.5 2.5
t8 96 105 105
t9 2 5 7.5
t10 8 10 10
t11 optional
t12 optional
t16 4 5 5
t13 12 15 15
t20 − − −
¹) Available in 100...110 V, please add AC 110 V to type reference when ordering

²) Reversed polarity protection according to Dutch installation standard: AGM30
Legend for the times t1 Pre-purge time with air damper open
t2 Safety time
t2' Safety time or 1st safety time with burners using pilot burners
t3 Pre-ignition time, short (ignition transformer on terminal 16)
t3' Pre-ignition time, long (ignition transformer on terminal 15)
t4 Interval between start of t2 and release of valve at terminal 19
t4' Interval between start of t2' and release of valve at terminal 19
t5 Interval between end of t4 and release of load controller or valve at terminal 20
t6 Post-purge time (with M2)
t7 Interval between start command and voltage on terminal 7 (start delay time for fan motor M2)
t8 Duration of startup (without t11 and t12)
t9 2nd safety time with burners using pilot burners
t10 Interval from startup to beginning of air pressure check without running time of air damper
t11 Running time of air damper into OPEN position
t12 Running time of air damper into low-flame position (MIN)
t13 Permissible after-burn time
t16 Interval until OPEN command for the air damper is given
t20 Interval until self-shutdown of the sequence mechanism after burner startup

Dimensions LFL1... with baseplate AGM410490550
1,5
123
25 25
6
18,9
15,5
7,5 5 7
15 15 15
7451m02/0296
27,5 27,5
37
103
7,5
103
Baseplate AGM410490550
5,2x6,7 40 18,5 13,5 5,7
13 14 15 16 17 18 19 20 21 22 23 24
12
51,5 7,5 18,9 5,7
11
40
10
9
12,8
8 1
31
7
4,4 15
6
26,8
5
51,5 4
N 1,5 25
3
2
32
1
5,2 5,2x6,7
5,7 12,8 40
51,5 51,5 7454m01/0296
© 1997 Landis & Staefa Produktion (Deutschland) GmbH

OPERATING INSTRUCTIONS SAFETY SUMMARY WIRING INSTRUCTIONS DTC303 / DTC303 - NX
This manual is meant for the personnel involved in wiring, CAUTION:
DTC503/503-N/203/303 installation, operation, and routine maintenance of the equipment. 1. To prevent the risk of electric shock power supply to the
short for
RTD short for 2 wire
RTD (PT 100)
short for SHORT FOR
All safety related codifications; symbols and instructions that equipment must be kept OFF while doing the wiring RTD R CONFIG
W TC
appear in this operating manual or on the equipment must be strictly arrangement. W
followed to ensure the safety of the operating personnel as well as 2.Terminals and electrically charged parts must not be touched 1 2 3 4 5 6 7 8 9
when the power in ON. TC+ TC- RTD3
the instrument.
3. Wiring shall be done strictly according to the terminal layout RTD1 RTD2
If the equipment is not handled in a manner specified by For SSR O/P
with shortest connections. Confirm that all connections are
the manufacturer it might impair the protection provided by the + - N L
correct.
equipment. 4. Use lugged terminals to meet M3 screws. 10 11 12 13 14 15 16 17 18
! CAUTION: Read complete instructions prior to installation and 5. To eliminate electromagnetic interference use of short wire NO COM NC (Not valid for DTC303) - +
operation of the unit. with adequate ratings and twists of the same in equal size
RELAY1
CAUTION: Risk of electric shock. shall be made. NOTE: R - Red, W - White
SPECIFICATIONS INSTALLATION INSTRUCTIONS
6. Cable used for connection to power source, must have a
MODELS
SENSOR cross section of 1 or greater. These wires shall have DTC303
!CAUTION: insulation capacity made of at least 1.5KV. DTC503 DTC503-N DTC203 DTC303
T ERMINAL NX
Sensor type Temperature range (0C) Resolution (0C) 1.This equipment, being built-in-type,normally becomes a part of DESCRIPTION
MAINTENANCE L 1 6 15 18 18
J (Fe/K) -99 to 750 1 main control panel and in such case the terminals do not 1. The equipment should be cleaned regularly to avoid blockage
K (Cr/Al) -99 to 999 1 remain accessible to the end user after installation and internal of ventilating parts. N 2 7 16 17 17
RTD (PT100) wiring. 2. Use soft cloth soaked in water for cleaning. Do not use any
-99 to 850 1 NO /
2.Conductors must not come in contact with the internal circuitry other cleaning agent. 3 8 7 10 10
SSR O/P +
DISPLAY: Type: 7 segment LED; Height: 0.5” Digits: 3 of the equipment or else it may lead to a safety hazard that may 3. Care must be taken to prevent the water from entering into
in turn endanger life or cause electrical shock to the operator. the electronic circuitry through the ventilating holes. NC 1 10 9 - 12
CONTROL ACTION
3.Circuit breaker or mains switch must be installed between
S.No. Control Setting Resolution 10 TERMINAL CONNECTIONS COM /
power source and supply terminals to facilitate power 'ON' or 4 9 8 1 11
SSR OP -
1 Proportional Band 1 to 99 'OFF' function. However this switch or breaker must be installed DTC503 SHORT FOR CONFIG
2 ON/OFF Hysteresis 1 to 99 in a convenient position normally accessible to an operator. TC+ / RTD1 6 2 3 3 3
Short for
L
! CAUTION:
RTD R
1 9 10 5 TC- / RTD2 7 3 4 4 4
ACCURACY ±0.25 % of full scale/±1OC (whichever is +
greater). After 20 min warmup time. 1.The equipment shall not be installed in environmental RTD3 12 5 6 6 6
- 2 TC+ 6
conditions other than those specified in this manual. SHORT FOR
SET POINT LIMIT Maximum limit of set point N RTD1
RTD
2.Fuse Protection-The equipment does not contain built-in fuse. 9 - 10 11-12 13-14 7-8 7-8
SETTING Via keys on front panel NO TC CONFIG
Installation of external fuse for electrical circuitry is highly 3
W
RTD2 7
RELAY ACTION a) Forward b) Reverse + SHORT FOR
7-8 3-4 4-5 4-5 4-5
Short for
RTD (PT 100)

short for 2 wire
recommended. Recommended rating of such fuse shall be SSR- TC
MANUAL RESET -99 to 99 OC
TC
275VAC/1A. 4 11 12 8
COM SHORT FOR
SENSOR BREAK Indicated on display, relay off 5-6 1-2 2-3 2-3 2-3
3.Since this is a built-in-type equipment (finds place in main NC
W RTD
TC REVERSE Indicated on display, relay off RTD3
control panel), its output terminals get connected to host TYPICAL CONNECTIONS FOR LOADS :
OUTPUT DTC503/503-N/203/303-EL/303-NX : equipment. Such equipment shall also comply with basic NOTE: R - Red, W - White
1 C/O (SPDT) 1) For load current less than 0.5A
EMI/EMC and safety requirements like BS EN 61326-1 and BS short for 2 wire L N
DTC303: 1 NO Relay rating 10A @ DTC503-N RTD RTD (PT 100)
EN 61010 respectively. TC
230VAC (SSR drive available against
3 WIRE
4.Thermal dissipation of equipment is met through ventilation TC
RTD
New
short for RTD short for TC
request) LOAD
holes provided on chassis of equipment. Such ventilation holes C NO
POWER 85 to 270 VAC/DC @ 50/60Hz, shall not be obstructed else it can lead to a safety hazard. 1 2 3 4 5
R C
24 VAC/DC models available on 5.The output terminals shall be strictly loaded to the manufacturer TC+ TC- RTD3 Snubber
request specified values/range. RTD1 RTD2
OR
OPERATING TEMP. 0-50OC INSTALLATION GUIDELINES 11 Short for config 12 2) For bigger loads use interposing relay/contractor
HOUSING CE marked products: Flame retardant L N
Mechanical Installation: For SSR O/P
plastic TC
For installing the controller + -
Non CE products: ABS plastic. 6 7 8 9 10 TC Contactor
1. Prepare the panel cutout with proper dimensions as shown in -N
HUMIDITY 95% RH
+
L NO COM NC C NO
OVERALL DIMENSIONS
R C
WEIGHT (gms) DTC503/503-N: 180, DTC203: 275, 2. Remove the clamp from the controller.
NOTE: R - Red, W - White
DTC303/303-NX: 227. 3. Push the controller into the panel cutout. Secure the controller Snubber
OVERALL DIMENSIONS (All dimensions in mm) in its place by pushing the clamp on the rear side. The screws, DTC203 RTD
short for 2 wire
RTD (PT 100)
C
LOAD
of the pane of the clamp, must be in the farthest forward slot. Short for short for
RTD R W TC
4. For proper sealing, tighten the screws evenly with required W NOTE: Use snubber as shown above to increase life of internal
torque. relay of temperature controller.
A DF Panel Cutout 1 2 3 4 5 6
! CAUTION: TC+ TC- RTD3
SHORT FOR CONFIG
RTD1 RTD2
ELECTRICAL PRECAUTIONS DURING USE
The equipment in its installed state must not come in close +
13 L 15 Electrical noise generated by switching of inductive loads and
B C G proximity to any heating sources, caustic vapors, oils, steam, or can create momentary disruption, erratic display, latch up,
E other unwanted process by-products. 14 N 16
- data loss or permanent damage to the instrument. To reduce
DIM A B C D E F G For SSR O/P
MODELS EMC Guidelines: + - noise:
DTC503 / 503-N 48 48 100 45 7 46 46 1. Use proper input power cables with shortest connections and a) Use of MOV across supply of temperature controller
7 8 9 10 11 12 & snubber circuits across loads are recommended
DTC203 72 72 15
1 68 10 69 69 twisted type.
NO COM NC b) Use separate shielded wires for inputs.
DTC303 / 2. Layout of connecting cables shall be away from any internal EMI
96 96 70 90 10 92 92
DTC303NX source. RELAY1 NOTE: R - Red, W - White Document name: Operating/0604/DTC503/503-N/203/303/ Ver1 OP170-V01 Page 1 of 2
CONFIGURATION SCHEME (parameter setting) Key press Display Description Programming Manual (offset adjustment) reset 3) Offset adjustment (manual reset): After some time
1) Before configuration: Short terminals marked NOTE: This selection is valid only if parameter 7 is the process temperature settles at some point and there
6. Press to select Maximum set point limit configured as Disable is a difference between the set temperature & the
SHORT FOR CONFIG o
2) Turn power ON
Factory setting: For J sensor: 400 C CAUTION : Ensure terminals marked SHORT FOR CONFIG controlled temperature. This difference can be removed
o
3) Program configuration setting as per instructions below. For K sensor: 400 C are open. To program Manual offset : Press + keys by setting the manual reset value equal & opposite to the
For PT100 sensor: 400oC together for 3 seconds. offset.
Key press Display Description Manual (offset adjustment) reset
(Display for 1 second) Factory setting: 00
1. To select sensor type. Factory setting: J Press + / TIME PROPORTIONAL WITH MANUAL OFFSET
Maximum Set Temp.
to change value Key press Display Description
point Limit
(Display for 1 second) offset
7. Press to select Manual reset (offset set point proportional band
J adjustment) lock (Display for 1 second) Manual offset
SENSOR TYPE o adjust
(-99 to 750 C) Factory setting: Enable Press + /
K New feature - Ver 1.1 onwards to change value Manual reset
Press + o Time
(-99 to 999 C)
To quit programming: Press + keys together for 3 seconds
Press + PT100 (Display for 1 second)
(-99 to 850oC) MANUEL RESET
USER GUIDE : (Specifications are subject to change as
(OFFSET Enable Lock
2. Press to select control mode ADJUSTMENT) 1) ON/OFF control action (for heater) : The relay is development is a continuous process).
Factory setting: On/Off LOCK 'ON' up to the set temperature and cuts 'OFF' above
the set temperature. As the temperature of the system
selectron Process Controls Pvt. Ltd.,
drops, the relay is switched 'ON' at a temperature slightly E-121, Ansa Industrial Estate, Saki Vihar Rd, Andheri
(Display for 1 second) Press + / East. Mumbai - 400 072. India,
Disable Lock lower than the set point.
to change value Website: www.selecindia.com
CONTROL
ON / OFF mode E- mail: sales@selecindia.com
MODE 8. Press to select reset all mode
At reset all: all parameters set to Factory setting value Document name: Operating/0604/DTC503/503-N/203/303/ Ver1 OP170-V01 Page 2 of 2
Press + Proportional mode Note: Reset all function to be used prior to changing Hysteresis: The difference between the temperature at
input (to realign related parameters) which relay switches ‘ON’ and at which relay switches
‘OFF’ is the hysteresis or dead band
(Display for 1 second)
3. Press to select Factory setting:
RESET ALL Temp.
proportional band or 1oC for on/off No reset Hysteresis
hysteresis value o set point
10 C for Prop
Press + No reset
(Display in ON/ OFF mode or
Press + No reset
in proportional mode for 1 second)
Press + No reset Heater
Press + / hysteresis value or ON OFF ON Time
(Relay)
to change value proportional band Press +
No reset
4. Press to select Cycle time
Press +
Factory setting: 20 sec Reset all
By pressing key it goes to sensor input menu 2) Time proportional control: In Proportional control,
the relay 'ON' time and relay 'OFF' time varies in
(Display for 1 second) After configuration setting: proportion to the deviation of the actual temperature
Valid for proportional mode only 1) Turn power OFF from the set value. The proportional action occurs within
2) Remove link between terminals marked SHORT FOR CONFIG. a band below the set point. The proportional mode of
Valid for
Press + / 3) Turn power on control gives closer control than ON/OFF type.
proportional
to change value
mode only
Programming Set Point
5. Press to select Relay output mode A) To view set point : Press key Temp.
Factory setting: forward B) To increase / decrease set point : Press + /
Continuous operation of above makes update speed offset
set point proportional band
(Display for 1 second) faster in 3 stages after 7 seconds.
RELAY
Forward (heating) If terminals marked SHORT FOR CONFIG are
OUTPUT Time
shorted at power on, temperature controller will go in to
the configuration mode. To quit configuration setting
Press + Reverse (cooling) mode, turn power off, remove link between terminals
marked SHORT FOR CONFIG & switch power on.
PXZ SERIES MODEL CONFIGURATION
Operation P X Z 1 V
Manual
Front panel size Code
1/16 DIN 4
1/8 DIN 5
72mm 7
1/4 DIN 9
Kinds of input Code

Thermocouple (°C) T
Thermocouple (°F) R
RTD/Pt100 (°C) N
RTD/Pt100 (°F) S
4-20mA DC, 1-5V DC B
0-20mA DC, 0-5V DC A
Control output 1 Code
Relay contact (reverse action) A
Relay contact (direct action) B
SSR/SSC driver (reverse action) C
SSR/SSC driver (direct action) D
4 to 20mA DC (reverse action) E
4 to 20mA DC (direct action) F
PID Autotune Control output 2* Code
Controllers None Y
Relay contact (reverse action) A
Featuring Fuzzy Logic Relay contact (direct action) B
SSR/SSC driver (reverse action) C
SSR/SSC driver (direct action) D
4 to 20mA DC (reverse action) E
4 to 20mA DC (direct action) F
*not available on PXZ-4 type
Alarm Options Code
Heater break alarm* 2
Process alarm & Heater break alarm* 3
None 4
Process alarm 5
*not available on PXZ-4, or with 4-20mA DC output
Power Supply Option Code

24V AC/DC Supply D
TABLE OF CONTENTS
ACCESSORIES (Sockets: only for PXZ-4 and sold separately)
____________________________________________________
Model Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8-pin sockets (for PXZ-4 without H / L Alarm Option)

ATX1NS Solder Type Socket (UL)
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PG-08 Screw-down type (terminals on back)
ATX2PSB Screw-down type socket (terminals on back) (UL)
Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 TP28X Screw-down type socket (terminals on front) (UL)
11-pin sockets (for PXZ-4 with H / L Alarm Option)
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 PG-11 Screw-down type (terminals on back)
TP311SB Screw-down type socket (terminals on back)
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 TP311S Screw-down type socket (terminals on front)
Heater Break Current Sensing Transformer:
Outer Dimensions and Panel Cutout Size . . . . . . . . . . . . . . . . . . . . . . . . 5 CTL-6-SF For heater current (1 to 30 amps)
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 CTL-12-S36-8F For heater current (20 to 50 amps)
____________________________________________________
Wiring Instructions: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Front Panel Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Front Panel Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Autotuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Programming
1. Primary Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2. Secondary Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Appendix A: Autotuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Free Technical Support:
Appendix B: Manual Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 1-800-235-8367 U.S. & Canada
802-863-0085 Int’l
Appendix C: Heater Break Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 8:30 A.M.- 6:00 P.M. E.S.T.
Appendix D: Heat/Cool Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Quick Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
V4.98.5
1
INTRODUCTION SAFETY PRECAUTIONS
Thank you for purchasing the Fuji Electric PXZ controller. All of these Before using this product, the user is requested to read the following
controllers are PID Autotune controllers that employ Fuji Electric’s precautions carefully to ensure safety. The safety requirements are
patented fuzzy logic algorithms. classified as either “warning” or “caution” according to the following
explanations:
It is a fully programmable temperature/process controller incorporat-
ing many user-friendly features. The following easy-to-use instruc- Warning
suggesting that the user's mishandling can
result in personal death or serious injury.
tions are intended to help you understand, set up, effectively operate,
suggesting that the user's mishandling can result
and achieve optimal performance from your PXZ controller. When Caution
in personal injury or damage to the property.
programmed and operated within the guidelines set up for them in this
manual, your PXZ controller will give you years of precise, reliable
control. If needed, we will provide free technical support throughout Warning
the life of the controller.
Wiring
1. If there is danger of serious accident resulting from a failure or
defect in this unit, provide the unit with an appropriate external pro-
tective circuit to prevent an accident.
FEATURES 2. The unit is normally supplied without a power switch or a fuse. Use
power switch and fuse as required (Rating of the fuse: 250V, 1A)
• Fuzzy Logic Control
• PID Autotune with manual override - heating or cooling Power supply
• Programmable control action - reverse or direct 1. Be sure to use the rated power supply voltage to protect the unit
• Programmable cycle time against damage and to prevent failure.
• Programmable inputs - Thermocouple/RTD, or, 2. Keep the power off until all of the wiring is completed so that elec-
Current/ and Voltage tric shock and trouble with the unit can be prevented.
• Sensor burn-out protection
• Input calibration by user General
• Outputs: Relay, Solid-state relay drive, and 4-20mA DC 1. Never attempt to disassemble, modify, or repair this unit. Tampering
• Secondary output for with the unit may result in malfunction, electric shock, or fire.
cooling (optional) 2. Do not use the unit in combustible or explosive gaseous atmos-
• High/low alarm pheres.
outputs (optional)
• Heater break alarm (optional) Caution
(only on PXZ-5, 7, 9)
• Menu driven format Installation
• Setting – touch keys on front panel 1. Avoid installing the unit in places where:
• Programmable 8-segment ramp/soak function • the ambient temperature may reach beyond the range of -10 to
• Digital filtering (to suppress factory noise) 50°C (32 to 122°F) while in operation
• Adjustable setpoint range • the ambient humidity may reach higher than 90% RH while in oper-
• Selectable °F/°C ation
• Offset adjustments • a change in the ambient temperature is so rapid as to cause con-
• Programmable decimal point densation
• Programmable lock-up feature • corrosive gases (sulfide and ammonia gas, in particular) or com-
• Advanced security options to prevent unauthorized parameter bustible gases are emitted
changes • the unit is subject to vibration or shock
• 4-digit, LED indication • the unit is likely to come in contact with water, oil, chemicals,
• Output status indication steam, or vapor
• Fault indication • the unit is exposed to dust, salt, or air containing iron particles
• Non-volatile memory • the unit is subject to interference with static electricity, magnet-
• 1/16, 1/8, 1/4 DIN and 72mm panel mount package ism, or noise
• NEMA 4X faceplate • the unit is exposed to direct sunlight
• ABS plastic housing • heat may be accumulated due to radiation
• Termination—screw-down type (PXZ-5, 7, 9) or socket with screw-
down terminals (PXZ-4) Maintenance
• Metal mounting bracket; plastic bracket for PXZ-4 1. Do not use organic solvents such as alcohol or benzene to wipe this
• 85 to 264V AC free voltage power supply unit. Use a neutral detergent.
• 24V AC/DC power supply (optional) 2. Three-year warranty is guaranteed only if the unit is properly used.
• UL, C-UL, and CE approvals
• 3-year warranty
2
SPECIFICATIONS 2-position action for cooling: 0.5% FS
________________________________________________________
Anti-reset wind-up 0-100% FS, setting in 1 E.U. steps, auto setting
with auto-tuning
________________________________________________________
INPUT RANGE TABLE:
________________________________________________________ Overlap/dead band ±50% of heating proportional band
________________________________________________________
Input Signal Input Range Input Range Remarks Input sampling cycle 0.5 sec
________________________________________________________
(°C) (°F)
________________________________________________________ Control cycle 0.5 sec
________________________________________________________
Thermocouple
J 0~800 32~1472 Cold Junction
K 0~1200 32~2192 compensating OUTPUT
R 0~1600 32~2912 function built-in (Single Output)
________________________________________________________
B 0~1800 32~3272 Control output One of the following three types is selected:
S 0~1600 32~2912
T -199~200 -328~392 (1) Relay contact (SPDT)
T -150~400 -238~752 220V AC/30V DC, 3A (resistive load)
E -199~800 -328~1472 Mechanical life: 107 times (under no load)
N 0~1300 32~2372 Electrical life: 105 times (under the rated load)
PL2 0~1300 32~2372
________________________________________________________ (2) SSR/SSC drive (voltage pulse):
RTD 15-30V DC at ON/0.5V DC or less at OFF.
Pt100 -150~850 -238~1562 Allowable wiring Current 60mA or less.
resistance 10 ohms (3) 4-20mA DC:
max (per wire).
________________________________________________________ Allowable load resistance– 600Ω or less.
________________________________________________________
DC Voltage/
Current
1-5V Scaling Range: -1999 to 9999 For current input,
0-5V Engineering Units use the 250Ω OUTPUT
resistor to (Dual Output)
________________________________________________________
4-20mA obtain 1-5V DC or Control output For dual output type, one of the following three
0-20mA 0-5V DC input.
________________________________________________________ types is selected on both heating and cooling
types:
CONTROL FUNCTION (Not available on PXZ-4 type)
(SINGLE OUTPUT)
________________________________________________________ (1) Relay contact (SPDT):
Control action PID control with auto-tuning 220V AC/30V DC, 3A (resistive load)
Fuzzy control with auto-tuning (2) SSR/SSC drive (voltage pulse):
________________________________________________________
15-30V DC at ON/0.5V DC or less at OFF.
Proportional band (P) 0-999.9%, of full scale (FS), setting in 0.1% steps
________________________________________________________ Current: 60mA or less
Integral time (I) 0-3200 sec, setting in 1 sec steps
________________________________________________________ (3) 4-20mA DC:
Differential time (D) 0-999.9 sec, setting in 0.1 sec steps
________________________________________________________ Allowable load resistance – 600Ω or less
P,I,D = 0: 2-position action (Note: When SSR/SSC drive output for heating/
I,D = 0: Proportional action cooling side is selected, the total current should
________________________________________________________ be less than 60mA)
Proportional cycle 1-150 sec, setting in 1 sec steps, for relay contact ________________________________________________________
output and SSR/SSC drive output only
________________________________________________________ SETTING AND INDICATION
________________________________________________________
Hysteresis width 0-50% FS, setting in 1 E.U. (Engineering Units)
steps, 2-position action only Parameter setting method PXZ: digital setting with eight keys
________________________________________________________
________________________________________________________
Anti-reset wind up 0-100% FS, setting in 1 E.U. steps, auto-setting PV/SV display methodPXZ-4: PV/SV red LED display, 4 digits
with auto-tuning PXZ-5, 7, 9: PV/SV individual LED display,
________________________________________________________ 4 digits each, PV= red, SV=green
Input sampling cycle 0.5 sec ________________________________________________________
________________________________________________________ Status display Control output, alarm output, heater break alarm
Control cycle 0.5 sec
________________________________________________________ output.
Setting accuracy 0.1% FS
________________________________________________________
CONTROL FUNCTION Indication accuracy Thermocouple: ± 0.5% FS ± 1 digit ± 1°C
(DUAL OUTPUT) (Heat/Cool Type)
________________________________________________________ (at 23°C) R thermocouple: 0-400°C; ± 1% FS ± 1 digit ± 1°C
Heating Proportional band P x 1/2 (P= 0-999.9%)
________________________________________________________ B thermocouple: 0-500°C; ± 5% FS ± 1 digit ± 1°C
Cooling Proportional band Heating proportional band RTD, voltage, current: ± 0.5% FS ± 1 digit
________________________________________________________
x Cooling proportional band coefficient
Cooling proportional band coefficient= 0-100 ALARM
________________________________________________________
0: 2-position action
________________________________________________________ Alarm output Relay contact (SPST),
Integral time 0-3200 sec for heating and cooling
________________________________________________________ 220V AC/30V DC, 1A (resistive load)
Differential time 0-999.9 sec for heating and cooling
________________________________________________________ PXZ-4 type: 1 point
P,I,D= 0: 2-position action (without dead band) for heating and cooling Other types: 2 points
________________________________________________________
I,D= 0: Proportional action
________________________________________________________ Heater break Relay contact (SPST),
Proportional cycle 1-150 sec, for relay contact output and SSR/SSC alarm output 220V AC/30V DC, 1A (resistive load)
drive output only PXZ-4 type: not available
________________________________________________________
________________________________________________________
Hysteresis width 2-position action for heating and cooling: 0.5% FS
3
GENERAL SPECIFICATIONS
_______________________________________________________ STRUCTURE
_______________________________________________________
Rated voltage 85-264V AC or 24V AC/DC
_______________________________________________________ Mounting method Panel flush mounting or surface mounting
Power consumption 10VA or less (100V AC) Surface mounting: PXZ-4 type only
_______________________________________________________
15VA or less (240V AC)
_______________________________________________________ External terminal PXZ-4 type: 8-pin or 11-pin socket
Insulation resistance 50MΩ or more (500V DC)
_______________________________________________________ Other types: screw terminal (M3.5 screw)
_______________________________________________________
Withstand voltage Power source-Earth: 1500V AC, 1 min Enclosure Black ABS plastic
_______________________________________________________
Power source-input terminal: 1500V AC, 1 min Dimensions PXZ-4 48 x 48 x 85.7mm (1/16 DIN)
Earth-relay output: 1500V AC, 1 min PXZ-5 52.5 x 100.5 x 95.8mm (1/8 DIN)
Earth-Alarm output: 1500V AC, 1 min PXZ-7 76.5 x 76.5 x 95.8mm (72 mm)
Between other terminals: 500V AC, 1 min
_______________________________________________________ PXZ-9 100.5 x 100.5 x 95.8mm (1/4 DIN)
_______________________________________________________
Input impedance Thermocouple: 1MΩ or more Weight PXZ-4 approx. 150g
Voltage: 450KΩ or more PXZ-5 approx. 300g
Current: 250Ω (external resistor)
_______________________________________________________ PXZ-7 approx. 300g
Allowable signal Thermocouple: 100Ω or less PXZ-9 approx. 400g
_______________________________________________________
source resistance Voltage: 1KΩ or less
_______________________________________________________ Protective structureFront panel water-proof structure;
Allowable wiring RTD: 10Ω or less per wire NEMA 4X (equivalent to IEC standards IP66)
resistance
_______________________________________________________ Rear case: IEC IP20
_______________________________________________________
Reference junction ± 1 °C (at 23°C)
compensation accuracy
_______________________________________________________ DELIVERY
_______________________________________________________
Process variable offset ±10% FS
_______________________________________________________ PXZ-4 type: controller, panel mounting bracket, socket (when specified),
Setpoint variable offset ± 50% FS
_______________________________________________________ water proof gasket, 250Ω precision resistor (when required), instruction
Input filter 0-900.0 sec, setting in 0.1 sec steps manual. Other types: controller, panel mounting bracket, water-proof gasket,
(primary lagging filter) 250Ω precision resistor (when required), instruction manual.
_______________________________________________________
_______________________________________________________
Noise rejection ratio Normal mode noise (50/60Hz): 50dB or more
Common mode noise (50/60Hz): 140dB or more
_______________________________________________________
POWER FAILURE PROTECTION

_______________________________________________________
Memory protection: Non-volatile memory. Parameter values
remain unchanged with disruption of power.
Ramp/soak function has to be re-initiated.
_______________________________________________________
SELF-CHECK
_______________________________________________________
Method: Watchdog timer monitors program error.
_______________________________________________________
OPERATION AND STORAGE CONDITIONS

_______________________________________________________
Operating temperature -10 to 50°C (14 to 122°F)
_______________________________________________________
Operating humidity 90% RH or less (non-condensing)
_______________________________________________________
Storage temperature -20 to 60°C (-4 to 140°F)
_______________________________________________________
Installation category II
_______________________________________________________
Pollution degree 2
_______________________________________________________
OTHER FUNCTIONS
_______________________________________________________
Parameter mask function Parameter display is disabled by software
_______________________________________________________
Ramp soak function 4-ramp/4-soak
_______________________________________________________
4
OUTER DIMENSIONS AND PANEL CUTOUT SIZE INSTALLATION
PXZ 4
NEMA 4X Integrity
7 85.7
The front side of this instrument conforms to NEMA 4X. To ensure the
71.5
48
waterproofness between the instrument and the panel, use the gasket
that is provided with the unit according to the installation procedure
F
C
PV
H L
described below.
SV
44.8
57
48
How to install the unit

PV/SV SEL DATA ENT For PXZ-5/7/9, install the two metal brackets, one on the top and the
PXZ-4
other on the bottom, and tighten the screws to a torque of about 14.7N-
48
Gasket
Gasket
9.5
cm (1.5kg-cm). For PXZ4, install the unit in the panel as shown below,
Panel and tighten the screws on the mounting bracket until the unit is secure.
Unit: mm Make sure there is no space between the front side of the unit and the
Panel thickness: 1 to 8 mm gasket, and between the gasket and the panel.
57
Figure 1 Unit Figure 2 Unit
Mounting bracket
63 or more
Front Gasket Case Panel Panel Mounting bracket Screw
Panel cutout size: when installing Caution: After the mounting bracket is installed, check the gasket for
63 or more
“n” numbers of units. displacement and detachment as shown in Figure 3.

0.5
45 -0
Gasket Figure 3 Gasket

0.5
45 -0
Case Case
(Bad) (Good)
PXZ 5,7,9
A 95.8
16.2
F
C1 C2 H L HB
PV
B SV C D
SV SEL DATA ENT

PXZ-
Gasket
18.7 Panel
Unit: mm
Panel thickness: 1 to 8 mm
Model A B C D E F G H
0.6 0.8
PXZ5 52.5 100.5 90.5 114.5 45 -0 92 -0 120Min. 92Min.
0.7 0.7
PXZ7 76.5 76.5 67 91 68 -0 68 -0 96Min. 116Min.
0.8 0.8
PXZ9 100.5 100.5 90.5 114.5 92 -0 92 -0 120Min. 140Min.
Panel cutout size: when installing F

“n” numbers of units. G
5
WIRING INSTRUCTIONS
PXZ7 *Voltage/
Current input RTD
Be sure to use the rated power supply voltage and polarity 7 7

A
B
8 8
PXZ4 socket type (standard) (viewing from the back Current output, B
9
of instrument) SSR/SSC driving output
– T.C. Alarm 1
Current output, SSR/SSC driving output +
+
(Upper limit alarm)
+ – 1 1 7 13
Alarm 2
Contact output Control output 1 2 8 14 (Lower limit alarm)
3 3 9 15 Heater break
– alarm output
RTD 4 5 4 10 16 Common
*Voltage/current B
3 6 5 11 17
– Power supply ~ CT input
B – 6 12 18
2 7
A
~ Power supply
+ + 1 8
Thermocouple Control output 2(on the cooling side)
input
12 10 Current output, SSR/SSC
When no alarms are provided – + driving output
PXZ4 socket type (with alarm) (viewing from the back of instrument)
Current output, SSR/SSC driving output

+ –
PXZ5, PXZ9
Contact output
6
5 7 *Voltage/
Alarm output Current output, SSR/SSC
4 8 Current
B RTD T.C.
*Voltage/ –
3 9 input driving output
B +
current – A +
2 10 1 1 1 10 10
+ A + 1 11 ~ Power supply B – Control output 2
2 11
RTD Thermocouple 2 2 (on the cooling side)
input B 3 12 12
Current output 3 –
SSR/SSC driving output 4 13 Alarm 1 (upper limit alarm)
When alarms are provided +
5 5 14 Alarm 2 (lower limit alarm)
Control output 1 6 15 Heater break alarm output
7 7 16 Common
–
* For current input, install the 250Ω precision 250Ω Power supply ~
8 17
– + 9 18
resistor (accessory) before using the unit. CT input
Wiring Power to Controllers that accepts current/voltage input would be necessary.
• Be sure to use the rated power supply voltage and polarity for the Thermocouple
unit to protect it against damage and to prevent the occurrence of • Connect thermocouples directly to the input terminals whenever
failure. possible.
• Keep the power off until all of the wiring is completed to prevent • If using extension wires, make sure they are of the same thermocou-
electric shock and abnormal operation. ple material and grade; any dissimilar metal junctions will lead to
• Keep the power supply wires separated from the input and output erroneous readings.
wires. • Ungrounded thermocouples are recommended for optimal perfor-
• Power connections should be made with 18-gauge or larger insulat- mance and to prevent ground loops.
ed wire. Stranded wire improves noise immunity. Noise filters and • Make sure the polarity is correct.
isolation transformers are recommended in case of noisy power
lines. RTD Pt100
• When the Heater Break option is selected, use the same power line • Use a 3-wire Pt100Ω RTD whenever possible. All three wires must
for both the controller and the heater. have low lead resistance (less than 10Ω) and no resistance differen-
tials among them.
Wiring Inputs • If using a 2-wire RTD, jumper the two B-legs with a wire of equal
resistance.
There are two input categories available: Thermocouple/RTD or cur- • Make sure A and B leads are connected to the right terminals.
rent/voltage. Make sure you have the right type before wiring the
inputs. Refer to Table of Input Type Codes and set the parameter Current/Voltage
“P-n2” accordingly. • The controller accepts 1-5V, 0-5V, 4-20mA, and 0-20mA DC signals. If
wiring for a voltage input, feed the signal directly to the input termi-
Note: In order to minimize the risk of high frequency noise induced by nals. For current inputs, first connect the 250Ω precision resistor
coils and windings in relays, solenoids, and transformers, use leads that comes with the unit.
which have braided sheath and ground one end of the sheath. Keep • Make sure the polarity is correct.
your input leads separate from power and output leads. If you have
to bring the input signal from a long distance, a signal transmitter
might be needed to maintain an accurate reading; in this case, a unit
6
Wiring Outputs System Wiring Diagram
Before wiring the outputs, make sure the unit has the right kind of Example:
control output, and that all the load handling devices conform to the
L
controller specifications. Note that it takes 5 seconds for the outputs 120V AC
N
to activate after the power is turned on.
Fuse
Refer to parameter “P-n1” and to the Table of Output Type Codes to Heater (3A or less)
Fuse
Contact
choose the preferred type of control action– reverse acting or direct Output
4 5
acting. If using two outputs in a heat/cool type control, please refer to
3 6
Appendix D for more details. PXZ4-RAY1-4V
– 7 Power
2
85 to 264 VAC
Relay +
1 8 50/60Hz
• Connecting a load to full capacity of the relay will shorten the relay Thermocouple
Input
life, especially if it is operated at a rapid rate. To protect the output
relay, an external relay or a contactor
PXZ4 PXZ9
should be used. If a higher current rating (8-pin)
is required, a solid-state relay driver type
5
output is recommended. 6
• Connect the load between the normally 7
opened contacts of the relay.This way, if 6 5 4 3 8
power to the controller is disrupted, the 9
output circuit would open, preventing the
load from running out of control.
• Set the proportional time cycle parameter, “TC” to 30 secs. or more.
• Use of “Z-trap” (manufacturer: Fuji Electric Co.) is recommended to
protect the relay against switching surges and to ensure the prod-
uct’s long life. Connect it between the contacts of the relay as
shown in the example.
Part No.:
ENC241D-05A (power supply voltage: 100V)
ENC471D-05A (power supply voltage: 200V)
SSR/SSC Driver (Pulsed DC Voltage)

• The non-isolated DC output is used to drive an external load-han-
dling device such as Solid-State Relay(SSR) or Solid-State
Contactor(SSC).
• The total current drawn, for both single and dual outputs, should be
within the allowed value.
• Make sure the polarity is correct.
• Set the proportional time cycle parameter, “TC” to 1 sec. or more.
4 to 20mA DC
• The output is a non-isolated analog signal used to drive a variety of
output devices such as SCRs and valve actuators.
• The load resistance must be less than 600Ω.
• Make sure the polarity is correct.
• The proportional time cycle parameter, “TC” is set to 0, and is not
displayed on the programming menu.
Wiring Alarms
• Make sure the load does not exceed the rated capacity of the relay.
• Several types of alarm configurations can be programmed and does
not require a change in the wiring. Refer to parameters AL, AH, P-
AH, P-AL, P-An.
• For details on Heater Break alarm, please refer to Appendix D and
the Heater Break Alarm Setpoint parameter “Hb” in the program-
ming section.
7
FRONT PANEL DESCRIPTION FRONT PANEL OPERATION
12 13 14 15
The PXZ controller programming menu consists of two blocks—
12 13 14
C
12 13 14 15
PRIMARY (SETPOINT) MENU and SECONDARY (SYSTEM) MENU. At
C1 C2 H L HB 1 C
17 C
PV
H L
C 16 1
3 PV 2
C1 C2 H L HB
3
power up, the controller will be in the operational mode– process
2 PV
11
SV
10 2 SV 10 11 SV 10 variable (PV), in the case of PXZ4, and both process variable and set-
4
PV/SV SEL DATA ENT
9 11
SEL DATA
9
4 9 point variable (SV), in the case of PXZ-5, 7, 9 will be displayed. PV is
4 7 SV SEL DATA ENT
PXZ-4
5
SV ENT
PXZ-5
8 PXZ-7
the variable that is being controlled, and it is not programmable.
18 6 7 8 5 6 7 8
6 When setting the parameters, turn off the power to the load (operat-
Model : PXZ4 Model : PXZ5 Model : PXZ7, 9 ing equipment) to ensure safety. Since it takes 30 minutes for the unit
Name Function to stabilize in terms of temperature, all measurements should be car-
1 Process Value (PV) display Displays the process value (PV). ried out at least 30 minutes after the power is turned on. Option-relat-
ed features are displayed only when the options are provided.
2 Set value (SV) indication lamp Stays on while a set value is on the display.
3 Set value (SV) and Set value (SV) or parameter symbols and codes
parameter display are displayed when setting various parameters.
Viewing and Setting Parameters
4 DOWN key Decrements the numerical value in the place • After setting the data, press ENT key for registration.
(common for each digit) selected with the UP key. Where various para- • If the data setting is left as it is for 30 secs, the display is automati-
meters are displayed, each parameter is dis- cally returned to the operational mode.
played one by one every time this key is
pressed. The sequence of displays however, is
opposite to the sequence of displays with the How to set Setpoint value (SV)
SEL key. Operation Display
5 Direct SV key By pressing this key, the set value (SV) is dis- 1. Power on – Operational mode
played. 2. Press UP (units, tens or hundreds) – Digit blinks
6 SELECT key The key to be used when switching over to the key to select digit
1st or 2nd block parameters, or when scrolling 3. Press the appropriate UP key or – SV value changes
through the parameters within a block. the DOWN key to increment or
7 Data display key Displays the data assigned to the parameter decrement digit value
selected with the SEL key
4. Press ENT key – SV value registered
8 Data entry key The key to be used for storing the data after pre-
vious data is changed. (none of changed data
PRIMARY (SETPOINT) MENU
can be registered unless this key is pressed.)
Operation Display
9 UP key for 1’s place By pressing once, the number in the units place 1. Operational mode – PV, SV
blinks. The number is continuously incremented 2. Press SEL key – “P” displayed
with the key held pressed.
3. Press DATA key – “P” data displayed
10 UP key for 10’s place By pressing once, the number in the tens place 4. Press the appropriate UP key – Corresponding digit blinks
blinks. The number is continuously incremented
with the key held pressed. once
5. Press the same UP key or the – Data changes accordingly
11 Up key for 100’s place By pressing once, the number in the hundreds
place blinks. The number is continuously incre- DOWN key to increment or
mented with the key held pressed. A numeric “9” decrement the data
is followed by “0” and , concurrently, a number of 6. Press ENT key – Data registered; “i” displayed
the thousands place is incremented by 1. 7. Press SEL key once to go to – “d” ....... “Mod”
12 Control output indication lamp C (for PXZ4 only): Comes on when the control out- the next parameter, or press
put is ON. and hold UP (hundreds) key or
C1: Comes on when the control output 1 is ON.
C2: Comes on when the control output 2 is ON. DOWN key to scroll down or up
the menu at a faster rate
13 Upper limit alarm Comes on when the upper limit alarm is activated.
8. Press SV (SV/PV for PXZ4) key – Operational mode
indication lamp (option)
14 Lower limit alarm Comes on when the lower limit alarm is activated.
SECONDARY (SYSTEM) MENU
indication lamp
Operation Display
15 Heater break alarm Comes on when the heater break alarm is output. 1. Operational mode – PV, SV
indication lamp
2. Press SEL key for about 3 secs – “P-n1”
16 Process value (PV)/ set Parameter symbols and codes are displayed 3. Press DATA key – “P-n1” data
value (SV)/parameter display for process value (PV) and set value (SV) and
(applicable to PXZ4 only) when setting various parameters. 4. Proceed as described before.
17 Process value (PV) Stays on while process value (PV) is on display.
indication lamp
18 PV/SV SELECT key The display of measured value (PV) and set value
(For PXZ4 only) (SV) is toggled each time this key is pressed.
8
AUTOTUNING PRIMARY MENU SETTINGS
Before initiating the autotune function, first decide if you would like PARAMETER DESCRIPTION
to autotune at setpoint or 10% of full scale below setpoint. Set the - SV Main Setpoint Variable: The main setpoint variable is
setpoint (SV), alarms (AL, AH) and the cycle time (TC). Bring your the control point you wish to maintain. The main set-
process near setpoint before starting the autotune procedure. point variable is set within the input range, between
the (P-SL) and the (P-SU) settings.
Set the parameter AT to either “1”(to autotune at setpoint) or “2” (to
autotune at 10% of full scale below setpoint) and press ENT key to ProG Ramp/Soak Command: The Ramp/Soak program auto-
start auto-tuning. The point indicator at lower right will then start matically changes the setpoint value with time in
blinking. When the auto-tuning is completed, the point indicator stops accordance with a preset pattern. ProG switches the
blinking and the parameter AT will automatically be set to “0.” operation modes.
Setting: oFF : Normal operation is performed
Duration of the autotune process varies with every application. The rUn : Ramp/Soak operation is performed
auto-tuning process may take between 1 and 30 minutes to complete. hLd : Ramp/Soak operation is suspended
If it fails to complete, an abnormality may be suspected. In this case,
recheck the wiring, control action, and input type code. Refer to page P Proportional Band: The proportional band is that area
16 and Appendix A for additional details. around main setpoint where the control output is nei-
ther fully on nor fully off.
Setting range: 0.0 to 999.9% of full scale
The PID parameters calculated by autotuning will be retained even if
For On/Off control, set to “0”
the power is lost. However, if the power is turned off during the auto-
tuning process, you must restart autotuning. To abort the autotune I Integral Time (reset): The Integral Time is the speed at
procedure, set AT to “0.” Auto-tuning has to be repeated if there is a which a corrective increase or decrease in output is
significant change in SV, P-SL or P-SU, or in the controlled process. made to compensate for offset which usually accom-
Autotuning can also be performed while fuzzy control is selected. panies proportional only processes. The more Integral
Time entered, the slower the action. The less Integral
Time entered, the faster the action. Enter as little
Integral Time as necessary to eliminate offset without
overcompensating resulting in process oscillation.
Setting Range: 0 to 3200 secs
Integral Action is turned off when set to “0”
d Derivative Time (Rate): The Derivative Time is that time
used in calculating rate of change and thermal lag in
helping eliminate overshoot which results in response
to process upsets. This overshoot usually accompanies
proportional only and proportional-integral processes.
The derivative action dampens proportional and inte-
gral action as it anticipates where the process should
be. The more Derivative Time entered, the more damp-
ing action. The less Derivative Time entered, the less
damping action. Enter as much Derivative Time as nec-
essary to eliminate overshoot without over-damping
the process resulting in process oscillation.
Setting Range: 0 to 999.9 secs
Derivative Action is disabled when set to “0”
Setpoint
TEMP
Integral
Proportional Action
Action Derivative
Action
TIME
9
AL Low Alarm Setpoint: The Low Alarm Setpoint is that HYS Hysteresis: The Hysteresis is that area around the main
point of the process below which, the low alarm output setpoint where the output does not change condition.
relay is energized. If the alarm type, programmed in the That area or deadband is intended to eliminate relay
secondary menu, includes an absolute value for the chatter at setpoint for On/Off control applications. The
Low Alarm Setpoint, enter the actual value you want wider the Hysteresis, the longer it takes for the con-
the alarm to be activated at regardless of what the troller to change output condition. The narrower the
main setpoint is set for. If the alarm type includes a Hysteresis, the less time the controller takes to change
deviation value for the Low Alarm Setpoint, enter the output condition. When the Hysteresis is narrow, the
number of units below main setpoint in which you want On/Off control is more accurate but the wear on the
the alarm to be activated at; the deviation alarm tracks output relay is increased. Enter a value which is small
main setpoint. enough to meet the control tolerance of the application
Settable within the Input Range. but large enough to eliminate relay chatter.
Not indicated without the alarm option. Setting range: 0 to 50% of full scale, set in E.U.
Hysteresis for On/Off action on dual outputs (heating
AH High Alarm Setpoint: The High Alarm Setpoint is that and cooling) is fixed at 0.5% of full scale.
point of the process above which, the high alarm out-
Output OFF Output OFF
put relay is energized. If the alarm type, programmed in
the secondary menu, includes an absolute value for Output ON Output ON
the High Alarm Setpoint, enter the actual value you
want the alarm to be activated at regardless of what
the main setpoint is set for. If the alarm type includes a
deviation value for the High Alarm Setpoint, enter the
number of units above main setpoint in which you want
Setpoints
the alarm to be activated at; the deviation alarm tracks
Narrow Wide
main setpoint. Hystersis
Hystersis
Settable within the Input Range.
Not indicated without the alarm option.
Hb Heater Break Alarm Setpoint: If the heater’s operating
TC Cycle Time (Output #1): The Cycle Time for output #1 is current falls below this setpoint, the heater break
that time where the output is on for a percentage of alarm output relay is energized. This option is used in
that time and off for a percentage of that time, creating cases where the PXZ is controlling a bank of heaters
a proportioning effect. The Cycle Time is only used wired in parallel. A current transformer around the hot
when the PXZ is used as a P, PI, PD, or PID controller lead going to the heater bank and connected to the
and when the output is time proportional as with the controller is tied with the controller’s output and sens-
relay or SSR/SSC drive outputs. The shorter the Cycle es the current used by the heater bank. If one or more
Time, the higher the proportioning resolution is, and of the zones burnout, resulting in cold spots, the cur-
better is the control, but there will be an increased rent used by the defective heater bank is reduced. By
strain on the output device. Enter a value that is based determining what the optimal current and the optimal
on the limitations of your controller’s output type. current minus one zone for the heater bank is, the
Setting range: 1 to 150 secs. Heater Break Alarm setpoint can be calculated and
For relay output: Set to 30 secs or more entered.
For SSR/SSC drive output: Set to 1 sec or more Setting Range: 0 to 50 amps.
For current output: Set to 0. (normally not indicated). Not indicated without the Heater Break Alarm output
option.
Not available on PXZ4, or with 4-20 mA DC outputs.
ON OFF
Detection is made only on a single-phase heater. This
ON OFF
function cannot be used when controlling a heater
30 sec. Cycle Time 30 sec. Cycle Time with SCR phase-angle control.
25% Output 75% Output Cycle Time, “TC,” must be set at 6 secs. or higher
Refer to Appendix C for more details.
ON OFF ON OFF
20 sec. Cycle Time 20 sec. Cycle Time

25% Output 75% Output Optimal Current of
ON OFF ON OFF Heater Bank
minus Optimal Current of Heater
Optimal Current of + Heater Bank = Break
10 sec. 10 sec. Heater Bank less One Zone Alarm
less One Zone Setpoint
25% 75%
10
AT Autotuning: Autotuning is the automatic calculation db Deadband/Overlap: The Deadband/Overlap is that per-
and entering of the control parameters (P, I and D) into centage of the heating side of the proportional band
memory. The PXZ will autotune both reverse and direct where the heating (output #1) and the cooling (output
acting control applications. Autotuning will also auto- #2) outputs are separated by a Deadband or where
matically set anti-reset wind-up (Ar). There are two they Overlap on a heat/cool PXZ controller. A value
types of Autotuning that can be performed by the con- greater than zero establishes a Deadband or area
troller, Autotuning at main setpoint or Autotuning at 10% where neither the heating nor cooling outputs are
of full scale below main setpoint. Autotuning at 10% of energized for more powerful heating and cooling loads.
full scale below main setpoint may yield slightly differ- A value less than zero establishes an Overlap or area
ent values, not as precise, but the process overshoot where both the heating and cooling outputs are ener-
encountered during the autotuning procedure would gized at the same time for less powerful heating and
not be as great. Enter the value for the type of autotun- cooling loads. Enter a value based on the power of
ing you would like to run on your particular application your heating and cooling loads as well as the applica-
based on overshoot tolerances and the precision of the tion’s efficiency in maintaining tight heat/cool control.
PID parameters needed. For more information on princi- Setting range: -50.0 to 50.0% of the heating proportion-
ples of Autotuning, refer to Appendix A. See also page al band.
9. Not indicated without control output #2 option
Setting: Deadband/Overlap Prop. Band for Heating X Input Range # of units in the
0 - Autotuning off 100%
= Proportional Band
for Heating
1 - Autotuning performed at setpoint
Prop. Band for Cooling X Input Range # of units in the
2 - Autotuning performed at 10% of full scale = Proportional Band
100% for Cooling
below setpoint
Deadband/Overlap X Input Range # of units in the
= Deadband/Overlap
Standard type (AT=1) Low PV type (AT=2) 100%
Input Range= ( minus )

Start of AT End of AT Start of AT End of AT
AT in operation AT in operation
100% Heating Side Coolng Side
Set value (SV) Set value (SV) <1
SV-10%FS OUTPUT
=1
PV (Measured value)
0% 2 >1
PV (Measured value)
(Control output)
(Control output)
100% 100% Setpoint TEMP

ON ON ON ON
OFF OFF OFF OFF
0% 0% OUTPUT
PID control Deadband
PID control ON-OFF action
ON-OFF action 0%
Setpoint TEMP

TC-2 Cycle Time (Output #2) The Cycle Time for output #2 is OUTPUT
Overlap
that time where the output is on for a percentage of 0%
that time and off for a percentage of that time, creating Setpoint TEMP
a proportioning effect. Output #2 is the cooling side of a
heat/cool PXZ controller. A shorter cycle time provides
higher proportioning resolution and better control but
causes increased strain on the output device. Enter a
value that is based on the limitations of your con-
troller’s output type.
Setting Range: 1 to 150 secs. bAL Balance: Balance is used to pre-position the propor-
For relay output: Set to 30 secs or more tional band with respect to setpoint. With Balance (MV
For SSR/SSC drive output: Set to 1 sec or more Offset) set at 50% the proportional band will be cen-
For current output: Set to 0 (normally not indicated). tered around setpoint. To move the band left or right,
Not indicated without the control output #2 option. decrease or increase the balance setting respectively.
Setting range: 0-100%
CooL Proportional Band Coefficient for Cooling: The
Proportional Band Coefficient for Cooling is a multiplier Ar Anti-Reset Wind-up: Anti-Reset is used to limit the
for the proportional band on the cooling side of a range where integration occurs. This helps in stabiliz-
heat/cool PXZ controller. It varies the width of the pro- ing a system. With Anti-Reset at 100%, integration will
portional band on the cooling side. A large value would occur throughout the proportional band. With Anti-
establish a larger proportional band for more powerful Reset set to 90%, integration will occur at 90% of the
cooling loads. A small value would establish a smaller band above the setpoint and 90% of the band below
proportional band for less powerful cooling loads. the setpoint.
Enter a value based on the power of your cooling load. Autotuning automatically sets Ar.
Setting range: 0-100% of full scale, set in E.U.
Setting Range: 0.0 to 100.0
Not indicated without control output #2 option.
Set to “0” for On/Off control.
Proportional Band Prop. Band for Heating X Input Range =

2
Prop. Band for Cooling X Input Range = X

2
Deadband/Overlap X Input Range = X

200% 11
LoC Lock-out: This function enables or disables changing Table of Ramp/Soak Modes
the settings of parameters. MOD Power on start Output on END Output on OFF Repeat function
Code: 0 No Going on control Going on control No
0 - All parameter settings are changeable 1 No Going on control Going on control Yes
1 - All parameter settings are locked; cannot be 2 No Going on control Stand-by mode No
changed 3 No Going on control Stand-by mode Yes
2 - Only the main setpoint can be changed; all other 4 No Stand-by mode Going on control No
parameter settings are locked and cannot be changed. 5 No Stand-by mode Going on control Yes
6 No Stand-by mode Stand-by mode No
STAT Ramp/Soak Status: The Ramp/Soak program automati- 7 No Stand-by mode Stand-by mode Yes
cally changes the setpoint value with time in accor- 8 Yes Going on control Going on control No
dance with a preset pattern, as shown in the figure 9 Yes Going on control Going on control Yes
below. This device allows a maximum of four ramp and 10 Yes Going on control Stand-by mode No
four soak segments. Ramp is the region in which SV 11 Yes Going on control Stand-by mode Yes
12 Yes Stand-by mode Going on control No
changes toward the target value. Soak is the region in
13 Yes Stand-by mode Going on control Yes
which the target value is maintained. STAT displays the
14 Yes Stand-by mode Stand-by mode No
current ramp/soak status. No setting can be made.
15 Yes Stand-by mode Stand-by mode Yes
oFF: Not in operation
1-rP – 4-rP: Executing 1st – 4th ramp 1. Power on Start: Program starts from the current PV value.
1-St – 4-St: Executing 1st – 4th soak In non-power-on-start the program starts from the
End: End of program main SV value.
2. Output on END: Output condition at the end of the program (ProG=End)
SV-1 Ramp Target Value: Sets the target value for each ramp 3. Output on OFF: Output condition when program is terminated (ProG=oFF)
to to segment.
4. Repeat function: Ramp-soak program operates repeatedly.
SV-4 Setting range: 0-100% of full scale
If the repeat function is off, the SV value on the last step is
maintained.
TM1r Ramp Segment Time: Sets the duration of each ramp
Stand-by mode: Output -3%, Alarm off.
to to segment.
TM4r Setting range: 00.00 to 99hrs 59mins. Going on Control: When program ends (End), control is at the SV value
on the last step.
TM1S Soak Segment Time: Sets the duration of each soak When program is terminated (oFF), control is at the main SV
to to segment. value.
TM4S Setting range: 00.00 to 99hrs 59mins.
Mod Ramp/Soak Mode: Up to 16 different modes of

ramp/soak operations are possible. Choose the appro-
priate code from the Table of Ramp/Soak Modes.
Setting: 0-15
Set Value
SV3
Third
ramp
SV2
Second
ramp
SV1
Third Fourth
Second soak
soak Ramp
SV4
PV
First First
ramp soak Fourth Soak
Time
TM1R TM1S TM2R TM2S TM3R TM3S TM4R TM4S
Ramp: Region in which the setpoint changes toward the target value.
Soak: Region in which the setpoint stays unchanged at the target value.
Note 1: SV cannot be changed while the operation is running or suspended.
Note 2: The use of fuzzy control is inhibited while Ramp-Soak operation is being
performed.
12
SECONDARY MENU SETTINGS P-dF Input Filter Constant: The Input Filter is used to filter
out the quick changes that occur to the process vari-
able in a dynamic or quick responding application
P-n1 Control Action & Sensor Burn-out Protection: The which makes the PXZ control erratically. By slowing
Control Action is the direction of the output relative to down the response time, the PXZ controller averages
the process variable. The PXZ can be programmed as out the peaks and valleys of a dynamic system which,
either a reverse or direct acting controller. As a reverse in turn, stabilizes the control. The Digital Filter also
acting controller, the PXZ’s output decreases as the aids the PXZ in controlling processes where the elec-
process variable increases. A heating application would trical noise is affecting the input signal. The larger the
require reverse acting control. As a direct acting con- value entered, the more filter added and the slower
troller, the PXZ’s output increases as the process vari- the controller reacts to process variable changes. The
able increases. A cooling application would require smaller the value entered, the less filter added and the
direct acting control. Enter the code from the Table of quicker the controller reacts to process variable
Output Type Codes which establishes the PXZ as either changes. Enter as small a value as possible at which
a reverse or direct acting controller. the PXZ maintains accurate and stable control.
Setting range: 0.0-900.0 secs
The Sensor Burn-out Protection is the intended direc-
tion of the output in the event of a thermocouple or RTD Table of Input Type Codes
sensor break, or a break in the analog input. The PXZ
can be programmed with either upper-limit or lower- Input Signal Code Range of Range of With With
measurement measurement decimal decimal
limit burn-out direction. With Upper-limit Burn-out, a (° C) (° F) point (°C) point (°F)
100% output will be delivered in the event of a sensor RTD (IEC) Pt100Ω 1 0 to 150 32 to 302 O O
Pt100Ω 1 0 to 300 32 to 572 O O
burn-out. With Lower-limit Burn-out, 0% output will be Pt100Ω 1 0 to 500 32 to 932 O O
delivered in the event of a sensor burn-out. Enter the Pt100Ω 1 0 to 600 32 to 1112 O X
Pt100Ω 1 -50 to 100 -58 to 212 O O
appropriate code from the Table of Output Type Codes. Pt100Ω 1 -100 to 200 -148 to 392 O O
Pt100Ω 1 -150 to 600 -238 to 1112 O X
Pt100Ω 1 -150 to 850 -238 to 1562 X X
Refer to Error Messages on page 15 for more details.
Thermocouple J 2 0 to 400 32 to 752 O O
J 2 0 to 800 32 to 1472 O X
Table of Output Type Codes K 3 0 to 400 32 to 752 O O
K 3 0 to 800 32 to 1472 O X
Control action Burn-out direction K 3 0 to 1200 32 to 2192 X X
Code Output type R 4 0 to 1600 32 to 2912 X X
Output 1 Output 2 Output 1 Output 2
B 5 0 to 1800 32 to 3272 X X
0 Reverse Lower limit S 6 0 to 1600 32 to 2912 X X
1 action Upper limit T 7 -199 to 200 -328 to 392 O X
Single --- ---
2 Direct Lower limit T 7 -150 to 400 -238 to 752 O X
3 action Upper limit E 8 -0 to 800 32 to 1472 O X
4 Lower limit E 8 -199 to 800 -328 to 1472 O X
Lower limit N 12 0 to 1300 -32 to 2372 X X
5 Reverse Upper limit
6 action Lower limit PL-II 13 0 to 1300 32 to 2372 X X
Upper limit
7 Direct Upper limit
8 action Lower limit -1999 to 9999 O= Enabled
Lower limit DC current/ 0-20mA/ 15
9 Direct Upper limit (Scaling is possible) X =Disabled
voltage 0-5V
10 action Lower limit 4-20mA/ 16
Upper limit
11 Upper limit 1-5V
Dual
12 Lower limit
Lower limit
14 action Lower limit
Upper limit P-SL Lower Limit of Input Range:
16 action Lower limit P-SU Upper Limit of Input Range: The Lower Limit and the
Lower limit
17 Direct Upper limit Upper Limit of Input Range establish the desired high
18 action Lower limit
19 Upper limit
Upper limit and low limit for the type of input used. The Lower limit
must be greater than or equal to the input type’s lower
limit, while the Upper Limit must be less than or equal
to the input type’s upper limit. Setpoint settings are
restricted to values between P-SL and P-SU.
Parameter values that are calculated as a percentage
P-n2 Input type: The Input Type is the type of sensor to be of full scale are affected by these settings. An under-
used with the PXZ controller in sensing the process scale or an overscale error is indicated if the process
variable. The Input Type must be correctly programmed value goes below or above the range by 5% of full
into the controller in order for the controller to perform scale. The primary purpose of these parameters when
with the selected sensor type. Depending on the type of used with thermocouple or RTD inputs is to limit set-
sensor to be used, the PXZ comes in two models. One point settings. When an analog input is used, the sig-
model accepts J, K, R, B, S, T, E, N thermocouples and nal is scaled for the engineering unit range selected.
RTDs (Pt100). The other model accepts 1-5/0-5V DC and For example, when a 4-20 mA input is used, the value
4-20/0-20mA DC signals. of P-SL corresponds to 4mA and the value of P-SU
The current/voltage model comes with a 250Ω precision corresponds to 20 mA.
resistor. Wired directly to the controller, it would con- The engineering unit range could be %, PSI, pH, or any
vert a current signal into a voltage signal. There is no range which can be scaled between -1999 and 9999
need to use the resistor if a voltage signal is applied units.
directly. Refer to the Table of Input Type Codes above to deter-
After the appropriate physical changes have been mine the measuring range for a particular input type.
made, the controller still needs the correct code for the
Input Type to be used. Enter the appropriate code.
13
SCALING THERMOCOUPLE AND RTD(Pt100) INPUT RANGES Table of Alarm Action Type Codes
Example: Program a J thermocouple for 50 to 500°F ALM1 ALM2
( ) ( ) Alarm type Action diagram
Input Type Minimum/Maximum Range
J Thermocouple 32 . . . . . . . . . . . . .1472 °F 0 0 No alarm PV
Program to 50 Absolute 1 1 High alarm AH

PV
value alarm AL
to 500
2 2 Low alarm AH
PV
AL
Full Range = (500-50) = 450 F
High alarm
27.5 50 500 522.5 3 3 PV
(with hold) AH
AL
Setpoint Range
5% 5% Low alarm
4 4 PV
(with hold) AH
AL
Indicating Range AH
AL
Deviation 5 5 High alarm SV PV
alarm
AH
AL
6 6 Low alarm SV PV
SCALING DC CURRENT/VOLTAGE INPUT RANGES AH AH

AL AL
7 7 High/Low alarm PV
Example: Program a 4-20mA DC signal for 0 to 100 E.U. SV
AH
AL
Input Type Minimum/Maximum Range High alarm
8 8 PV
(with hold) SV
4-20mA DC -1999 . . . 9999 Enginerring Units AH

AL
Low alarm
9 9 PV
(with hold) SV
Program to 0 AH AH
High/Low alarm AL AL
10 10
to 100 (with hold) SV
PV
AH AH
High/Low deviation AL AL
Full Range = (100-0) = 100 Engineering Units Zone alarm 11 11 alarm
(ALM 1/2 independent action) SV PV
-5 0 100 105
Setpoint Range High/Low
— 12 PV
5% 5% absolute alarm AL AH
AL AH
High/Low
— 13
Indicating Range deviation alarm PV
SV
AL
High absolute/
— 14
Low deviation alarm PV
SV AH
AH
High deviation/
— 15
Low absolute alarm PV
AL SV
P-AL Alarm Type 2:

P-AH Alarm Type 1: This function sets the control action for
P-An Alarm Hysteresis: The Alarm Hysteresis is that area
the optional alarm output relays. The PXZ5, 7, and 9
on one side of the alarm setpoint where the output
comes with two relays while the PXZ4 comes with
does not change condition. That area or deadband is
one. They can be programmed for absolute, deviation,
intended to eliminate relay chatter at alarm setpoint
combination, or zone alarm configuration. The high
with less wear on the relay. With a wide Alarm
and low alarm setpoints are set with primary menu
Hysteresis, the controller takes a longer time to
parameters AH and AL. The absolute alarm configura-
change output condition. With a narrow Alarm
tions are independent of main setpoint. The alarm out-
Hysteresis, the controller takes a short time to change
put relays are energized when the process variable
output condition. Enter a value which is just large
exceeds the alarm setpoint, an absolute value. The
enough to eliminate relay chatter.
deviation alarm configuration is main setpoint track-
Setting Range: 0 to 50% of full scale, set in E.U.
ing. The alarm output relays are energized when the
process variable exceeds the main setpoint by a devi- Alarm OFF Alarm OFF
ation value set by AL or AH. The combination alarm Alarm ON Alarm ON
configurations are a mixture of both the deviation and
absolute value settings for the high and low alarms.
With zone alarm configurations the alarm output is Low Alarm High Alarm High Alarm
Low Alarm Main
energized between the range set by AL and AH. Setpoint Hysteresis Setpoint Hysteresis Setpoint
One of the alarm types is Alarm with Hold. In this case
the alarm is not turned on the first time the measured
P-dP Decimal Point Position (Resolution): The Decimal
value is in the alarm band. Instead it turns on only
Point Position is the resolution at which the PXZ con-
when the measured value goes out of the band and
troller displays the process variable and other para-
enters it again. This type is useful when using devia-
meter values. The PXZ can indicate integers, tenths or
tion alarm with step type input.
hundredths of a unit. The Decimal Point Position does
Enter the code for P-AH and P-AL from the Table of
not increase the accuracy of the controller, it only
Alarm Action Type Codes.
increases the resolution. For a thermocouple, integers
are usually sufficient due to the accuracy rating and
Note 1: A change of alarm action type can cause the
the programmed input range. For a RTD (Pt100), inte-
alarm set value to change, but this is not a malfunction.
gers or tenths of a degree may be entered, because of
Note 2: After the alarm type is changed, turn off the
the increased accuracy of these sensors, depending
power to the unit once.
on the programmed input range. For a 1-5/0-5V DC or
4-20/0-20mA DC signal, integers, tenths or hundredths
of a unit may be entered depending on the pro-
14
grammed input range. ADJ0 Input Calibration: This function is used for input cali
The input range can be anywhere between -1999 and ADJS bration by the user in a simple manner. Calibration is
9999 units and must be programmed in the lower limit effected by applying signal for zero and span points of
of input range and the upper limit of input range para- the input range being used and then by setting errors.
meters with decimal place values. Enter a Decimal The user calibration function is an independent func-
Point Position code dependent on the desired resolution and the instrument can easily be reset to condi-
tion, the input type, and the programmed input range. tions prior to delivery.
Setting: Example:
0 -None Input range 0-400°C
1- Tenths of a unit Indication at 0°C : -1°C
2 - Hundredths of a unit Indication at 400°C: 402°C
Change ADJ0 to 1 and ADJS to -2 to correct the error.
PVOF Process Variable Offset: The Process variable Offset The instrument can be set back to factory values by
is the amount by which the indicated process variable setting ADJ0 and ADJS to 0.
is shifted in a positive or negative direction. Both the
indicated as well as the measured process variable
will be changed. This parameter can be used to cor- dSP1 Parameter Mask function: This function is used to indi-
rect for differences in sensors, sensor placement, and to to vidually mask the display of parameters that are not
standardization problems. Enter a value which is the dSP7 used for your application, or parameters that are not
difference between the measured process value and to be accessed by the operator. To mask or unmask a
the actual process value of the system. parameter appropriate values should be selected from
Setting range: -10 – 10% of full scale, set in Eng. units the DSP Assignment table.
SVOF Setpoint Variable Offset: The Setpoint Variable Offset Example 1: To mask parameter P
is that amount of offset which shifts the measured set- 1) Determine the dSP value for P from the Quick
point variable in a positive or negative direction. The Reference guide. P = dSP1 – 2
measured setpoint variable is changed but the indicat- 2) Add 2 to the existing dSP1 value.
ed setpoint variable remains unchanged. Be careful
when using this variable because what you see as the Example 2: To display/unmask the parameter P-F
setpoint variable may be very different from the actual 1) Determine the dSP value for P-F from the Quick
setpoint variable. Reference guide. P-F = dSP6 – 64
Setting range: -50 – 50% of full scale, set in Eng. units 2) Subtract 64 from the existing dSP6 value.
Indicated Setpoint Variable is Unchanged
Measured Setpoint Variable is Changed
ERROR MESSAGES
P-F C/F Selection: The C/F Selection is that function which
scales the process variable and other setting variables
to either the Celsius or Fahrenheit scale. If using the Error
Indication Cause Control Output
controller to control a process other than temperature
using the current/voltage input model, the C/F 1. Thermocouple burnt out. When the burn-out
Selection is not important because the scaling is done 2. RTD (A) leg burnt out. control output is set for
using the lower limit of the input range and upper limit 3. PV value exceeds P-SU lower limit (standard):
of input range parameters. If using the by 5% FS. OFF, or 4mA or less.
thermocouple/RTD (Pt100) input model, however, the
C/F Selection is important in scaling the controller’s 1. When RTD (B or C) is When the burn-out
parameters. Setting: °C or °F burnt out. control output is set for
2. When RTD (between upper limit: ON, or 20mA
A and B, or between or less.
FUZY Fuzzy Logic Control: Employing Fuzzy Logic Control in A and C) is shorted.
addition to PID control eliminates system overshoot 3. When PV value is below
and effectively suppresses fluctuation of the process P-SL by 5% FS.
variable due to external disturbances. This function 4. When analog input wiring
may be enabled even during auto-tuning. Note that is open or short.
fuzzy control is not effective in units with dual outputs,
When PV value goes below Control is continued
due to the complexity of the process. Fuzzy control is
-1999. the value reaches -5% FS
also inhibited while the Ramp/Soak function is in oper- or less, after which burn-
ation. out condition will occur.
HB lamp Heater break condition Normal control output

ON for heating is continued.
When the setting of OFF, or, 4mA or less.

P-SL/P-SU is improper
Fault in the unit Undefined. Stop use

immediately.
15
APPENDIX A The PXZ then reads the reaction of these test signals on the process.
Keep in mind that every process is different and therefore every reac-
Autotuning tion to the test signals is different. This is why PID parameters are not
the same for different processes. The amplitude (L) or lag time which
By autotuning, the controller selects what it calculates to be the opti- is the overshoot and undershoot of the system when autotuning and
mal PID control parameters for a particular process and then stores the time constant (T) which is the time the process takes to go
them in EEPROM memory for future use. The PID parameters are through one On/Off cycle is measured. See diagram below.
stored so that when the controller is powered up after being shut Time Constant
down, the controller does not need to be autotuned again. The PXZ
uses the same autotuned PID parameters until the Autotune function Overshoot
is again initiated. The Autotune parameters are only good for the
process the Autotune function was used on. If the setpoint is signifi- Amplitude
cantly changed, the input sensor is changed, the load or output Undershoot
device is changed or relocated, or any other disturbances occur
which might change the dynamics of the system, the Autotune func- Time Time
tion should be performed again. The autotuned control parameters OFF ON
are not always perfect for every application but almost always give
the operator a good starting point from which further refinement of
the control parameters can be performed manually.
The measurements are then used with the Autotune algorithm for cal-
The PXZ’s autotuning algorithm is particularly suited for temperature culation of the proper PID parameters for the system. See the PXZ
control applications and may not always autotune effectively for other Autotune algorithm below, where K is the proportionality constant and
processes. Here are cases where the Autotune function does not per- S is the Laplace operator.
form well or does not perform at all:
1. The system is affected by process disturbances external to the K

control loop. Adjacent heater zones, changing material levels, e-LS
exothermic reactions are examples of process disturbances which (1+TS)
are external to the control loop. The PXZ would never be able to
autotune such an unstable process.
2. The system is very dynamic. The process variable changes very
quickly. Certain pressure and flow applications would be charac-
terized as very dynamic. Because of how the Autotune function is
performed, a very dynamic system would create very large over-
shoots which could damage the process.
3. The system is very insulated and cannot cool down in a timely
manner. With such heating systems the autotuning function would
take a very long time to complete with questionable results.
In Autotune, the PXZ sends test signals to the process. The test sig-
nals are 100% output and 0% output at the Autotune point. The
Autotune point can either be at setpoint or 10% of full scale below
setpoint..
The controller performs as an On/Off controller. See diagram below.
Autotune
Point
Process
Variable
Time
100% ON OFF ON OFF ON
Output
Time
0%
Autotune Period
16
APPENDIX B al band too small, however, can lead to over-responsiveness leading
to process oscillation.
Manual Tuning
A proportional band which is correct in width approaches main set-
Tune the PXZ controller if any of the following occurs: point as fast as possible while minimizing overshoot. If a faster
approach to setpoint is desired and process overshoot is not a prob-
• PXZ is installed in a new system lem, a smaller or narrower proportional band may be used. This would
• PXZ is used as a replacement in an existing system establish an over-damped system or one where the output would
• The input sensor is relocated or changed change greatly, proportional to the error. If process overshoot cannot
• The output device is relocated or changed be tolerated and the approach to setpoint does not have to be quick, a
• The setpoint is significantly changed larger or wider proportional band may be used. This would establish
• Any other condition that will alter the dynamics of the system an under-damped system or one where the output would change little,
proportional to the error.
Proportional Band To Calculate Proportional Band:
The proportional band is a band around the setpoint of the PXZ where
the output is between 0% and 100%. The percentage of output is pro- Proportional Band Proportional Band
(as a percentage) = ____________________ X 100%
portional to the amount of error between the setpoint variable (SV) Input Range
and the process variable (PV). Outside of the proportional band the
output is either 0% or 100% Example:
30°C
The proportional band on the PXZ is equidistant from the main set- 3% = __________ X 100%
100°C
point as illustrated below.
Reverse Action Direct Action Proportional Band
(as a percentage)
PB PB Proportional Band Range = ____________________ X 1000°C
100%
100% 100%
Output Output Example:
0% PV 0% PV 3%
30°C = __________ x 1000°C
100%
Main Setpoint Main Setpoint
Note: PB = Proportional Band
An example of proportioning would be a vehicle approaching a stop

sign at an intersection. If the driver were traveling at 50mph and only Integral Time
applied his brakes once at the intersection, his car would skid through With the proportional band alone, the process tends to reach equilib-
the intersection before coming to a full stop. This illustrates how rium at some point away from the main setpoint. This offset is due to
On/Off control acts. If, however, the driver started slowing down some the difference between the output needed to maintain setpoint and
distance before the stop sign and continued slowing down at some the output of the proportional band at setpoint. In the case of the PXZ
rate, he could conceivably come to a full stop at the stop sign. This controller where the proportional band is equidistant from the main
illustrates how proportional control acts. The distance where the setpoint, the output is around 50%. If anything more or less than 50%
speed of the car goes from 50 to 0 MPH illustrates the proportional output is required to maintain setpoint, an offset error will occur.
band. As you can see, as the car travels closer to the stop sign, the Integral action eliminates this offset. See the diagrams below.
speed is reduced accordingly. In other words, as the error or distance
between the car and the stop sign becomes smaller, the output or
speed of the car is proportionally diminished. Figuring out when the
vehicle should start slowing down depends on many variables such
as speed, weight, tire tread, and braking power of the car, road condi-
tions, and weather much like figuring out the proportional band of a
control process with its many variables.
The width of the proportional band depends on the dynamics of the

system. The first question to ask is, how strong must my output be to Integral action eliminates offset by adding to or subtracting from the
eliminate the error between the setpoint variable and process vari- output of the proportional action alone. This increase or decrease in
able? The larger the proportional band (low gain), the less reactive output corrects for offset error within the proportional band in estab-
the process. A proportional band too large, however, can lead to lishing steady-state performance at setpoint. It is not intended to cor-
process wandering or sluggishness. The smaller the proportional rect for process disturbances. See the following diagram.
band (high gain), the more reactive the output becomes. A proportion-
Main Setpoint
PV PV PV 100%
Time Time Output

Time
0%
PV
Proportional Band
Proportional Band Proportional Band with Correct Width
Too Small Too Large
17
Integral Time is the speed at which the controller corrects for offset. Tuning
A short integral time means the controller corrects for offset quickly. Tuning the PXZ, as with any PID loop, requires tuning each parameter
If the integral time is too short, the controller would react before the separately and in sequence. To achieve good PID control manually,
effects of previous output shifts, due to dead time or lag, could be you can use the trial and error method explained below.
sensed causing oscillation. A long Integral time means the control
corrects for offset over a long time. If the integral time is too long, the Tune the Proportional Band
offset will remain for some time causing slow responding or sluggish Set Integral Time = 0 (off)
control. See the diagram below. Set Derivative Time = 0 (off)
PV Setpoint Start with a large Proportional Band value which gives very sluggish
Offset control with noticeable offset and tighten by decreasing the value in
Time half. Analyze the process variable. If the control is still sluggish, tight-
en by decreasing the value in half again. Continue with the same pro-
cedure until the process starts to oscillate at a constant rate. Widen
Short Integral Time
Output the Proportional Band by 50%, or multiply the setting 1.5 times. From a
Long Integral Time cold start, test and verify that the Proportional Band allows maximum
Proportional Action Only rise to setpoint while maintaining minimum overshoot and offset. If not
completely satisfied, fine-tune the value, up or down, as needed and
Time
test until correct. The Proportional Band is now tuned.
Derivative Time Add Integral Time

In the case of a process upset, proportional only or proportional-inte- Start with a large Integral Time value which gives very sluggish
gral action cannot react fast enough in returning a process back to response to process offset and tighten by decreasing the value in
setpoint without overshoot. The derivative action corrects for distur- half. Analyze the process variable. If the response to process offset is
bances providing sudden shifts in output which oppose the diver- still sluggish, tighten by decreasing the value in half again. Continue
gence of the process from setpoint. See the diagram below. with the same procedure until the process starts to oscillate at a con-
stant rate. Increase the Integral Time value by 50%, or multiply the
setting 1.5 times. From a cold start, test and verify that the Integral
Time allows maximum elimination of offset with minimum overshoot. If
not completely satisfied, fine-tune the value, up or down, as needed
and test until correct. The Integral Time is now tuned.
Add Derivative Time

Do not add Derivative Time if the system is too dynamic. Start with a
The derivative action changes the rate of reset or integration propor- small Derivative Time value which gives sluggish response to process
tional to the rate of change and lag time of the system. By calculating upsets and double the value. Analyze the process variable. If the
the rate of change of the process and multiplying it by the lag time response to process upsets is still sluggish, double the value again.
which is the time it takes the controller to sense an output change, Continue with the same procedure until the process starts to oscillate
the controller can anticipate where the process should be and at a quick constant rate. Decrease the Derivative Time value by 25%.
change the output accordingly. This anticipatory action speeds up and From a cold start, test and verify that the Derivative Time value allows
slows down the effect of proportional only and proportional-integral maximum response to process disturbances with minimum overshoot.
actions to return a process to setpoint as quickly as possible with If not completely satisfied, fine-tune the value, up or down, as needed
minimum overshoot. See the diagram below. and test until correct. Note that the Derivative Time value is usually
somewhere around 25% of the Integral Time value.
Rate of Change X Lag Time=
Anticipated Process Variable
Another tuning method is the closed-loop cycling or Zeigler-Nichols
method. According to J.G. Zeigler and N.B. Nichols, optimal tuning is
achieved when the controller responds to a difference between set-
point and the process variable with a 1/4 wave decay ratio. That is to
PV
Time say that the amplitude of each successive overshoot is reduced by 3/4
until stabilizing at setpoint. The procedure is explained below.
1. Integral Time=0
Derivative Time=0
2. Decrease the Proportional Band to the point where a constant rate
Derivative time is the amount of anticipatory action needed to return a of oscillation is obtained. This is the response frequency of the
process back to setpoint. A short derivative time means little deriva- system. The frequency is different for each process.
tive action. If the derivative time is too short, the controller would not
react quickly to process disturbances. A long derivative time means 3. Measure the Time Constant which is the time to complete one cycle
more derivative action. If the derivative time is too large, the con- of the response frequency. The Time Constant will be defined as
troller would react too dramatically to process disturbances creating “T” when calculating Integral and Derivative Times.
rapid process oscillation. A process which is very dynamic such as
pressure and flow applications is more efficiently controlled if the
derivative action is turned off because of the oscillation problem
which would result.
18
Time APPENDIX C
Constant
Heater Break Option
PV
Time The Heater Break Option is used to detect heater break conditions
and to energize an alarm relay when such conditions exist. In most
cases, the option is used to detect the failure of one or more zones in
4. Widen the Proportional Band until only slightly unstable. This is the a multi-zoned heater where all individual resistive heater zones are
Proportional Band’s Ultimate Sensitivity. The Proportional Band’s wired in parallel. Failed heater zones would create cold spots in a
Ultimate Sensitivity width will be defined as “P” when calculating system which could hamper the process and even ruin the product. If
the actual Proportional Band. cold spots in a system are a problem, the Heater Break Option is an
effective way of alerting the operator of a heater break condition, a
5. Use the following coefficients in determining the correct PID set- cause of cold spots.
tings for your particular application.
The PXZ controller is able to detect a heater problem by analyzing the
current used by the heater. The actual sensing is done by a current
Control P I D sensing transformer, sold separately, which is placed around the hot
Action Setting Setting Setting lead going to the heater and connected to the controller. The signal
P Only 2P * * sent by the current sensing transformer is timed with the output of the
PXZ. When the output is energized the signal sent from the current
PI 2.2P .83T *
sensing transformer is analyzed. When the output is de-energized the
PID 1.67P .5T .125T
signal sent from the current sensing transformer is not analyzed. This
eliminates the alarm condition turning on and off due to the output
condition of the controller. If the signal sent when the output is ener-
gized indicates that the current level is below what the Heater Break
alarm is set for, the alarm is energized. The alarm is non-latching.
Notes:
1. The Heater Break Option is available on the PXZ-5, 7, and 9
controllers only.
2. The Heater Break Option cannot be used on the PXZ controller with
a 4-20mA DC output. The current sensing transformer would pick
up current changes due to fluctuating power output, between 0%
and 100%, which would result in a heater break alarm condition
even though no such condition existed.
3. The Cycle Time must be set at 6 secs. or higher in order for the
controller to correctly analyze the signal sent by the current sens-
ing transformer.
4. The power supply used should be the same for the PXZ and heater
to eliminate current fluctuations due to power differences between
different power supplies.
19
Wiring and Setting: APPENDIX D
1. Choose the correct current sensing Heat/Cool Option
Connection to PXZ
transformer based on the maximum (Polarity not important)
current usage of the heater. With the Heat/Cool Option, the PXZ can control a temperature appli-
Hot lead to Heater
0 - 30 Amps (part # CTL-6-SF) cation with one input at one main setpoint using two outputs, a heat-
0 - 50 Amps (part # CTL-12-S36-8F) ing output and a cooling output. By using a heating and cooling out-
put, a process is able to quickly bring the temperature to setpoint in
2. Thread the hot lead going to the heater through the donut of the both directions and to limit the amount of overshoot. The larger the
current sensing transformer. Connect the wires of the current deviation from setpoint, the more output applied to the system on both
sensing transformer to the current sensing transformer input termi- the heating and cooling sides. Heat/Cool control is a very effective
nals in the back of the controller. way of controlling exothermic processes, processes that generate
3. Set Heater Break alarm setpoint parameter “Hb”. With the current their own heat, or processes where ambient temperature is not ade-
sensing transformer connected and the heater in operation, output quate or fast enough in returning a process back to setpoint.
energized, change the Heater Break Alarm setting from the maxi-
mum current setting for the particular current sensing transformer The two outputs on the PXZ are independent and sent to two different
being used to a lower value. Allow 3 secs. or more between setting output devices. The PXZ can be equipped with two of the same or
changes. Continue lowering the setting until the relay is energized two different output types. Output #2 can be relay, SSR/SSC driver, or
and the “HB” status indicator is lit. This is the maximum current 4-20mA DC, regardless of what Output #1 is. Both output types must
usage of the heater. Using the same procedure, find the maximum be specified when ordering.
current usage of the heater minus one zone. Set the setpoint in
between the two current readings. In this way, the operator knows The PXZ controls the cooling side with three additional parameters,
if one or more zones fail because the current sensed will only be TC-2, COOL, and DB. Each is explained below:
below the Heater Break Alarm setting if one or more zones fail.
TC-2 Cycle Time (Output #2): Because Output #2 is not
necessarily the same as Output #1, the cycle time may
Power Supply be different
CooL Proportional Band Coefficient for Cooling: Because the

cooling power may not necessarily be the same as the
heating power, the cooling proportional band may need
8 4 to be different from that of the heating proportional
9 band.
5 15 db Deadband/Overlap: Deadband is that area where
Alarm Output
Main 7 16 neither outputs are energized. Overlap is that area
Output + –
17 18 1 2 when both outputs are energized. This function lets
you decide where you want the heating action to stop
and the cooling action to begin.
Current Sensing Transformer Notes:
1. The Heat/Cool Option is available on the PXZ-5, 7, and 9 con-

trollers only. Output #2 type can be the same or different than
Input Sensor
Output #1 type (Relay, SSR/SSC driver, or 4-20mA DC)
2. Integral and Derivative Times are the same for both the heating
Heater and cooling sides of a process with PID control because the
response frequency or time constant of the system does not
change at main setpoint when cooling is added.
3. The Proportional Band for heating and cooling are almost always
different. Rarely does the same amount of cooling output remove
the same percentage of process error as the heating output does.
The Cooling Proportional Band must be manually and separately
tuned.
4. If the heating side is set for On/Off control, the cooling side will be
set for On/Off control also. Regardless of what the COOL parame-
ter is set for, if the Proportional Band is set to zero, the Heating
Proportional Band and the Cooling Proportional Band will always
be zero or On/Off.
20
5. If the cycle times of one or both outputs are long and the process
dynamic, there is a good chance that both outputs will be cycling
on and off at the same time around main setpoint. This is evident
if one or both outputs are relays.
6. Autotune is not effective on the cooling side of Heat/Cool control.
Autotune the controller for heat only and then manually tune the
cooling parameters.
Wiring and Setting

1. Make sure that your PXZ has the correct output type installed for
Output #2. Verify that the TC2, COOL, and DB parameters are indi-
cated in the primary (setpoint) menu.
2. Wire your cooling load to the Output #2 terminals located on the

back of your PXZ controller.
3. In the secondary (system) menu, program the correct code for

Heat/Cool action. See page 13 for the complete code table.
4. In the primary (setpoint) menu, program TC2, the cycle time for
Output #2. The table below is a general guide to TC2 settings.
Output#2 Type Setting(Secs)
Relay 30
SSR Driver (pulsed DC) 2
4-20mA DC Not indicated or 0
5. Autotune or manually tune the PID parameters of your PXZ

controller. Autotune will work for the heating PID parameters
but not on the cooling parameters. You must manually tune the
cooling parameters.
Heating Side Cooling Side
Heating Side Cooling SIde
Heating Proportional Band Cooling Proportional Band
[P/2] [P/2 COOL]
I I (same as for heating)
D D (same as for heating)
6. With the heat side tuned, manually set the COOL parameter or
Proportional Band Coefficient for Cooling. If the cooling output is
less powerful than the heating output, the Cooling Proportional
Band must be narrower than the Heating Proportional Band; the
COOL parameter would be less than “1”. If the cooling output is
more powerful than the heating output, the Cooling Proportional
Band must be wider than the Heating Proportional Band; the COOL
parameter would be more than “1”. See the programming section
for more details.
7. Finally, you can add a Deadband/Overlap. The programmed

Deadband/Overlap parameter can be within -50% to +50% of the
Heating Proportional band. To establish a Deadband, parameter
“db” is set somewhere between 0% and 50% of the Heating
Proportional band. To establish an Overlap, db is set somewhere
between -50% and 0% of the Heating Proportional Band.
8. Manually fine-tune the parameters COOL and db until just the right
amount of cooling is achieved. Refer to the programming section
for more details on these parameters.
21
PXZ QUICK REFERENCE PXZ QUICK REFERENCE
Primary Menu Secondary Menu
Parameter Range Description Default DSP Parameter Range Description Default DSP
settings settings settings settings
ProG oFF/rUn/HLd Ramp/soak command oFF dSP1-1 P-n1 0 -19 Control Action code † dSP5-4
P 0.0 - 999.9%FS Proportional band 5.0 dSP1-2 P-n2 0 - 16 Input type code † dSP5-8
I 0 - 3200sec Integral time 240 dSP1-4 P-dF 0.0 - 900.0sec Input filter constant 5.0 dSP5-16
D 0.0 - 999.9sec Derivative time 60 dSP1-8 P-SL -1999 - 9999 Lower range of input 0%FS dSP5-32
AL 0 - 100%FS Low Alarm Setpoint 10 dSP1-16 P-SU -1999 - 9999 Upper range of input 100%FS dSP5-64
AH 0 - 100%FS High Alarm Setpoint 10 dSP1-32 P-AL 0 - 15 Alarm Type 2 code 9 dSP5-128
TC 1 - 150sec Cycle Time (output #1) † dSP1-64 P-AH 0 - 11 Alarm Type 1 code 5 dSP6-1
HYS 0 - 50%FS Hysteresis 1 dSP1-128 P-An 0 - 50%FS Alarm Hysteresis 1 dSP6-2
Hb 0.0 - 50.0A Heater-break alarm S.P. 0.0 dSP2-1 P-dP 0-2 Decimal point position 0 dSP6-4
AT 0-2 Auto-tuning command 0 dSP2-2 rCJ - - ON dSP6-8
TC2 1 - 150sec Cycle Time (output #2) † dSP2-4 PVOF -10 - 10%FS PV offset 0 dSP6-16
CooL 0.0 - 100.0 Proportional band 1.0 dSP2-8 SVOF -50 - 50%FS SV offset 0 dSP6-32
coefficient for cooling
P-F °C/°F °C/°F Selection † dSP6-64
db -50.0 - 50.0% FS Deadband/Overlap 0.0 dSP2-16
PLC2 - N/A -3.0 dSP6-128
PLC1 - N/A -3.0 dSP2-32
PHC2 - N/A 103.0 dSP7-1
PHC1 - N/A 103.0 dSP2-64
FUZY OFF/ON Fuzzy control OFF dSP7-2
PCUT - N/A 0 dSP2-128
GAIN - N/A 1 dSP7-4
bAL 0 - 100% Balance 0.0/50.0 dSP3-1
ADJO - Zero calibration 0 dSP7-8
Ar 0 - 100%FS Anti-reset windup 100%FS dSP3-2
ADJS - Span calibration 0 dSP7-16
LoC 0-2 Lock out 0 dSP3-4
OUT - N/A -3.0 dSP7-32
STAT -- Ramp/soak status oFF dSP3-8
dSP1-7 0-255 Parameter mask † -
SV-1 0 - 100%FS 1st S.P. 0%FS dSP3-16
TM1r 0 - 99hr 59min 1st ramping time 0.00 dSP3-32
TM1S 0 - 99hr 59min 1st soaking time 0.00 dSP3-64
SV-2 0 - 100%FS 2nd S.P. 0%FS dSP3-128
TM2r 0 - 99hr 59min 2nd ramping time 0.00 dSP4-1
TM2S 0 - 99hr 59min 2nd soaking time 0.00 dSP4-2
SV-3 0 - 100%FS 3rd S.P. 0%FS dSP4-4
TM3r 0 - 99hr 59min 3rd ramping time 0.00 dSP4-8
TM3S 0 - 99hr 59min 3rd soaking time 0.00 dSP4-16
SV-4 0 - 100%FS 4th S.P. 0%FS dSP4-32 † Based on the model
TM4r 0 - 99hr 59min 4th ramping time 0.00 dSP4-64
TM4S 0 - 99hr 59min 4th soaking time 0.00 dSP4-128
MOD 0 -15 Ramp/Soak Mode code 0 dSP5-1
22
THERMAX (WANSON) BURNER ASSEMBLY

The typical assembly of ‘thermax wanson burner’ along with the burner housing is as
shown below :

CONSTRUCTION / FUNCTION:
The Burner assembly mainly consists of following components,
a. Burner Housing.
b. Guide Pipe Assembly.
c. Burner Rod.
d. Electrode Assembly
e. Burner Nozzle.
f. Wegman Cone.
g. Diffuser Plate.

a. Burner housing: it houses the entire guide pipe assembly, burner rod along with
burner nozzle, diffuser plate, Wegman cone which is fitted on the housing,
electrode assembly which is being connected to the guide pipe via diffuser plate
holder. The burner housing provides the path required for
Passage of hot air in the furnace inorder to ensure complete combustion of the
fuel. The air is normally passed through the slots which are being provided on
the burner housing.
b. Guide Pipe assembly : The guide pipe assembly being connected to the
burner mounting plate plays a very important role. The diffuser plate and
electrode assembly are connected to the guide pipe by means of diffuser plate
holder as shown in the above figure. The guide pipe assembly can be moved in
the burner housing upwards and downwards this helps in adjusting the air fuel
ratio required for complete combustion.

c. Burner Rod : The sketch of the burner rod assembly is as shown below

The oil bypass port as shown in the figure above is being provided only for
burners supplied with modulation provision.
The oil enters in the burner through the inlet port and is atomised and sprayed
into the heater / boiler furnace through the nozzle being connected as shown
above. The excess oil pumped into the burner is collected through the return
port for unit having ON‐OFF operation and through bypass port for units with
modulation operation. When electric supply is given to the burner the solenoid
coil as shown in above figure gets energised and as a result it lifts the stem rod
and provides clear passage for the flow of oil to the nozzle and hence eventually
into the furnace.

d. Electrode Assembly : The ignition electrode assembly connected to the guide
pipe provides the electric spark for initiating the combustion process.

e. Burner Nozzle: In order to ensure combustion of the oil into the furnace it is
required to be atomised into fine droplets and this is achieved by means of fuel
nozzle which is being provided on the burner rod.

f. Wegman Cone: The Wegman cone helps in ensuring proper mixture of air
and fuel thus ensuring complete combustion.

g. Diffuser Plate: It helps in retention of flame during combustion process. By
means of diffuser plate the main air stream is divided into primary and
secondary air streams which helps in the combustion process.
GAS TRAIN:
• The train is fitted close to the burner of the boiler in the boiler house .The function of the gas
train is to provide the clean ,regulated flow of gas at the desired pressure to the burner of
the boiler / heater and to provide essential safety incase of abnormalities .
Gas Pressure gauge Gas Pressure gauge
Ball valve Gas filter Safety Shut Gas Pressure Gas pressure switch Main Gas Solenoid Valves
off Valve Regulator
Figure No 1 : Standard Gas Train
Figure No .2: P&I Diagram: Gas Train Assembly

The gas train will also provide the following actions, with the help of the various components:
Sr no Component Description Function

A Manual Ball Valve/quick shut off Manual start/Isolation of gas supply
valve
B Gas filter Filtration of gas
C Safety Shut off valve: High pressure shut off of gas supply
D Gas Pressure regulator Regulation of the gas flow & pressure
E Gas Pressure gauges Indications of the gas pressures ,at inlet of the gas
train & at the inlet of the burner
F Safety relief valve Venting of the excessive gas pressure
G Solenoid valve–pilot burner Supply gas to pilot burner
H Main Gas Solenoid valves ( 2nos) Supply gas to main gas burner ,
after establishing normal pilot flame -
I High & Low Gas pressure switches. Gas pressure high & low-pressure
Shut off gas supply
Where gas inlet pressure to gas train is below 500 mbar safety shut off valve & safety relief valve is
not required.
The gas train shuts of the gas supply to the burner in case of abnormal conditions
The abnormal conditions will arise when,
• Gas pressure in the gas train, will rise above or fall below the set pressures in the gas pressure
switch. If the high gas pressure safeties fail to operate, the safety relief valve will vent out the
excess gas pressure.
• Burner Flame or ignition failure.
The pilot & main burner solenoid valves are connected to the sequence controller of the boiler.
GENERAL DESCRIPTION ABOUT GAS TRAIN COMPONENTS.
a. Quick shut-off valve
This is manually operated quarter turn shut off valve to supply or

cut off gas to the burner, and is fitted at the start of the gas train.
b. Filter
This is to prevent any dust/Rust particles or impurities from entering

the pressure regulators and solenoid valves, thereby avoiding
leakages.
c. Pressure Regulator (Gas governor)
This is the most important part of gas train. It regulates the

downstream pressure of the gas at the set value required for
correct firing rate of main burner. The set pressure of the regulator
(#) can be adjusted by changing the tension of spring located
above the diaphragm.
d. Safety Relief Valve
Safety relief valve is mainly required to relieve sudden pressure

surges in the line. A safety relief valve is positioned downstream of
the gas pressure regulator. The setting of relief valve is 20% above
regulator set pressure.
e. Safety Shut off Valve (Slam Shut off Valve)
Safety shut off valve is used to protect the down stream

components in case supply pressure exceeds the withstanding
pressures of downstream components of pressure regulator.
The setting of the valve is 20% above safety relief valve pressure.
f. Pressure switch (Gas pressure high)
This is a protection of safe guard the burner from over firing in the
event of high gas pressure occurring downstream of the
regulators. If the pressure of gas increases above the set limit the
gas pressure switch de-energizes safety circuit and cuts off the
burners, giving audio-visual alarm.
g. Burner Solenoid valves
Every time the burner trips(safety interlock) or is put off (controlled

shutdown in ON-OFF operations), two solenoid valves on the main
gas line shut tightly isolating the burner from the gas flow.
In addition, the solenoid valves should close when there is power
failure, without extra energy. These are NC type solenoid valves.
When the power fails, the burner blower switches off. If solenoid
valves are not closed, then gas will continuously flow and
accumulate into furnace without any firing, which may result in fire
hazard, while restarting the burner.
Figure No. F 3.6.10.h
1. Quick opening solenoid valve: - It is installed first out of two solenoid valve. The valve is
closed when not connected to power supply. After voltage is supplied to drive unit the
valve opens and gas flows.
2. Slow opening solenoid valve: - It is installed after quick opening valve, when voltage is
applied the disk is pulled upwards by the drive unit. The damping prevents the movement
being too fast. The valve opens slowly.
I. Pressure gauges
Pressure gauges are provided at different locations, one before the

regulator and the other after the regulator. The former indicates the
gas supply pressure, where as the latter indicates the pressure at
which gas enters main gas solenoid valves.
One pressure gauge is provided after the regulator (governor) in the
gas pilot line.
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D GB F I
Betriebs- und Montage- Operation and assembly Notice d'emploi et de Istruzioni di esercizio e di
anleitung instructions montage montaggio
Kugelhahn Ball valve Robinet à boisseau sphé- Rubinetto a sfera

Typ KH… Type KH… rique type KH… Tipo KH…
Nennweiten Nominal diameters Diamètres nominaux Diametri nominali
Rp 1/4 - Rp 2 Rp 1/4 - Rp 2 Rp 1/2 - Rp 2
Rp 1/4 - Rp 2
R 1/4 - R 2 R 1/4 - R 2 R 1/4 - R 2
R 1/4 - R 2
DN 25 - DN 200 DN 25 - DN 200 DN 25 - DN 200
DN 25 - DN 200
Einbaulage Stellung Handhebel Niemals Handhebel entfernen! Auf vibrationsfreien Einbau

Installation position Lever position Never remove lever achten!
Position de montage Position du levier Ne jamais enlever le levier! Ensure that the pressure limiter
Posizione de montaggio Posizione della leva a mano Non togliere mai la leva mais installed free of vibration!
nuale! Veiller à ce que l'appareil ne
subisse pas de vibrations !
Evitare possibilità di vibrazioni!
Max. Betriebsdruck Umgebungstemperatur

Max. operating pressure ¡C Ambient temperature
Pression de service maxi. +60 Température ambiante
Max. pressione di esercizio Temperatura ambiente
0
KH 50…pmax.= 5 bar (500 kPa) [A] -20 KH 50… -20 °C … +60 °C
[mbar] KH 160…pmax. = 16 bar (1600 kPa) DIN
EN3537
1854 KH 160… -20 °C … +60 °C
KH 160025-16100…pmax. = 4 bar
(4000 kPa) @ HTB 650 °C
Kugelhahn Familie 1+2+3

Ball valve Family 1+2+3
Robinet à boisseau sphérique Famille 1+2+3
Rubinetto a sfera Famiglia 1+2+3
nach / acc. / selon / a norme
Gas Gaz
DIN EN 331
DIN EN 13774 KH 50… DIN EN 331
KH 160… DIN EN 13774
M/CD • Edition 01.12 • Nr. 241 014
1…5
Einbaumaße / Dimensions / Cotes déncombrement / Dimensioni [mm]
b
b
KH 50… KH 160…
Rp (Rp 1/2 - Rp 2) DN (DN 25 - DN 200)
SW
SW
a
a
KH 50…
R (Rp/R 1/2 - Rp/R 2)
SW
SW
Einbaumaße / Dimensions /
Cotes d'encombrement / Dimensioni
SW
Typ pmax. Bestell-Nr. [mm] Gewicht
Type Ord. No. Rp/R/DN a b c SW Weight
Type No. de com. Poids
Tipo Codice art. Peso [kg]
KH 5002 II 5 bar 096 784 Rp 1/4 50,0 38 82 20 0,158

KH 5003 II 5 bar 098 400 Rp 3/8 60,0 38 82 20 0,154
KH 5005 II 5 bar 098 418 Rp 1/2 75,0 43 100 25 0,246
KH 5007 II 5 bar 098 426 Rp 3/4 80,0 50 120 32 0,386
KH 5010 II 5 bar 098 434 Rp 1 90,0 54 120 41 0,624
KH 5012 II 5 bar 239 097 Rp 1 1/4 110,0 73 160 50 0,976
KH 5015 II 5 bar 098 442 Rp 1 1/2 120,0 79 160 55 1,202
KH 5020 II 5 bar 098 459 Rp 2 140,0 86 160 70 1,990
KH 5002 IA 5 bar 239 098 Rp 1/4 ----- R 1/4 56,5 38 82 20 0,158

KH 5003 IA 5 bar 239 099 Rp 3/8 ----- R 3/8 56,5 38 82 20 0,154
KH 5005 IA 5 bar 239 100 Rp 1/2 ----- R 1/2 70,0 43 100 25 0,246
KH 5007 IA 5 bar 239 101 Rp 3/4 ----- R 3/4 76,0 50 120 32 0,386
KH 5010 IA 5 bar 239 102 Rp 1 ------- R 1 92,5 54 120 41 0,624
KH 5012 IA 5 bar 239 103 Rp 1 1/4 -- R 1 1/4 106,0 73 160 50 0,976
KH 5015 IA 5 bar 239 104 Rp 1 1/2 -- R 1 1/2 113,0 79 160 55 1,202
KH 5020 IA 5 bar 239 105 Rp 2 ------- R 2 133,0 86 160 70 1,990
KH 160 025 4 / 16 bar 1) 238 579 DN 25 125 114 165 3,200

KH 160 032 4 / 16 bar 1) 238 580 DN 32 130 125 165 4,700
KH 160 040 4 / 16 bar 1) 238 581 DN 40 140 136 185 5,700
KH 160 050 4 / 16 bar 1) 238 582 DN 50 150 143 185 7,600
KH 160 065 4 / 16 bar 1) 238 583 DN 65 170 158 230 12,000
KH 160 080 4 / 16 bar 1) 238 584 DN 80 180 186 360 15,500
KH 160 100 4 / 16 bar 1) 238 585 DN 100 190 203 360 22,600
KH 160 125 16 bar 238 586 DN 125 200 223 360 24,500
KH 160 150 2) 16 bar 238 587 DN 150 210 230 625 38,500
KH 160 200 16 bar 096 818 DN 200 400 245 700 91,000
M/CD • Edition 01.12 • Nr. 241 014
1)
4 bar @ HTB 650 °C
2)
kann nur bei geöffneter Kugel ein- bzw. ausgebaut werden / can only be mounted and dismounted with opened ball / ne peut être monté ou démonté
que lorsque la sphère est ouverte / può essere montato o smontato solo con sfera aperta
2…5
Geeignetes Werkzeug einsetzen! Schrauben kreuzweise anziehen!
Please use proper tools! Tighten screws crosswise!
Utiliser des outils adaptés! Serrer les vis en croisant!
Impiegare gli attrezzi adeguati! Stringere le viti incrociate!
max. Drehmomente / Flanschverbindung M 16 x 65 (DIN 939) M 20 x 90 (DIN 939) Stiftschraube

max. torque / Flange connection Setscrew
couple maxi. / Joint à brides 50 Nm 50 Nm Goujon
ISO 7005-2 max. coppia / Collegamento a flangia Vite per acciaio
Einbau Assembly Montage Montaggio

Gewindeausführung Thread version Version taraudée Tipo di filettatura
KH 50… KH 50… KH 50… KH 50…
(Rp 1/2 - Rp 2) (Rp 1/2 - Rp 2) (Rp 1/2 - Rp 2) (Rp 1/2 - Rp 2)
1. Gewinde schneiden 1. Tap thread 1. Fileter 1. Eseguire la filettatura
2. Geeignetes Dichtmittel ver- 2. Use suitable sealing agent and 2. Utiliser un produit d’étanchéité 2. Fare uso di guarnizioni di tenuta
wenden, geeignetes Werkzeug proper tools. adéquat, utiliser un outil adé- e di attrezzi appropriati.
verwenden. quat
3. Gerät darf nicht als Hebel be- 3. Do not use unit as lever. 3. Ne pas utiliser la vanne comme 3. L'apparecchio non deve essere
nutzt werden. un levier. usato come leva.
4. Nach Einbau Dichtheits kontrol- 4. After assembly, perform a leak- 4. Après le montage, procéder à un 4. Dopo il montaggio controllare
le durchführen! age test. contrôle de l’étanchéité! la tenuta!
Einbau Assembly Montage Montaggio

Flanschausführung Flange version Version avec bride Tipo di flangia
KH 160… KH 160… KH 160… KH 160…
(DN 25 - DN 200) (DN 25 - DN 200) (DN 25 - DN 200) (DN 25 - DN 200)
1. Stiftschrauben einsetzen. 1. Insert set screws. 1. Mettre les goujons en place 1. Montare le vita
2. Dichtung einsetzen 2. Insert seal. 2. Mettre le joint d’étanchéité en 2. Mettere la guarnizione
3.Stiftschrauben festziehen. Dreh- 3. Tighten set screws. Torques are place 3. Serrare i perni filettati attenen-
momentetabelle beachten! listed in torque table! 3. Serrer les goujons. Respecter le dosi alle coppie indicate nella
4. Nach Einbau Dichtheitskontrolle 4. After assembly, perform a leak- tableau des couples! relativa tabella!
durchführen! age test. 4. Après le montage, procéder à un 4. Dopo il montaggio controllare
contrôle de l’étanchéité! la tenuta!
DN -- -- -- -- 25 32 40 50 65 80 100 125 150 200 M max.
Rp 1/4 3/8 1/2 3/4 1 1 1/4 1 1/2 2 – – – – – – Tmax. M max.

Mmax.
Mmax. [Nm] t ≤ 10 s 25 70 105 225 340 475 610 1100 1600 2400 5000 6000 7600 7600
Tmax. [Nm] t ≤ 10 s 15 35 50 85 125 160 200 250 325 400 400 400 400 400 Tmax.
Mmax.
M/CD • Edition 01.12 • Nr. 241 014
3…5
Arbeiten am KH… dürfen Work on the KH… may Seul du personnel spé- Qualsiasi operazione ef-
nur von Fachpersonal only be performed by cialisé peut effectuer des fettuata sulle KH… deve
durchgeführt werden. specialist staff. travaux sur le KH…. essere fatta da parte di
personale competente.
Auf spannungsfreien Make sure that the de- Lors du montage, éviter les Stringere le viti in modo
Einbau achten! vice is mounted free of tensions mécaniques incrociato. Provvedere
strain! a che il montaggio sia
fatto senza tensione mec-
canica!
Direkter Kontakt zwischen Do not allow any di- Eviter tout contact direct Non é consentito il con-
Ag ¯C+80 KH… und dem aushär- rect contact between the entre KH… et la maçonne- tatto diretto fra la KH…
tendem Mauerwerk, Be- ballvalve and hardened rie, les cloisons en béton e murature invecchiate,
tonwänden, Fußböden ist masonry, concrete walls et planchers en cours de pareti in calcestruzzo,
0
[A] -15 nicht zulässig. or floors. séchage. pavimenti.
DIN
EN3537
1854
Rohrleitungsdichtheits- Pipeline leakage test: Contrôle de l'étanchéité Per la prova di tenuta delle
p r ü f u n g : Ku g e l h a h n close ball valve. de la conduite: fermer tubature:
schließen. le robinet à boisseau chiudere il rubinetto a
sphèrique. sfera.
Nach Abschluß von Ar- On completion of work Une fois les travaux sur Al termine dei lavori
Safety beiten am KH…: Dicht- on the ballvalve, perform KH… terminés, procéder effettuati su un KH…:
heitskontrolle durchfüh- a leakage test. toujours à un contrôle predisporre un controllo
first ren. d'étanchéité. della tenuta.
O.K.
Niemals Arbeiten durch- Never perform work if Ne jamais effectuer des In nessun caso si debbono
führen, wenn Gasdruck gas pressure or power travaux sous pression et effettuare lavori in presen-
oder Spannung anliegt. is applied. No naked ou sous tension. Eviter za di pressione gas o di
Offenes Feuer vermeiden. flame. Observe public toute flamme ouverte. tensione elettrica. Evitare
Öffentliche Vorschriften regulations. Observer les réglemen- i fuochi aperti e osservare
beachten. tations. le prescrizioni di sicurezza
Pecali.
Bei Nichtbeachtung der If these instructions are En cas de non-respect La non osservanza di
Hinweise sind Personen- not heeded, the result de ces instructions, des quanto suddetto può
oder Sachfolgeschäden may be personal injury or dommages corporels ou implicare danni a persone
denkbar. damage to property. matériels sont possible. o cose.
Schutz vor Umwelt- und Protection against envi- Une protection contre La protezione da influssi
Witterungseinflüße: ronmental and weather les influences environne- ambientali e da quelli del
impacts: mentales et intempéries : tempo atmosferico come:
Pressure
Equipment • Korrosion • Corrosion • corrosion • Corrosione
Directive • Regen • Rain • pluie • Pioggia
[97/23/EC] • Schnee • Snow • neige • Neve
• Vereisung • Icing • givrage • Formazione di giaccio
• Feuchtigkeit (z.B. • Humidity (e.g. due to • humidité (par ex. par • Umidità (ad es. con-
durch Kondensation) condensation) condensation) densa)
• Schimmel • Mould • moisissure • Muffa
• UV-Strahlung • UV radiation • rayonnement UV • Radiazione UV
• schädliche Insekten • harmful insects • insectes nuisibles • Insetti dannosi
• giftige, ätzende • toxic, caustic solu- • solutions / liquides • Soluzioni/liquidi tos-
Lösungen/Flüssig- tions/liquids (e.g. cut- toxiques, corrosifs sici e corrosivi (ad es.
keiten (z.B. Schneid- ting fluids and cool- (par ex. liquides de liquidi da taglio e di
und Kühlflüssig- ing liquids) coupe et de refroidis- raffreddamento)
keiten) must be guaranteed. sement) deve essere garantita.
muss sichergestellt doit être garantie.
sein.
M/CD • Edition 01.12 • Nr. 241 014
Änderungen, die dem technischen Fortschritt dienen, vorbehalten / We reserve the right to make modifications in the course of technical development.
Sous réserve de tout modification constituant un progrès technique / Ci riserviamo qualsiasi modifica tecnica e costruttiva 4…5
M/CD • Edition 01.12 • Nr. 241 014
Hausadresse Karl Dungs GmbH & Co. KG Briefadresse Karl Dungs GmbH & Co. KG
Head Offices and Factory Siemensstr. 6-10 Postal address Postfach 12 29
Usine et Services Administratifs D-73660 Urbach, Germany Adresse postale D-73602 Schorndorf
Amministrazione e Stabilimento Telefon +49 (0)7181-804-0 Indirizzare la corrispondenza a e-mail info@dungs.com
Telefax +49 (0)7181-804-166 Internet www.dungs.com
5…5
D GB F I
Gas- und Luftfilter Gas- and Airfilter Filtres pour gaz et air Filtro per aria e gas
Typ GF, GF/1, GF/3, GF/4 Type GF, GF/1, GF/3, GF/4 Typ GF, GF/1, GF/3, GF/4 Tipo GF, GF/1, GF/3, GF/4
Rp 1/2 - Rp 2 Rp 1/2 - Rp 2 Rp 1/2 - Rp 2 Rp 1/2 - Rp 2
DN 40 - DN 200 DN 40 - DN 200 DN 40 - DN 200 DN 40 - DN 200
Einbaulage Filter regelmäßig warten, nur

einwandfreie Filtereinsätze
Installation position
schützen die nachgeschalteten
Position de montage Armaturen!
Posizione di montaggio
Maintain filter regularly; only
proper filter inserts protect
beliebig downstream fittings!
any
au choix Entretenir régulièrement les
a piacimento filtres, seules les cartouches
filtrantes parfaites protègent les
pièces de robinetterie en aval.
Provvedere alla regolare ma-

nutenzione del filtro; soltanto
inserti per filtri intatti proteggono
le armature montate a valle.

+80
Pression de service maxi. Température ambiante
0
GF 5…/1: pmax. = 500 mbar (50 kPa) [A] -15 -15 °C … +80 °C
[mbar] GF/3, GF/4, GF 40125...40200, DIN
EN3537
1854
GF4…/1: pmax. = 4 bar (400 kPa)
Filter Familie 1+2+3
Filter ➞➞➞➞ Family 1+2+3
Filtres ➞➞
➞ ➞➞
➞➞➞ Famille 1+2+3
Filtro
Gas Gaz Famiglia 1+2+3
nach / acc. / selon / a norme
DIN 3386 DIN 3386
Druckabgriffe
Pressure taps
Prises de pression
Manopola a pressione 2
1
1 2
A
A B
B
M/CD • Edition 01.12 • Nr. 222 686
A,B Verschlußschraube (VS) G 1/4 1,2 Meßstutzen (MS) G 1/4

G 1/4 screwed sealing plug (VS) G 1/4 Measuring nozzle (MS)
Bouchon (VS) G 1/4 Prise de pression (MS) G 1/4
Tappo a vite (VS) G 1/4 Presa pressione (MS) G 1/4
1…8
Einbaumaße / Dimensions / Cotes déncombrement / Dimensioni [mm] a
h Platzbedarf für Filtereinsatzwechsel d
h Space requirement for filter insert

replacement b
h Encombrement pour le remplacement

de l`élément filtrant
h Fabbisogno di spazio per la sostitu-
zione dell’inserto del filtro
Karl Dungs GmbH & Co.
Typenschild
73660 Urbach
Germany
GF 505/1 - GF 520/1 GF 40040/3 - GF 40200
Typ Rp/DN Ausführung pmax. Einbaumaße / Dimensions / Cotes déncombrement / Dimensioni Gewicht
Type Design [mm] Weight
Type Conception Poids
Tipo Versione a b c d h Peso [kg]
GF 505/1 Rp 1/2 MS 0,5 120 90 35 55 115 0,7

GF 507/1 Rp 3/4 MS 0,5 120 90 35 55 115 0,7
GF 510/1 Rp 1 MS 0,5 160 105 54 51 145 1,1
GF 515/1 Rp 1 1/2 MS 0,5 160 105 54 51 145 1,1
GF 520/1 Rp 2 MS 0,5 186 140 75 65 195 1,9
GF 4005/1 Rp 1/2 VS 4,0 120 90 35 55 115 0,7
GF 4007/1 Rp 3/4 VS 4,0 120 90 35 55 115 0,7
GF 4010/1 Rp 1 VS 4,0 160 105 54 51 145 1,1
GF 4015/1 Rp 1 1/2 VS 4,0 160 105 54 51 145 1,1
GF 4020/1 Rp 2 VS 4,0 186 140 75 65 195 1,9
GF 40040/3 DN 40 VS1) 4,0 132 195 49 47 96 2,8

GF 40050/4 DN 50 VS1) 4,0 159 220 69 50 119 4,1
GF 40065/4 DN 65 VS1) 4,0 194 252 93 95 188 6,0
GF 40080/4 DN 80 VS1) 4,0 234 300 105 101 206 8,3
GF 40100/4 DN 100 VS1) 4,0 281 352 119 110 229 12,3
GF 40125 DN 125 VS1) 4,0 281 360 182 183 365 19,5
GF 40150 DN 150 VS1) 4,0 281 385 257 259 516 25,5
GF 40200 DN 200 VS1) 4,0 388 455 236 239 475 40,0
[Nm] max. Drehmomente / Systemzubehör M4 M5 M6 M8 G 1/8 G 1/4 G 1/2 G 3/4

max. torque / System accessories
19
y
an
m
er
G
in
e
couple maxi. / Accessoires du système 2,5 Nm 5 Nm 7 Nm 15 Nm 5 Nm 7 Nm1) 10 Nm 15 Nm

ad
M
✸
l
ee
St
e
om
hr
C
18
max. coppie / Accessorio di sistema

1)
VS G 1/4: 20 Nm (GF/3, GF/4, GF 40125...40200)

max. Drehmomente / Flanschverbindung M 16 x 65 (DIN 939) M 20 x 90 (DIN 939) Stiftschraube

couple maxi. / Joint à brides 50 Nm 50 Nm Goujon
ISO 7005-2 max. coppia / Collegamento a flangia Vite per acciaio
Gerät darf nicht als Hebel benutzt werden.

M max. Do not use unit as lever.
Ne pas utiliser la vanne comme un levier.
L'apparecchio non deve essere usato come leva.
Tmax. M max.
DN 15 20 25 40 50 65 80 100 125 150 200

M/CD • Edition 01.12 • Nr. 222 686
M max.
Rp 1/2 3/4 1 1 1/2 2 – – – – – –
Mmax. [Nm] t ≤ 10 s 105 225 340 610 1100 1600 2400 5000 6000 7600 7600
Tmax. M max.
Tmax. [Nm] t ≤ 10 s 50 85 125 200 250 325 400 400 400 400 400
2…8
Gewindeausführung Thread version Version taraudée Tipo di filettatura
GF 5../1, GF 40…/1 GF 5../1, GF 40…/1 GF 5../1, GF 40…/1 GF 5../1, GF 40…/1
(Rp 1/2 - Rp 2) (Rp 1/2 - Rp 2) (Rp 1/2 - Rp 2) (Rp 1/2 - Rp 2)
Ein- und Ausbau Assembly and disassembly Montage et démontage Montaggio e smontaggio
1. Gewinde schneiden 1. Tap thread 1. Fileter 1. Eseguire la filettatura
2. Geeignetes Dichtmittel ver- 2. Use suitable sealing agent and 2. Utiliser un produit d’étanchéité 2. Fare uso di guarnizioni di tenuta
wenden, geeignetes Werkzeug proper tools. adéquat, utiliser un outil adé- e di attrezzi appropriati.
verwenden. quat
3. Nach Einbau Dichtheits kontrolle 3. After assembly, perform a leak- 3. Après le montage, procéder à un 3. Dopo il montaggio controllare
durchführen! age test. contrôle de l’étanchéité! la tenuta!
Flanschausführung Flange version Version avec bride Tipo di flangia

GF 40.../3 DN 40 GF 40.../3 DN 40 GF 40.../3 DN 40 GF 40.../3 DN 40
GF 40.../4 DN 50 - DN 100 GF 40.../4 DN 50 - DN 100 GF 40.../4 DN 50 - DN 100 GF 40.../4 DN 50 - DN 100
GF 40... DN 125 - DN 200 GF 40... DN 125 - DN 200 GF 40... DN 125 - DN 200 GF 40... DN 125 - DN 200
1. Stiftschrauben einsetzen. 1. Insert set screws. 1. Mettre les goujons en place 1. Montare le vita
2. Dichtung einsetzen 2. Insert seal. 2. Mettre le joint d’étanchéité en 2. Mettere la guarnizione
3. Stiftschrauben festziehen. Dreh- 3. Tighten set screws. Torques are place 3. Serrare i perni filettati attenen-
momentetabelle beachten! listed in torque table! 3. Serrer les goujons. Respecter le dosi alle coppie indicate nella
4. Nach Einbau Dichtheitskontrolle 4. After assembly, perform a leak- tableau des couples! relativa tabella!
durchführen! age test. 4. Après le montage, procéder à un 4. Dopo il montaggio controllare
contrôle de l’étanchéité! la tenuta!
Vorzugsweise Filterdeckel senk- If possible, place filter cover Couvercle du filtre de préférence Montare preferibilmente il co-
recht! vertically. vertical! perchio del filtro in posizione
Senkrechter Filterdeckel ermög- A vertically placed cover en- Un couvercle de filtre vertical verticale!
licht einfache Reinigung des sures easy cleaning of the filter permet de nettoyer facilement le Ciò facilita la pulizia della sca-
Filtergehäuses. casing. carter de filtre. tola del filtro
GF 505/1 - GF 520/1 GF 40040/3 - GF 40200

Ersatz- Filtereinsatz Bestell-Nr. Ersatz- Filtereinsatz Bestell-Nr.
Replacement filter insert Order No. Replacement filter insert Order No.
Elément filtrant de rechange No. de commande Elément filtrant de rechange No. de commande
Ersatz- Filtereinsatz Codice articolo Ersatz- Filtereinsatz Codice articolo
GF 505/1 222 687 GF 40040/3 222 691
GF 507/1 222 687 GF 40050/4 257 124
GF 510/1 222 688 GF 40065/4 222 693
GF 515/1 222 688 GF 40080/4 222 694
GF 520/1 222 689 GF 40100/4 222 695

M/CD • Edition 01.12 • Nr. 222 686
GF 4005/1 222 687 GF 40125 222 696
GF 4007/1 222 687 GF 40150 222 697
GF 4010/1 222 688 GF 40200 222 698
GF 4015/1 222 688
GF 4020/1 222 689

3…8
GF 5.../1, GF 40…/1, GF 40.../3, GF 5.../1, GF 40…/1, GF 40.../3, GF 5.../1, GF 40…/1, GF 40.../3, GF 5.../1, GF 40…/1, GF 40.../3,
GF 40.../4, GF 40... GF 40.../4, GF 40... GF 40.../4, GF 40... GF 40.../4, GF 40...
Filterwechsel Filter check Vérification du filtre Controllare il filtro
Filterkontrolle mindestens Check the filter at least once Vérification de l`élement filtrant Controllare il filtro almeno
einmal jährlich! a year! au moins une fois par an! una volta l'anno!
Filterwechsel, wenn ∆p Change the filter, if ∆p be- Remplacement de l`élement Cambiare, il filtro se il ∆p fra
zwischen Druckanschluß 1/A tween pressure connection filtrant: si le ∆p entre prise de gli attacchi pressione 1/A e
und 2/B > 10 mbar. 1/A and 2/A > 10 mbar. pression 1/A et 2/B est > 10 mbar. 2/B é > di 10 mbar.
Filterwechsel, wenn ∆p Change the filter, if ∆p be- Remplacement du filtre: le Cambiare, il filtro se il ∆p fra
zwischen Druckanschluß tween pressure connection ∆p entre prise de pression gli attacchi pressione 1/A e
1/A und 2/B im Vergleich zur 1/A and 2/B is twice as high 1/A et 2/B a doublé par rapport 2/B al confronto con l'ultimo
letzten Kontrolle doppelt so compared to the last check. à la dernière mesure. controllo é raddoppiato
hoch ist.
Filterwechsel kann ohne Aus- You can change the filter without Le remplacement du filtre peut Il cambio del filtro può essere
bau der Armatur erfolgen removing the fitting. se réaliser sans démonter le effettuato senza smontare l'ar-
filtre matura.
1. Gaszufuhr unterbrechen, Ku- 1. Disconnect gas supply, close ball 1. Interrompre l’arrivée de gaz, fermer 1. Interrompere il flusso del gas
gelhahn schließen valve. le robinet à boisseau sphérique. chiudendo il rubinetto a sfera
2. Schrauben A mit geeignetem 2. Remove screws A using proper 2. Dévisser les vis A à l’aide d’un 2. Svitare le viti A servendosi di
Werkzeug herausdrehen, Fil- tool, then remove filter cover B. outil adapté, enlever le couvercle un attrezzo adatto e togliere il
terdeckel B abnehmen. 3. Remove filter insert C, replace B du filtre. coperchio B del filtro
3. Filtereinsatz C entnehmen, gegen with new one, if necessary clean 3. Enlever l’élément filtrant C, 3. Togliere l’inserto C del filtro e
neuen Filtereinsatz tauschen, filter casing D. l’échanger contre un élément sostituirlo con uno nuovo. Se
gegebenenfalls Filtergehäuse D 4. Mount filter cover B and tighten filtrant neuf, le cas échéant, necessario, pulire la scatola del
reinigen. using screws A without using any nettoyer le carter de filtre D. filtro
4. Filterdeckel B aufsetzen, Schrau- force. 4. Poser le couvercle B, y visser les 4. Rimettere il coperchio B del filtro,
ben A ohne Gewalt hineindrehen 5. Perform a function and leakage vis A sans forcer ni serrer. avvitare senza usare forza le viti
und anziehen. test. 5. Contrôler le fonctionnement et A e serrarle
5. Funktion und Dichtheitsprüfung Pressure connection via screwed l’étanchéité. 5. Effettuare controllo funzionale
durchführen. sealing plugs: Prise de pression par bou- e di tenuta.
Druckanschluß über Verschluß- pmax. = 500 mbar for GF 5../1 chons: Attacco di pressione attraverso
schrauben: or pmax. = 500 mbar pour GF 5../1 i tappi a vite:
pmax. = 500 mbar für GF 5../1 pmax.= 4.0 bar for GF 40.../3, ou pmax. = 500 mbar per GF 5../1
oder GF 40.../4, GF 40... and pmax.= 4.0 bar pour GF 40.../3, oppure
pmax.= 4.0 bar für GF 40.../3, GF 40…/1 G F 4 0 . . . / 4 , G F 4 0 . . . et pmax.= 4.0 bar per GF 40.../3,
GF 40.../4, GF 40... und GF 40…/1 GF 40.../4, GF 40... oppure
GF 40…/1 GF 40…/1
Der Prüfdruck darf den Do not allow the test pres- La pression de contrôle ne La pressione di prova non
maximalen Betriebsdruck sure to exceed the maxi- doit pas dépasser la pression deve superare la pressio-
der nachfolgenden Armaturen mum operating pressure of de service maximale des pièces de ne massima di esercizio delle
nicht überschreiten! downstream fittings. robinetterie suivantes! armature a valle!
GF 505/1 - GF 520/1 GF 40040/3 - GF 40200

GF 4005/1 - GF 4020/1
B C
A C
A
D
M/CD • Edition 01.12 • Nr. 222 686
4…8
Durchfluß-Diagramm / Flow Diagram / Courbe des débits / Diagramma di portata
Rp 1 1/2
DN 200
DN 100
DN 125
DN 150
Rp 1/2
Rp 3/4
DN 40
DN 50
DN 65
DN 80
Rp 1
Rp 2
20
10
9
8
7 empfohlener Arbeitsbereich
6 recommended working range
5 zone de travail recommandée
campo di lavoro raccomandato
4 ∆ pmax.= 10 mbar
1,0
0,8
0,7
0,6
∆p [mbar]
0,5
0,4
0,3
0,2 Basis +15 °C, 1013 mbar, trocken

Based on +15 °C, 1013 mbar, dry
Base +15 °C, 1013 mbar, sec
Base +15 °C, 1013 mbar, secco
0,1
1 2 4 6 8 10 20 40 60 80 100 200 400 600 800 1000 2000 4000

° [m 3/h] Luft / Air / Aria dv = 1,00
Vn
1 2 4 6 8 10 20 40 60 80 100 200 400 600 800 1000 2000 4000

° [m3 /h] Erdgas / Natural gas / Gaz Naturel / Gas metano dv = 0,65
Vn
Gasart Dichte
°
V = °
verwendetes Gas/gas used/ gaz utilisé/gas utilizzato
V Luft/air/air/aria x f Type of gas Spec. Wgt.
Type de gaz poids spécifique dv f
Tipo di gas Peso specifico
[kg/m3]
Erdgas/Nat.Gas/ 0.81 0.65 1.24

M/CD • Edition 01.12 • Nr. 222 686
Dichte Luft Gaz naturel/Gas metano

Spec. weight air
Poids spécifique de láir Stadtgas/City gas/ 0.58 0.47 1.46
Peso specifico aria Gaz de ville/Gas città
f=
Dichte des verwendeten Gases Flüssiggas/LPG/ 2.08 1.67 0.77
Spec. weight of gas used Gaz liquide/Gas liquido
Poids spécifique du gaz utilisé
Peso specifico del gas utilizzato Luft/Air/ 1.24 1.00 1.00
Air/Aria
5…8
Arbeiten am Gas- und Work on the filter may only Seul du personnel spé- Qualsiasi operazione sui
Luftfilter dürfen nur von be performed by author- cialisé autorisé peut ef- filtri deve essere effettuata
Fachpersonal durchge- ized specialist staff. fectuer des travaux sur soltanto da personale com-
führt werden. le filtre. petente e autorizzato.
Flanschflächen schützen. Protect flange surfaces. Protéger les surfaces de Proteggere le superfici
Schrauben kreuzweise Tighten screws cross- brides. Serrer les vis en della flangia. Stringere
anziehen.Auf spannungs- wise. Make sure that the croisant. Lors du montage le viti in modo incrocia-
freien Einbau achten! device is mounted free il faut éviter de tirer sur to. Provvedere a che il
of strain! les vis du filtre! montaggio sia fatto senza
tensione meccanica!
Direkter Kontakt zwischen Do not allow any direct Eviter tout contact direct Non é consentito il con-
¯C
+80 Filter und dem aushär- contact between the filter entre le filtre et la ma- tatto diretto tra il filtro
tendem Mauerwerk, Be- and hardened masonry, çonnerie, les cloisons e murature invecchiate,
tonwänden, Fußböden ist concrete walls or floors. en béton et planchers en pareti in calcestruzzo,
0
[A] -15 nicht zulässig. cours de séchage. pavimenti.
DIN
EN3537
1854
Grundsätzlich nach Always use new seals Après un démontage ou In linea di massima, dopo
Teileausbau/-umbau neue after dismounting and une modification, utili- lo smontaggio e il rimon-
Dichtungen verwenden. mounting parts. ser toujours des joints taggio di alcune parti,
neufs. utilizzare nuove guarni-
zioni.
Rohrleitungsdichtheits- Pipeline leakage test: Contrôle de l´étanchéité de Per la prova di tenuta

prüfung: Kugelhahn vor close ball valve upstream la conduite: fermer le robi- delle tubature: chiudere il
dem Filter schließen. of filter. net à boisseau sphèrique rubinetto a sfera davanti
avant le filtre. ai corpi filtro.
Nach Abschluß von Ar- On completion of work Une fois les travaux sur Al termine dei lavori
beiten am Filter: Dicht- on the filter, perform a filtre terminés, procéder eseguiti su un filtro,
heitskontrolle durchfüh- leakage test. toujours à un contrôle effettuare un controllo
ren. d´étanchéité. di tenuta.
Niemals Arbeiten durch- Never perform work if gas Ne jamais effectuer des In nessun caso si debbono
führen, wenn Gasdruck pressure or power is app- travaux lorsque la pres- effettuare lavori in presen-
oder Spannung anliegt. lied. No naked flame. sion ou la tension sont za di pressione gas o di
Offenes Feuer vermeiden. Observe public regula- présentes. Eviter toute tensione elettrica. Evitare
Öffentliche Vorschriften tions. flamme ouverte. Observer i fuochi aperti e osservare
beachten. les réglementations. i regolamenti.
Hinweise sind Personen- not heeded, the result de ces instructions, des quanto suddetto può im-
oder Sachfolgeschäden may be personal injury or dommages corporels ou plicare danni a personne
Alle Einstellungen und Any adjustment and appli- Effectuer tous les régla- Realizzare tutte le impo-
Einstellwerte nur in Über- cation-specific adjustment ges et réaliser les valeurs stazioni e i valori imposta-
einstimmung mit der Be- values must be made in de réglage uniquement ti solo in conformità alle
triebsanleitung des Kes- accordance with the appli- selon le mode d'emploi du istruzioni per l'uso del
sel-/Brennerherstellers ance-/boiler manufacturers fabricant de chaudières et costruttore della caldaia/
ausführen. instructions. de brûleurs. del bruciatore.
Schutz vor Umwelt- und Protection against envi- Une protection contre les La protezione da influssi
Witterungseinflüße: ronmental and weather influences environnemen- ambientali e da quelli del
• Korrosion impacts: tales et intempéries : tempo atmosferico come:
Pressure
Equipment • Regen • Corrosion • corrosion • Corrosione
Directive • Schnee • Rain • pluie • Pioggia
• Vereisung • Snow • neige • Neve
M/CD • Edition 01.12 • Nr. 222 686
[97/23/EC]
• Feuchtigkeit (z.B. durch • Icing • givrage • Formazione di giaccio
Kondensation) • Humidity (e.g. due to con- • humidité (par ex. par • Umidità (ad es. condensa)
• Schimmel densation) condensation) • Muffa
• UV-Strahlung • Mould • moisissure • Radiazione UV
• schädliche Insekten • UV radiation • rayonnement UV • Insetti dannosi
• giftige, ätzende Lö- • harmful insects • insectes nuisibles • Soluzioni/liquidi tossici e
sungen/Flüssigkeiten • toxic, caustic solutions/ • solutions / liquides toxiques, corrosivi (ad es. liquidi da
(z.B. Schneid- und liquids (e.g. cutting flu- corrosifs (par ex. liquides taglio e di raffreddamen-
Kühlflüssigkeiten) ids and cooling liquids) de coupe et de refroidisse- to) deve essere garantita.
muss sichergestellt sein. must be guaranteed. ment) doit être garantie. 6…8
D GB F I
Die Druckgeräterichtlinie The Pressure Equipment La directive concernant les La direttiva per apparecchi a
(PED) und die Richtlinie Directive (PED) and the chauffe-bains à pression pressione (PED) e la direttiva
über die Gesamtener- Energy Performance of (PED) et la directive sur la per l‘efficienza dell‘energia
gieeffizienz von Gebäu- Buildings Directive (EPBD) performance énergétique des totale per edifici (EPBD), esi-
den (EPBD) fordern eine require a periodic inspec- bâtiments (EPBD) exigent gono il controllo regolare degli
regelmässige Überprüfung tion of heating applianc- une vérification régulière des impianti di riscaldamento per
von Heizungsanlagen zur es in order to ensure a high installations de chauffage, la garanzia a lungo termine di
langfristigen Sicherstel- degree of efficiency over a afin de garantir à long terme un alto grado di rendimento e
lung von hohen Nutzungs- long term and, consequent- des taux d‘utilisation éle- con ciò di basso inquinamen-
graden und somit gering- ly, the least environmental vés et par conséquent une to ambientale. Ciò rende
ster Umweltbelastung. Es pollution. It is necessary charge environnementale necessaria la sostituzione
besteht die Notwendig- to replace safety-rele- minimum. Il est nécessaire di componenti rilevanti dal
keit sicherheitsrelevante vant components after de remplacer les compo- punto di vista della sicu-
Komponenten nach Er- they have reached the sants relatifs à la sécurité rezza alla scadenza della
reichen ihrer Nutzungs- end of their useful life. lorsqu‘ils ont atteint la fin loro durata di utilizzazione.
dauer auszutauschen. This recommendation de leur vie utile. Cette re- Questo suggerimento vale
Diese Empfehlung gilt applies only to heating commandation ne s‘appli- solo per impianti di riscal-
nur für Heizungsanla- appliances and not to que qu‘aux installations damento e non per impie-
gen und nicht für Ther- industrial heating proc- de chauffage et non aux ghi per processi termici.
mprozessanwendungen. esses. DUNGS recom- applications de processus DUNGS consiglia detta
DUNGS empfiehlt den mends replacing such thermique. DUNGS recom- sostituzione in conformità
Austausch gemäss fol- components according mande le remplacement, alla sottostante tabella:
gender Tabelle: to the following table: conformément au tableau
qui suit :
Sicherheitsrelevante Komponente NUTZUNGSDAUER Schaltspiele

Safety relevant component DUNGS empfiehlt den Austausch nach: Operating cycles
Composant relatif à la sécurité USEFUL LIFE Cycles de manoeuvres
Componenti rilevanti dal punto di vista della sicurezza DUNGS recommends replacement after: Cicli di comando
VIE UTILE
DUNGS recommande le
remplacement au bout de :
DURATA DI UTILIZZAZIONE
DUNGS consiglia la sostituzione dopo:
Ventilprüfsysteme / Valve proving systems
10 Jahre/years/ans/anni 250.000
Systèmes de contrôle de vannes / Sistemi di controllo valvole
Druckwächter / Pressure switch / Manostat / Pressostati 10 Jahre/years/ans/anni N/A
Feuerungsmanager mit Flammenwächter
Automatic burner control with flame safeguard
Dispositif de gestion de chauffage avec contrôleur de flammes
Gestione bruciatore con controllo fiamma
UV-Flammenfühler
10.000 h
Flame detector (UV probes)
Betriebsstunden / Operating hours
Capteur de flammes UV
Heures de service / Ore di esercizio
Sensore fiamma UV
Gasdruckregelgeräte / Gas pressure regulators
15 Jahre/years/ans/anni N/A
Dispositifs de réglage de pression du gaz / Regolatori della pressione del gas
Gasventil mit Ventilprüfsystem / Gas valve with valve testing system nach erkanntem Fehler / after error detection
Vanne de gaz avec système de contrôle de vanne / Valvola del gas con sistema di controllo valvola après détection du défaut / dopo il rilevamento di errori
Gasventil ohne Ventilprüfsystem* / Gas valve without valve testing system*
Vanne de gaz sans système de contrôle de vanne* / Valvola del gas senza sistema di controllo valvola*
Min. Gasdruckwächter / Low gas pressure switch
Manostat de gaz min. / Pressostato gas min.
Sicherheitsabblaseventil / Pressure relief valve
Soupape d‘évacuation de sécurité / Valvola di scarico di sicurezza
Gas-Luft-Verbundsysteme / Gas-air ratio control system
Systèmes combinés gaz/air / Sistemi di miscelazione gas-aria
* Gasfamilien I, II, III / Gas families I, II, III N/A kann nicht verwendet werden / not applicable
Familles de gaz I, II, III / per i gas delle famiglie I, II, III ne peut pas être utilisé / non può essere usato
M/CD • Edition 01.12 • Nr. 222 686
Sous réserve de tout modification constituant un progrès technique / Ci riserviamo qualsiasi modifica tecnica e costruttiva
7…8
M/CD • Edition 01.12 • Nr. 222 686
8…8
D GB F I
Gas-Druckregelgerät Gas pressure regulator Régulateur de pression de gaz Regolatore di pressione gas
Typ FRS Type FRS Type FRS Tipo FRS

Rp 3/8 - Rp 2 1/2 Rp 3/8 - Rp 2 1/2 Rp 3/8 - Rp 2 1/2 Rp 3/8 - Rp 2 1/2
DN 40 - DN 150 DN 40 - DN 150 DN 40 - DN 150 DN 40 - DN 150
Einbaulage Atmungsstopfen
Installation position Vent plug
Position de Montage bouchon percé
Posizione di montaggio tappo di sfiato
Atmungsdüse
Vent nozzle
Raccordement de
mise à l'air libre
ugello di sfiato
Atmungsdüse niemals verschließen!
Never close vent nozzle!
Ne jamais obturer le raccordement de
mise à l'air libre!
non otturare mai l'ugello di sfiato!

+70
pmax. = 500 mbar (50 kPa) 0
-15 –15 °C … +70 °C
[mbar]
Klasse A, Gruppe 2 Familie / Family / Famille / Famiglia 1 + 2 + 3

Class A, Group 2 ➞➞➞➞ Buntmetallfrei, geeignet für Gase bis max. 0,1 vol. % H2S
Classe A, Groupe 2 ➞➞➞➞ trocken. / It does not contain any non-ferrous metals,
➞➞➞➞
Classe A, Gruppo 2 suitable for gases of up to max. 0.1 vol.% H2S, dry. / En
Gas Gaz
nach / acc. / selon / a norme alliages non-cuivreux, convient aux gaz jusqu’à max.0,1 %
EN 88 EN 88, DIN 3380 en vol. d’H2S sec. / Esso è esente da metalli non ferrosi ed è
adatto per gas fino ad un volume max.% di 0,1 H2S.
Eingangsdruckbereich Ausgangsdruckbereich
Inlet pressure range Outlet pressure range
p1
IEC 529
Zone de pression d’alimentation
Campo pressione di entrata
p 1= 5 - 500 mbar (0,5 - 50 kPa)
p2
IEC 529
Zone de pression de sortie
Campo pressione di uscita
p2: 2,5 - 200 mbar (0,25 - 20 kPa)
(p1 = pe) (p2 = pa)
Druckabgriffe Prises de pression
1 Atmungsstopfen 1 Bouchon de mise à l'atmos-

2 Anschluß für externen Impuls phère
Verschlußschraube G 1/4 ISO 2 Raccordement pour impulsion
228, beidseitig, optional. externe bouchon fileté G1/4 ISO
3 Verschlußschraube G1/4 228, bilatéral, en option 1
ISO 228 im Eingangsbereich, 3 Bouchon fileté G1/4 ISO 24,
beidseitig dans la zone d’entrée, bilatéral
Pressure taps Manopola a pressione
1 Vent plug 1 Tappo di sfiato

2 Connection for external pulse 2 Attacco per impulso esterno 2
G 1/4 screw plug ISO 228, on Tappo a vite G 1/4 ISO 228 da
M/CD • Edition 02.12 • Nr. 219 598
both sides, optional. entrambi i lati, opzionale

3 G 1/4 screw plug ISO 228, in 3 Tappo a vite G 1/4 ISO 228 nel
inlet pressure range, on both campo di entrata, da entrambi 3
sides i lati
1 … 12
Atmungsleitung, Ventilation pipe, Conduite de ventilation, Tubo di scarico,
nur in Sonderfällen notwendig only neccessary in special cases nécessaire uniquement dans des necessario solo in casi speciali.
Sicherheitsmembrane ein- Safety diaphragm built in. cas spéciaux. All'interno dello stabilizzatore
gebaut Membrane de securite installé. é montata una membrana di
sicurezza.
³ DN 15
Einbaumaße / Dimensions / Cotes d'encombrement / Dimensioni [ mm]
b b
e e
h
h
d
d
g
g
DN
DN
c
c
f f
a a
Typ Bestell-Nummer Einbaumaße / Dimensions Gewicht

Type Order Number Cotes d'encombrement / Dimensioni Weight
Type No. de commande pmax. [mm] Poids
Tipo Codice articolo [mbar] Rp / DN a b c d e f g h Peso [kg]
FRS 503 086 462 500 Rp 3/8 77 115 24 143 G 1/4 G 1/4 G 1/8 225 0,60
FRS 505 070 383 500 Rp 1/2 77 115 24 143 G 1/4 G 1/4 G 1/8 225 0,60
FRS 507 070 391 500 Rp 3/4 100 130 28 165 G 1/4 G 1/4 G 1/8 245 1,00
FRS 510 070 409 500 Rp 1 110 145 33 190 G 1/4 G 1/4 G 1/8 310 1,20
FRS 515 058 446 500 Rp 1 1/2 150 195 40 250 G 1/2 G 1/4 G 1/4 365 2,50
FRS 520 058 628 500 Rp 2 170 250 47 310 G 1/2 G 1/4 G 1/4 450 3,50
FRS 525 083 303 500 Rp 2 1/2 230 285 60 365 G 1/2 G 1/4 G 1/4 550 6,00
FRS 5040 065 144 500 DN 40 200 195 65 280 G 1/2 G 1/4 G 1/4 395 3,50
FRS 5050 065 151 500 DN 50 230 250 75 340 G 1/2 G 1/4 G 1/4 480 5,00
FRS 5065 058 792 500 DN 65 290 285 95 405 G 1/2 G 1/4 G 1/4 590 7,50
FRS 5080 079 681 500 DN 80 310 285 95 405 G 1/2 G 1/4 G 1/4 590 10,00
FRS 5100 082 552 500 DN 100 350 350 105 495 G 1/2 G 1/4 G 1/4 760 16,00
FRS 5125 013 250 500 DN 125 400 400 135 635 G 1/2 G 1/4 G 1/4 1000 28,00
FRS 5150 013 268 500 DN 150 480 480 160 780 G 1/2 G 1/4 G 1/4 1180 38,00
M/CD • Edition 02.12 • Nr. 219 598
Gerät darf nicht als Hebel be- DN 40 50 65 80 100 125 150

nutzt werden. Rp 3/8 1/2 3/4 1 1 1/2 2 2 1/2 –– –– –– ––
Do not use unit as lever. M max.
Ne pas utiliser le régulateur Mmax. 70 105 225 340 610 1100 1600 2400 5000 6000 7600
comme un levier. [Nm] t )10 s
L'apparecchio non deve essere
usato come leva. FR... Tmax. 35 50 85 125 200 250 325 400 –– –– ––
Tmax. M max. [Nm] t ) 10 s
2 … 12
Druckregelgerät durch geeigneten Schmutzfänger vor Verunreinigung schützen!
Protect pressure regulator against contamination using suitable dirt traps!
Protéger le régulateur de pression contre les impuretés à l'aide d'un filtre!
Proteggere il regolatore di pressione con mezzi adeguati contro la sporcizia!
[Nm] max. Drehmomente / Systemzubehör M4 M5 M6 M8 G 1/8 G 1/4 G 1/2 G 3/4

19 max. torque / System accessories
y
an
m
er
G
in
e
max. couple / Accessoires du système 2,5 Nm 5 Nm 7 Nm 15 Nm 5 Nm 7 Nm 10 Nm 15 Nm

ad
M
✸
l
ee
St
e
om
hr
C
18
max. Drehmomente / Flanschverbindung M 16 x 65 (DIN 939) Stiftschraube

max. couple / Joint à brides 50 Nm Goujon
ISO 7005-2 max. coppie / Collegamento a flangia Vite per acciaio

Gewindeausführung FRS Threaded version FRS Version filetée FRS Esecuzione filettata FRS
Einbau Mounting Pose Montaggio
Vor Einbau Staubschutzkappen Remove dirt protection caps Avant la pose, enlever le capu- Prima di eseguire il montaggio,
entfernen! before mounting. chon de protection contre la togliere le calotte parapolvere!
Durchflußrichtung beachten: Note flow direction: Arrow on poussière! Fare attenzione alla direzione di
Pfeil am Gehäuse. housing Tenir compte du sens du débit: flusso: freccia sull’involucro.
flèche sur le boîtier
1. Gewinde schneiden. 1. Tap thread. 1. Fileter. 1. Tagliare il filetto

2. Geeignetes Dichtmittel verwen- 2. Use suitable sealing agent. 2. Employer un produit d'étanchéité 2. Utilizzare adeguate guarnizioni.
den. 3. Use suitable tool. approprié. 3. Utilizzare adeguate guarnizioni.
3. Geeignetes Werkzeug verwen- 4. Perform leak tests after mount- 3. Utiliser un outillage adapté. 4. Dopo il montaggio effettuare una
den. ing. 4. Après la pose, effectuer un prova di tenuta.
4. Nach Einbau Dichtheitskontrolle. contrôle d'étanchelté .
Flanschausführung FRS Flange version FRS Version à brides FRS Esecuzione flangiata FRS
Einbau Mounting Pose Montaggio
Vor Einbau Staubschutzkappen Remove dirt protection caps Avant la pose, enlever le capu- Prima di eseguire il montaggio,
entfernen! before mounting. chon de protection contre la togliere le calotte parapolvere!
Durchflußrichtung beachten: Note flow direction: Arrow on poussière! Fare attenzione alla direzione di
Pfeil am Gehäuse. housing flusso: freccia sull’involucro.
1. Stiftschrauben unten einsetzen. 1. Insert setscrews. 1. Insérer les goujons du bas. 1. Inserire le viti.
2. Dichtungen einsetzen. 2. Insert seals. 2. Insérer les joints. 2. Inserire le guarnizioni.
3. Stiftschrauben oben einsetzen. 3. Insert setscrews. 3. Insérer les goujons du haut. 3. Inserire le viti.
4. Stiftschrauben festziehen. Dreh- 4. Tighten setscrews. Refer to 4. Serrer les goujons à fond en 4. Stringere le viti osservando la
momentetabelle beachten! torque table respectant les couples indiqués tabella del momento torcente.
Auf korrekten Sitz der Dichtung Ensure correct seating of the dans le tableau. Prestare attenzione al corretto
achten ! seal! Veiller à ce que le joint soit posizionamento della guarni-
5. Nach Einbau Dichtheitskontrolle. 5. Perform leak tests after mount- bien en place! zione!
ing. 5. Après la pose, effectuer un 5. Dopo il montaggio effettuare una
contrôle d'étanchéité. prova di tenuta.
M/CD • Edition 02.12 • Nr. 219 598
3 … 12
Justage des Ausgangsdrucks Adjustment of outlet pressure Réglage de la pression de Taratura fine della pressione
(Sollwerteinstellung) (setpoint adjustment) sortie (réglage de la valeur de di uscita (regolazione valore
consigne) nominale)
Werkseitig eingebaute Einstell- Factory setting: Réglage d'usine: Taratura in fabbrica:

feder: p2 10-30 mbar Standard spring p2 10-30 mbar ressort standard p2 10 à 30 mbar molla standard p2 10 - 30 mbar
1. Schutzkappe A abschrau- 1. Unscrew protective cap A. 1. Dévisser le capuchon protec- 1. svitare la calotta A di prote-
ben. 2. Adjustment (+) teur A. zione
2. Justage (+) Setting spindle B 2. Réglage (+) 2. Taratura (+)
Verstellspindel B "Turn clockwise" = tige de réglage B ruotare a destra la vite di rego-
"Rechtsdrehen" = Increasing outlet pressure "tourner vers la droite" = lazione B =
Vergrößerung des Ausgangs- (setpoint) augmentation de la pression de Aumento della pressione /
druckes (Sollwertes) sortie (valeur de consigne) uscita (valore nominale)
oder or ou bien oppure
Justage (-) Adjustment (-) Réglage (-) Taratura (-)

Verstellspindel B Setting spindle B tige de réglage B ruotare verso sinistra il
"Linksdrehen" = "Turn counter-clockwise" = "tourner vers la gauche" = la vite B =
Verkleinerung des Ausgangs- Reducing outlet pressure diminution de la pression de diminuzione della pressione/
druckes (Sollwertes) (setpoint) sortie (valeur de consigne) uscita (valore nominale)
4. Überprüfen des Sollwertes. 4. Check setpoint 4. Vérifier la valeur de consigne 4. controllare il valore nominale tarato
5. Schutzkappe A aufschrauben 5. Screw on protective cap A. 5. Revisser le capuchon protecteur A 5. riavvitare la calotta di protezione A
6. Plombierung (Seite 5). 6. Attach lead seal (Page 5). 6. Plombage (page 5). 6. piombatura (vedere pag. 5)
– +
A B
B
Austausch der Einstellfeder Replace setting spring Remplacement du ressort de Cambio della molla
réglage.
1. Schutzkappe A entfernen. 1. Remove protective cap. A. 1. Enlever le capuchon protecteur 1. Togliere la calotta A. Ruotan do
Durch Linksdrehen der Verstell- Release spring by turning adjust- A. Détendre le ressort en tour- a sinistra B la molla si libera.
spindel B die Feder entspannen. ment spindle B counter clockwise. nant vers la gauche la tige de Ruotare fino contro l'arresto.
Bis gegen den Anschlag dre- Turn spindle to stop. réglage. 2. Svitare completamente il dis-
hen. 2. Unscrew complete adjustment 2. Tourner jusqu'à la butée. positivo B e sfilare la molla C
2. Komplette Verstelleinrichtung B device B and remove spring C. 3. Insérer le nouveau ressort D. 3. inserire la nuova molla D
abschrauben und Feder C entneh- 3. Insert new spring D. 4. Monter le dispositif de réglage 4. montare il dispositivo completo
men. 4. Assemble complete adjustment complet et régler l'offset souhai- e tarare l' uscita desiderata
3. Neue Feder D einsetzen. device and adjust desired off- tée. 5. riavvitare la calotta A. Incollare
4. Komplette Verstelleinrichtung set. 5. Visser le capuchon protecteur A. l'adesivo E sulla targhetta
montieren und gewünschten 5. Screw on protective cap A. Coller l'autocollant E sur la plaque 6. Piombatura
Offset justieren. Stick adhesive label E onto type- de type.
5. Schutzkappe A aufschrauben. plate. 6. Plombage
Klebeschild E auf das Typen- 6. Attach lead seal.
schild aufkleben.
6. Plombierung
A
entspannen B
release
détendre –
scaricare
C/D
B
M/CD • Edition 02.12 • Nr. 219 598
4 … 12
Plombierung
Attaching lead seal
Plombage
Piombatura
97
1. Plombierungsöse in der Ver- 1. ø 1.5 mm dia. lead seal eye in 1. Oeillet de plombage dans le 1. Occhiello per piombatura nella
schlußkappe ø 1,5 mm. sealing cap. capuchon obturateur ø 1,5 mm. calotta di chiusura ø 1,5 mm.
2. Plombierungsöse im Reglerge- 2. ø 1.5 mm dia. lead seal eye in 2. Oeillet de plombage dans le 2. Occhiello per piombatura sull'invo-
häuse ø 1,5 mm. regulator housing. boîtier du régulateur ø 1,5 mm. lucro del regolatore ø 1,5 mm.
Nach Einstellung des gewünsch- After setting desired pressure set- Après réglage de la pression de Dopo la regolazione del valore
ten Drucksollwertes / Offset: point / offset: consigne souhaitée / offset: nominale desiderato / offset:
1. Schutzkappe aufschrauben. 1. Screw on protective cap. 1. Visser le capuchon protecteur 1. avvitare la calotta di chiusura
2. Draht durch 1 und 2 ziehen. 2. Pull wire through 1 and 2. 2. Faire passer le fil entre 1 et 2 2. Tirare il filo attraverso i punti 1 e 2
3. Plombe um Drahtenden drü- 3. Press lead seal around wire ends, 3. Comprimer le plomb et lesextré- 3. Piombare le estremità del filo
cken, Drahtschlaufe kurzhal- keep wire loop small mités du fil. Maintenir laboucle lasciando corto l'anello passante.
ten. courte.
Außerbetriebsetzung Putting out of operation Mise hors service Messa fuori servizio
Blockierung der Reglerfunktion Blocking regulator function Blocage de la fonction de réglage Bloccaggio della funzione del
regolatore
1. Schutzkappe A entfernen. 1. Remove protective cap A. 1. Enlever le capuchon protecteur 1. Togliere la calotta di chiusura.
Durch Linksdrehen der Verstell- Release spring by turning adjust- A. Détendre le ressort en tournant Routando in senso antiorario la
spindel B die Feder entspannen. ment spindle B counter clockwise. vers la gauche la tige de réglage vite B la molla si libera.Ruotare
Bis gegen den Anschlag dre- Turn the spindle to stop. B. Tourner jusqu'à la butée. fino contro l'arresto.
hen. 2. Unscrew complete adjustment 2. Dévisser l'ensemble du dispositif 2. Svitare completamente il dispo-
2. Komplette Verstelleinrichtung device B and remove spring C. de réglage B et extraire le ressort sitivo B e sfilare la molla C
B abschrauben und Feder C 3. Insert blocking sleeve. C. 3. Inserire il cilindretto di bloc-
entnehmen. 4. Reassemble complete adjust- 3. Insérer la douille de blocage. caggio
3. Blockierhülse einsetzen. ment device and turn to bottom 4. Remonter le dispositif complet 4. Rimontare il dispositivo com-
4. Komplette Verstelleinrichtung stop. de réglage et tourner jusqu´à la pleto di regolazione e ruotare
wieder montieren und bis an den butée inférieure. fino all'arresto inferiore
unteren Anschlag drehen.
Keine Gewalt anwenden. Do not use any force! Ne pas forcer. Non effettuare alcuna forzatura
5. Schutzkappe A aufschrauben. 5. Screw on protective cap A. Mark 5. Visser le capuchon protecteur A. 5. Avvitare la calotta A e siglare il
Regler kennzeichnen "Blo- regulator "blocked". Marquer le régulateur "bloqué". regolatore con la voce "blocca-
ckiert" 6. Attach lead seal. 6. Plombage. to"
6. Plombierung 6. Piombatura
Kennlinie siehe Diagramm 1: Characteristic see Diagram 1: Ligne caractéristique :voir diagram- Linea caratteristica vedi dia-
mechanisch offen mechanically open me 1 : mécaniquement ouvert gramma 1: apertura meccanica
A
B
entspannen
release
détendre –
scaricare
M/CD • Edition 02.12 • Nr. 219 598
C/D
B
5 … 12
Verschließen interner Impuls, Sealing internal pulses, Fermeture impulsion interne, Chiusura della presa d’impulso
externer Impuls nur optional external pulse only optional impulsion interne uniquement interno; impulso esterno solo
en option opzionale
Bei Verwendung des externen When using the external pulse, Si l'on utilise l'impulsion externe, Se si fa uso dell’impulso ester-
Impulses muß der interne Im- seal the internal pulse. il faut impérativement obstruer no, si deve chiudere la presa
puls verschlossen werden. l'impulsion interne. dell'impulso interno.
Der im Ausgangsbereich des Seal the pulse tap located in the La prise d'impulsion qui se trouve La presa di impulso nel campo di
Druckregelgerätes angeord- outlet of the pressure regulator using dans la zone de sortie du pres- uscita del regolatore di pressione,
nete Impulsabgriff wird mit einer a suitable silicon compound. sostat est scellée à l'aide d'une si deve otturare con un mastice di
geeigneter Silikondichtmasse Fill the pulse tube to approx. 2/3 of masse d'étanchéité adéquate en silicone appropriato.
verschlossen. the length. silicone. Pour ce faire, on remplit Riempire allo scopo il tubo di
Hierzu wird das Impulsrohr auf ca Please follow the instructions of the au 2/3 env. de sa longueur le tube impulso fino a ca. 2/3 della sua
2/3 der Länge gefüllt. sealing compound manufacturer d'impulsion. lunghezza.
Unbedingt die Anleitung des Dicht- and make sure that the compound Respecter impérativement les ins- Attenersi assolutamente alle istru-
massen Herstellers beachten hardens completely. tructions du fabricant de la masse zioni del fabbricante del mastice
und für vollständige Aushärtung d'étanchéité et faire le nécessaire e provvedere al totale indurimento
sorgen. pour obtenir un durcissement com- di quest'ultimo.
plet.
Dichtmasse
Sealing compound
Masse d’étanchéité
Mastice
Externer Impulsanschluß, External pulse connection, Prise d'impulsion interne, im- Collegamento dell'impulso
externer Impuls nur optional external pulse only optional pulsion externe uniquement en esterno; solo opzionale
option
Der externe Impulsanschluß Connect the external pulse line to La prise d'impulsion externe s'ef- Il collegamento dell’impulso ester-
er-folgt an den Anschlüssen der the connections on the diaphragm fectue aux raccordements prévus no si effettua agli attacchi della
Membranschale. shell. sur le corps du régulateur. coppa della membrana.
Der Anschluß muß sicher gegen Secure the connection against La prise doit être résistante aux dé- L'attacco deve essere sicuro con-
Verformung, Abriß, gasdicht deforming and break-off. It must formations, à la déchirure, étanche tro deformazione e strappi; deve
und dauerhaft sein. Er muß den be gas-tight and permanent. It must au gaz et solide. Elle doit résister aux essere a tenuta di gas e duraturo.
mechanischen, thermischen und withstand mechanical, thermal and charges mécaniques, thermiques Deve essere resistente alle solle-
chemischen Belastungen stand- chemical stresses. et chimiques. citazioni meccaniche, termiche e
halten. You can seal the opposite connec- La prise qui se trouve en face peut chimiche.
Der gegenüberliegende Anschluß tion using a test nipple. être fermée à l’aide d’une prise de L'attacco sul lato opposto, si può
kann durch einen Meßstutzen Using the test nipple, you can mesure. chiudere mediante un misuratore.
verschlossen werden. measure the actual active regulator La prise de mesure permet de me- Il misuratore permette la misura-
Der Meßstutzen erlaubt die Mes- outlet pressure. surer la pression de sortie effective zione della pressione di uscita del
sung des tatsächlich wirkenden Follow the dimension specifications du régulateur. regolatore veramente efficace.
Reglerausgangsdruckes. of the equipment manufacturer Prise de l'impulsion externe de Per il collegamento dell'impulso
Der Anschluß des externen Im- when connecting the external pulse l'appareil à gaz conformément esterno all’apparecchio del gas,
pulses am Gasgeräterfolgt nach line to the gas equipment. aux instructions du fabricant de attenersi alle istruzioni del fabbri-
Maßgabe des Geräteherstellers. l'appareil. cante dell’apparecchio.
Externer Impulsanschluß
External pulse connection
M/CD • Edition 02.12 • Nr. 219 598
Prise d’impulsion externe

Attacco impulso esterno
6 … 12
Durchfluß-Diagramm 1 / Flow Diagramm 1 / Courbe des débits 1 / Diagramma di portata 1
mechanisch offen / für Geräteauswahl FRS Durchflußdiagramm 2 anwenden

mechanically open / use flow diagram 2 for equipment selection FRS
mécaniquement ouvert / pour sélectionner un FRS, utiliser la courbe des débits 2
aprire meccanicamente / per scelta dellápparecchio FRS utilizzare diagramma portata 2
Rp 21/2
Rp 11/2
DN 100
DN 125
DN 150
Rp 3/8
Rp 1/2
Rp 3/4
DN 40
DN 50
DN 65
DN 80
Rp 1
Rp 2
100
90
80
70
60
50
40
30
20
10
9
8
7
6
∆p [mbar]
5
4
2 Basis + 15° C, 1013 mbar, trocken

Based on + 15° C, 1013 mbar, dry
Base + 15° C, 1013 mbar, sec
Base + 15° C, 1013 mbar, secco
1,0
1 2 4 6 8 10 20 40 60 80 100 200 400 600 800 1000 2000 4000

° [m 3/h] Luft / Air / Aria dv = 1,00
Vn
1 2 4 6 8 10 20 40 60 80 100 200 400 600 800 1000 2000 4000

° [m 3/h] Erdgas/Natural gas/Gaz Naturel/Gas metano dv = 0,65
Vn
Gerätevorauswahl, blockierte Equipment preselection, blocked Choix de l'appareil, régulateurs Preselezione degli apparecchi,
Druckregelgeräte pressure regulators bloqués regolatori di pressione bloccati
Mit Hilfe der Volumenstrom - Using the volume flow pressure La ligne caractéristique de chute Con l’ausilio della curva caratteri-
Druckgefällekennlinie der Druck- reduction characteristic of the de pression de débit volumétrique stica della differenza di pressione
regelgeräte im mechanisch of- pressure regulators in mechanically du pressostat mécaniquement del flusso volumetrico dei regolato-
fenem Zustand ist eine Vorauswahl open state, you can preselect the ouvert permet une présélection du ri di pressione allo stato di apertura
der Nennweite möglich. nominal diameter. diamètre nominal. meccanica, è possibile effettuare la
Das Druckgefälle zwischen Ein- The pressure reduction between La chute de pression entre la pres- preselezione del valore nominale.
gangsdruck p1 und Regleraus- inlet pressure p1 and regulator sion d’alimentation p1 et la pres- La differenza fra la pressione di
gangsdruck p2 in Verbindung mit outlet pressure p2 in connection sion de sortie du régulateur p2 en entrata p1 e la pressione di uscita
dem maximalem Volumenstrom with the maximum volume flow Vmax relation avec le débit volumétrique dal regolatore p2, in combinazione
Vmax bestimmen die Nennweite determine the nominal diameter of maximum Vmaxi.. déterminent le con il flusso volumetrico massimo
des Druckregelgerätes. the pressure regulator. diamètre nominal du pressostat. Le Vmax, determinano il valore nomi-
Der durch ∆pmin und Vmax be- The working point described by point de fonctionnement décrit par nale del regolatore di pressione.
schriebene Betriebspunkt liegt ∆pmin and Vmax is on the left of the ∆pmin. et Vmax. se trouve à gauche Il punto di esercizio descritto con
links der zuwählenden Nennweite nominal diameter of the pressure du diamètre nominal à sélectionner ∆pmin e Vmax, si trova a sinistra del
des Druckregelgerätes. regulator to be selected. du régulateurs. valore nominale del regolatore di
Der Druckabfall über blockierte The pressure reduction via blocked La chute de pression par l'intermé- pressione, da selezionare.
Druckregelgeräte wird durch die pressure regulators is described diaire de régulateurs bloqués est La caduta di pressione attraverso
Kennlinien "mechanisch offen" by the „mechanically open“ char- décrite par la ligne caractéristique regolatori di pressione bloccati,
beschrieben. acteristics. „mécaniquement ouvert“. viene descritta tramite la curva ca-
Die entgültige Festlegung erfolgt Final definition is performed accord- La détermination définitive s’effec- ratteristica „apertura meccanica“.
M/CD • Edition 02.12 • Nr. 219 598
nach Maßgabe des Gasgeräte- ing to dimension specification of the tue conformément aux instructions La determinazione definitiva avviene
herstellers. equipment manufacturer. du fabricant de l’appareil à gaz. secondo le indicazioni del fabbricante
degli apparecchi del gas.
7 … 12
Durchfluß-Diagramm 2 / Flow Diagramm 2 / Courbe des débits 2 / Diagramma di portata 2
im eingeregelten Zustand
in regulated state
en régulation
già tarato
Rp 1 1/2
Rp 2 1/2
DN 100
DN 125
DN 150
Rp 3/8
Rp 1/2
Rp 3/4
DN 40
DN 50
DN 65
DN 80
Rp 1
Rp 2
500
400
300
200
empfohlener Arbeitsbereich
150
150
recommended working range
DN
100 zone de travail recommandée
80 campo di lavoro raccomandato
60
50
40
°
V °
= 0,05 x V
30 min. max.
Æp [mbar]
20
10
8
6
5
4
2 Basis + 15¡ C, 1013 mbar, trocken

Based on + 15¡ C, 1013 mbar, dry
Base + 15¡ C, 1013 mbar, sec
Base + 15¡ C, 1013 mbar, secco
1 2 3 4 5 6 8 10 20 30 40 50 60 100 200 300 400 600 2000 4000

¡ [m /h] Luft / Air / Aria dv = 1,00
Vn
3
2 3 4 5 6 8 10 20 30 40 50 60 80 100 200 300 400 600 800 1000 2000 4000

¡ [m /h] Erdgas/Natural gas/Gaz Naturel/Gas metano dv = 0,65
Vn
3
°
V = °
V Luft/air/air/aria x f Gasart Dichte
Type of gas Density
Type de gaz Densité dv f
Tipo di gas Densità
[kg/m3]

Air density
Densité de l'air Stadtgas/City gas/ 0.58 0.47 1.46
Densità dell'aria Gaz de ville/Gas città
f=
M/CD • Edition 02.12 • Nr. 219 598
spez. Gweicht des verwendeten Gases Flüssiggas/LPG/ 2.08 1.67 0.77

poids spécifique du gaz utilisé
peso specifico del gas utilizzato Luft/Air/ 1.24 1.00 1.00
Air/Aria
8 … 12
Ersatzteile / Zubehör Bestell-Nummer Ersatzteile / Zubehör Bestell-Nummer
Spare parts / Accessories Order Number Spare parts / Accessories Order Number
Pièces de rechange / acces. No. de commande Pièces de rechange / acces. No. de commande
Parti di ricambio / Accessori Codice articolo Parti di ricambio / Accessori Codice articolo
Verschlußschraube mit Dich- 5 Stück/Set Federauswahl FRS / Selection of FRS springs / Sélection des
tring 5 Pieces/Set ressorts FRS / Scelta della molla FRS
Locking screw and sealing ring 5 Pièces/Set Nr.1 2,5 - 9 mbar braun/brown/brun/marrone
Bouchon fileté avec bague 5 Pezzi/Set Nr.2 5 - 13 mbar weiß/white/blanc/bianco
d'étanchéite Nr.3 5 - 20 mbar orange/orange/orange/arancia
Tappo a vite con guarnizione Nr.4 10 - 30 mbar blau/blue/bleu/blu
G 1/8 230 395 Nr.5 25 - 55 mbar rot/red/rouge/rosso
G 1/4 230 396 Nr.6 30 - 70 mbar gelb/yellow/jaune/giallo
G 1/2 230 401 Nr.7 60 - 110 mbar schwarz/black/noir/nero
G 3/4 230 402 Nr.8 100 - 150 mbar rosa/pink/rose/rosa
Nr.9 140 - 200 mbar grau/grew/gris/grigio
Meßstutzen mit Dichtring 5 Stück/Set
Test nipple with sealing ring 5 Pieces/Set FRS 503/505 FRS 507
Prise de pression avec joint 5 Pièces/Set Nr.1 2,5 - 9 mbar 229 817 229 833
Misuratore con guarnizione 5 Pezzi/Set Nr.2 5 - 13 mbar 229 818 229 834
G 1/8 230 397 Nr.3 5 - 20 mbar 229 820 229 835
G 1/4 230 398 Nr.4 10 - 30 mbar 229 821 229 836
Nr.5 25 - 55 mbar 229 822 229 837
Atmungsstopfen 5 Stück/Set Nr.6 30 - 70 mbar 229 823 229 838
Vent plug 5 Pieces/Set Nr.7 60 - 110 mbar 229 824 229 839
Bouchon de mise à l'atmosphère 5 Pièces/Set Nr.8 100 - 150 mbar 229 825 229 840
Tappo di sfiato 5 Pezzi/Set Nr.9 140 - 200 mbar 229 826 229 841
G 1/4 230 399
G 1/2 230 403 FRS 510 FRS 515/5040
Nr.1 2,5 - 9 mbar 229 842 229 851
Schutzkappe mit Plombierösen 5 Stück/Set Nr.2 5 - 13 mbar 229 843 229 852
Protective cap with lead seal 5 Pieces/Set Nr.3 5 - 20 mbar 229 844 229 853
option 5 Pièces/Set Nr.4 10 - 30 mbar 229 845 229 854
Goujon avec joint 5 Pezzi/Set Nr.5 25 - 55 mbar 229 846 229 869
Calotta di protezione con pos- Nr.6 30 - 70 mbar 229 847 229 870
sibilita di piombatura Nr.7 60 - 110 mbar 229 848 229 871
FRS 503 -510 230 400 Nr.8 100 - 150 mbar 229 849 229 872
FRS 515 - 520, 5040 - 5050 230 404 Nr.9 140 - 200 mbar 229 850 229 873
FRS 525, 5065 - 5100 230 405
FRS 5125, 5150 230 428 FRS 520/5050
Nr.1 2,5 - 9 mbar 229 874
Dichtungen für Flansche 2 Stück/Set Nr.2 5 - 13 mbar 229 875
Sealing ring for flanges 2 Pieces/Set Nr.3 5 - 20 mbar 229 876
Joints d'étanchéité pour brides 2 Pièces/Set Nr.4 10 - 30 mbar 229 877
Guarnizioni per flange 2 Pezzi/Set Nr.5 25 - 55 mbar 229 878
DN 40 231 600 Nr.6 30 - 70 mbar 229 879
DN 50 231 601 Nr.7 60 - 110 mbar 229 880
DN 65 231 603 Nr.8 100 - 150 mbar 229 881
DN 80 231 604 Nr.9 140 - 200 mbar 229 882
DN 100 231 605
DN 125 231 606 FRS 525/5065/5080
DN 150 231 783 Nr.1 2,5 - 9 mbar 229 883
Nr.2 5 - 13 mbar 229 884
Stiftschraubensatz 4 Stück/Set Nr.3 5 - 20 mbar 229 885
Set of setscrews 4 Pieces/Set Nr.4 10 - 30 mbar 229 886
Goujon 4 Pièces/Set Nr.5 25 - 55 mbar 229 887
Serie di viti per acciaio 4 Pezzi/Set Nr.6 30 - 70 mbar 229 888
M 16 x 55 (DN 40 - DN 50) 230 422 Nr.7 60 - 110 mbar 229 889
M 16 x 65 (DN 65 - DN 100) 230 424 Nr.8 100 - 150 mbar 229 890
M 16 x 75 (DN 125) 230 430 Nr.9 140 - 200 mbar 229 891
M 20 x 80 (DN 150) 238 141
M 20 x 90 (DN 150; DMV) 230 446 FRS 5100
Nr.1 2,5 - 9 mbar 229 892
Blockierhülse Nr.2 5 - 13 mbar 229 893
Blocking sleeve Nr.3 5 - 20 mbar 229 894
Douille de blocage Nr.4 10 - 30 mbar 229 895
Cilindretto di bloccagio Nr.5 25 - 55 mbar 229 896
FRS 503 - FRS 5150 auf Anfrage Nr.6 30 - 70 mbar 229 897
on request Nr.7 60 - 110 mbar 229 898
à la demande Nr.8 100 - 150 mbar 229 899
su richiesta Nr.9 140 - 200 mbar 229 900
Meßwerke
M/CD • Edition 02.12 • Nr. 219 598
FRS 5125 FRS 5150

Repair Kits Nr.1 2,5 - 9 mbar 229 901 229 909
Eléments de mesure Nr.2 5 - 13 mbar 229 902 229 910
Apparecchi di misurazione Nr.3 5 - 20 mbar 229 903 229 911
FRS 503 - FRS 5150 auf Anfrage Nr.4 10 - 30 mbar 229 904 229 912
on request Nr.5 25 - 55 mbar 229 905 229 913
à la demande Nr.6 30 - 70 mbar 229 906 229 914
su richiesta Nr.7 60 - 110 mbar 229 907 229 915
Nr.8 100 - 150 mbar 229 908 229 916
Nr.9 140 - 200 mbar 243 416 243 417
9 … 12
Arbeiten am Gas-Druck- Work on the gas pressure Seul du personnel auto- Qualsiasi operazione
regelgerät dürfen nur von regulator may only be risé peut effectuer des effettuata sul regolatore
Fachpersonal durchge- performed by specialist travaux sur le régulateur di pressione gas deve
führt werden. staff. de pression. essere fatta da parte di
Flanschflächen schüt- Protect flange surfaces. Protéger les surfaces de Proteggere le superfici
zen. Tighten screws cross- brides. della flangia.
Schrauben kreuzweise wise Serrer les vis en croisant. Stringere le viti in modo
anziehen. incrociato.
Direkter Kontakt zwi- Do not allow any direct Eviter tout contact direct Non é consentito il con-
schen dem Gas-Druck- contact between the gas entre le régulateur de tatto diretto fra il rego-
regelgerät und dem aus- pressure regulator and pression et la maçonne- latore di pressione gas
härtendem Mauerwerk, hardened masonry, con- rie, les cloisons en béton e murature invecchiate,
Betonwänden, Fußböden crete walls or floors. et planchers en cours de pareti in calcestruzzo,
ist nicht zulässig. séchage. pavimenti.
Nennleistung bzw. Druck- Always adjust nomi- Régler toujours le débit no- Effettuare in linea di massima
sollwerte grundsätzlich nal output or pressure minal ou les pressions de la regolazione di potenza
p [mbar] nominale e valori nominali di
am Gas-Druckregelgerät setpoints on the gas consigne sur le régulateur
einstellen. Leistungsspe- pressure regulator and de pression. Limi- tation pressione sul regolatore di
¡
V
zifische Drosselung über performance-specific pressione gas. La regolazione
[m3/ h] au niveau de vanne, en
das Magnetventil. throttling using the sole- specifica di potenza va fatta
fonction du débit.
attraverso la valvola.
noid valve.
Grundsätzlich nach Always use new seals Après un démontage ou In linea di massima, dopo
Teileausbau/-umbau neue after dismounting and une modification, utili- lo smontaggio e il rimon-
Dichtungen verwenden. mounting parts. ser toujours des joints taggio di alcune parti,
neufs. utilizzare nuove guarni-
zioni.
Rohrleitungsdichtheits- Pipeline leak test: close Contrôle de l'étanchéité Per la prova di tenuta delle
prüfung: Kugelhahn vor ball cock upstream of de la conduite: fermer tubature:
den Armaturen/Gas- fittings/FRS. le robinet à boisseau chiudere il rubinetto a
Druckregelgerät schlie- sphérique avant les robi- sfera davanti ai corpi
ßen. netteries / FRS. valvola / FRS.
Nach Abschluß von Ar- On completion of work on Une fois les travaux sur le Al termine dei lavori
Safety beiten am Gas-Druckre- the FRS, perform leak and FRS terminés, procéder effettuati su un FRS:
gelgerät: Dichtheitskon- function test. toujours à un contrôle predisporre un controllo
first trolle und Funktionskon- ptest ≤ 500 mbar d´étanchéité et de fonc- sia della tenuta che del
trolle durchführen. tionnement. funzionamento.
O.K. pPrüf ≤ 500 mbar ptest ≤ 500 mbar ptest ≤ 500 mbar
führen, wenn Gasdruck gas pressure or power is travaux lorsque la pres- effettuare lavori in presen-
oder Spannung anliegt. applied. No naked flame. sion ou la tension sont za di pressione gas o di
Offenes Feuer vermeiden. Observe public regula- présentes. Eviter toute tensione elettrica. Evitare i
Öffentliche Vorschriften tions. flamme ouverte. Observer fuochi aperti e osservare le
beachten. les réglementations. prescrizioni pubbliche.
Hinweise sind Personen- not heeded, the result de ces instructions, des quanto suddetto può
oder Sachfolgeschäden may be personal injury or dommages corporels ou implicare danni a persone
denkbar. damage to property. matériels sont possibles. o cose.
M/CD • Edition 02.12 • Nr. 219 598
10 … 12
D GB F I
qui suit :

VIE UTILE
DUNGS recommande le
UV-Flammenfühler
10.000 h
Sensore fiamma UV
M/CD • Edition 02.12 • Nr. 219 598
11 … 12
M/CD • Edition 02.12 • Nr. 219 598
12 … 12
Pressure gauge
Push button cock
Pressure gauge shutoff
valve
12.05
Technical Description Pressure measuring instruments with spiral

Pressure measuring instruments with element and steel housing, as per DIN EN
capsule element and steel housing, as 837-1, for measuring high overpressures:
per DIN EN 837-3, for measuring small
overpressures: • accuracy class 1.6
• high reliability
• accuracy class 1.6 • sheet steel case
• high reliability
• overload-proof (1.3 x scale interval) Display ranges
• zero point correction 0 - 1.0 bar (0 - 100 kPa) 0 - 6.0 bar (0 - 600 kPa)
Printed in Germany • Edition 02.10 • Nr. 225 920
• measuring system copper alloy 0 - 1.6 bar (0 - 160 kPa) 0 - 10.0 bar (0 - 1,000 kPa)
0 - 2.5 bar (0 - 250 kPa) 0 - 25.0 bar (0 - 2,500 kPa)
Display ranges 0 - 4.0 bar (0 - 400 kPa)
0 - 25 mbar (0 - 2.5 kPa)
0 - 40 mbar (0 - 4.0 kPa) Application
0 - 60 mbar (0 - 6.0 kPa) The pressure measuring instruments are
0 - 100 mbar (0 - 10.0 kPa) used in the areas of burner monitoring,
0 - 160 mbar (0 - 16.0 kPa) filter status measurement, air condition-
0 - 250 mbar (0 - 25.0 kPa) ing engineering and in laboratories.
0 - 400 mbar (0 - 40.0 kPa) Suitable for gases of gas families 1, 2, 3
1…4 0 - 600 mbar (0 - 60.0 kPa) and other neutral gaseous media.
Technical Data KP, D201 RF, D201
Accuracy class 1.6 as per EN 837-3 1.6 as per EN 837-1
Display ranges 0 - 25 mbar to 0 - 600 mbar 0 - 1 bar to 0 - 25 bar

(0 - 2.5 kPa to 0 - 60 kPa) (0 - 100 kPa to 0 - 2,500 kPa)
Housing Sheet steel, black Sheet steel, black
inspection window Plastic Plastic

Dial face Al white, dial and inscription Al white, dial and inscription
black black
Pointer Al black Al black
Segment unit Brass with zero offset compensation Brass
Measuring component CuBe Cu alloy
Pressure connection, position radial, below radial, below

Thread connection G 1/2 B G 1/2 B
Ambient temperature Tmin. -20 °C, Tmax. +60 °C Tmin. -20 °C, Tmax. +60 °C
Medium temperature Tmin. -20 °C, Tmax. +60 °C Tmin. -20 °C, Tmax. +60 °C
Temperature-related behaviour 0.6 % / 10 K for a deviation 0.4 % / 10 K for a deviation
from normal temperature + 20 ˚C from normal temperature + 20 ˚C
Installation position vertical vertical
Degree of protection IP 32 (EN 60529) IP 32 (EN 60529)
Dimensions [mm]
b c
f
e
TX!33
d
H!203
2…4
Type Accuracy Order Connection Dimensions [mm] Weight
range No. a b c d e [kg]
KP 80 0 - 25 mbar 217 101 G 1/2 B 80 43.3 20 69 14.8 0.4

KP 80 0 - 40 mbar 099 028 G 1/2 B 80 43.3 20 69 14.8 0.4
KP 80 0 - 60 mbar 103 697 G 1/2 B 80 43.3 20 69 14.8 0.4
KP 80 0 - 100 mbar 082 081 G 1/2 B 80 43.3 20 69 14.8 0.4
KP 80 0 - 160 mbar 104 083 G 1/2 B 80 43.3 20 69 14.8 0.4
KP 80 0 - 250 mbar 077 396 G 1/2 B 80 43.3 20 69 14.8 0.4
KP 80 0 - 400 mbar 104 307 G 1/2 B 80 43.3 20 69 14.8 0.4
KP 80 0 - 600 mbar 103 705 G 1/2 B 80 43.3 20 69 14.8 0.4
KP 100 0 - 25 mbar 248 312 G 1/2 B 100 44 20 87 15.6 0.5
KP 100 0 - 40 mbar 248 311 G 1/2 B 100 44 20 87 15.6 0.5
KP 100 0 - 60 mbar 248 310 G 1/2 B 100 44 20 87 15.6 0.5
KP 100 0 - 100 mbar 220 054 G 1/2 B 100 44 20 87 15.6 0.5
KP 100 0 - 160 mbar 247 342 G 1/2 B 100 44 20 87 15.6 0.5
KP 100 0 - 250 mbar 244 612 G 1/2 B 100 44 20 87 15.6 0.5
KP 100 0 - 400 mbar 230 678 G 1/2 B 100 44 20 87 15.6 0.5
KP 100 0 - 600 mbar 227 467 G 1/2 B 100 44 20 87 15.6 0.5
RF 80 0 - 1 bar 119 073 G 1/2 B 80 31 20 72 11.7 0.25
RF 80 0 - 1.6 bar 227 146 G 1/2 B 80 31 20 72 11.7 0.25
RF 80 0 - 2.5 bar 217 201 G 1/2 B 80 31 20 72 11.7 0.25
RF 80 0 - 4 bar 052 415 G 1/2 B 80 31 20 72 11.7 0.25
RF 80 0 - 6 bar 217 202 G 1/2 B 80 31 20 72 11.7 0.25
RF 80 0 - 10 bar 227 283 G 1/2 B 80 31 20 72 11.7 0.25
RF 80 0 - 25 bar 248 314 G 1/2 B 80 31 20 72 11.7 0.25
RF 100 0 - 1 bar 240 829 G 1/2 B 100 29.5 20 82 11 0.3
RF 100 0 - 1.6 bar 240 830 G 1/2 B 100 29.5 20 82 11 0.3
RF 100 0 - 2.5 bar 248 313 G 1/2 B 100 29.5 20 82 11 0.3
RF 100 0 - 4 bar 241 419 G 1/2 B 100 29.5 20 82 11 0.3
RF 100 0 - 6 bar 230 679 G 1/2 B 100 29.5 20 82 11 0.3
RF 100 0 - 10 bar 247 356 G 1/2 B 100 29.5 20 82 11 0.3
RF 100 0 - 25 bar 245 298 G 1/2 B 100 29.5 20 82 11 0.3
Accessories Order
No.
Push button cock DKH 033 621

Pressure gauge shutoff valve MAV 230 762
Technical description
DKH: Manually operated shutoff device be-
tween measuring line and pressure gauge
according to DIN 3537-1. In the normal state,
the push-button cock is closed. Therefore,
the pressure gauge is permanently relieved
of pressure. The push-button is pushed in
order to apply pressure on the pressure
gauge and indicate the operating pressure.
MAV: Manually operated shutoff and flow
control device between measuring line
and pressure gauge in accordance with
DIN 16270.
Application
Suitable for gases of families 1, 2, 3 and
other neutral gaseous media.
Approvals
EC type test approval as per EC Gas
Appliance Directive:
DKH CE-0085 AQ 0985
DVGW type approval certificate:
DKH DG-4315 AO 0724
3…4 MAV DG-4315 BO 0429
Pressure gauge
Push button cock
Pressure gauge shutoff valve
Technical Data DKH MAV
Connection Rp 1/2 G 1/2 / G 1/2 B
Max. operating pressure 5 bar (500 kPa) 100 bar (10,000 kPa)
Temperature range -15 °C … +70 °C -5 °C … +60 °C
Housing Nickel-plated brass Brass
Dimensions DKH [mm] Dimensions MAV [mm]
64 F
Rp 1/2"
L2
S1
71,5
L1
Rp 1/2"
We reserve the right to make any changes in the interest of technical progress.
Head Offices and Factory Postal address
Karl Dungs GmbH & Co. KG Karl Dungs GmbH & Co. KG
Siemensstraße 6-10 Postfach 12 29
D-73660 Urbach, Germany D-73602 Schorndorf, Germany
Telephone +49 (0)7181-804-0 e-mail info@dungs.com
Fax +49 (0)7181-804-166 Internet www.dungs.com 4…4
E HC G J
Betriebs- und Montagean- Operation and assembly Notice d'emploi et de mon- Istruzioni di esercizio e di
leitung instructions tage montaggio
Doppelmagnetventil Double solenoid valve Electrovanne double Valvole doppie

Typ DMV-D.../11 Type DMV-D.../11 Type DMV-D.../11 Tipo DMV-D.../11
Typ DMV-DLE.../11 Type DMV-DLE.../11 Type DMV-DLE.../11 Tipo DMV-DLE.../11
Nennweiten Nominal widths Diamètres nominaux Diametri nominali
Rp 1/2 - Rp 2 Rp 1/2 - Rp 2 Rp 1/2 - Rp 2 Rp 1/2 - Rp 2
Einbaulage Elektrischer Anschluß Erdung nach örtlichen Vorschriften

Installation position Electrical connection Grounding acc. local regulations
Mise à la terre selon normes locales
Position de montage Raccordement électrique Messa a terra secondo prescrizioni locali
Posizione di montaggio Allacciamento elettrico M!)W2* O M!)W3*
IEC 730-1 (VDE 0631 T1) AC 2 1 3
W2 W3
O
.
,!)W2*
DC
2 . ,!)W3*
M!)W3* 2 1 3
,!)W3*
4 3
M!)W2*
,!)W2* W2 W3

Max. operating pressure °C Ambient temperature
+60
0
pmax. = 500 mbar (50 kPa) -15 -15 °C … +60 °C
[mbar]
V1+V2 Klasse A, Gruppe 2 Schutzart

V1+V2 Class A, Group 2 Degree of protection
V1+V2 Class. A, Groupe 2 Protection
V1+V2 Classe A, Gruppo 2 Protezione
nach / acc. / selon / a norma IP 54 nach / acc. / selon /a norma
IEC 529
EN 161 EN 161 IEC 529 (DIN EN 60 529)
Un ~(AC) 230 V oder/or/ou/o Familie / Family 1+2+3

~(AC) 110 V - 120 V, Famille / Famiglia 1 + 2 + 3
=(DC) 24 V - 28 V Buntmetallfrei, geeignet für Gase bis max. 0,1 vol. % H2S,
Einschaltdauer/Switch-on duration/ Gas Gaz trocken. / It does not contain any non-ferrous metals, suit-
Dureé de mise sous tension/ Durata able for gases of up to max. 0.1 vol.% H2S, dry. / En alliages
[V] inserzione 100 % non-cuivreux, convient aux gaz jusqu’à max. 0,1 % en vol./
Esso è esente da metalli non ferrosi ed è adatto per gas
fino ad un volume max.% di 0,1 H2S d’H2S sec.
DMV 505-520/11 DMV 525/11
Druckabgriffe / Pressure taps Druckabgriffe / Pressure taps
Prises de pression / Manopola a Prises de pression / Manopola a
pressione pressione
4 4 4 4
1, 2, 3, 4 1, 2, 3, 5 3
2
4 3
2
Verschlußschraube 2 Verschlußschraube 1 5 1
Sealing plug Sealing plug
1 3 1
Bouchon fileté Bouchon fileté

Vite di chiusura 1 2 3 Vite di chiusura 1 2 3 5
G 1/8 DIN ISO 228 G 1/8 DIN ISO 228

4
pmax. = 500 mbar pmax. = 500 mbar
4 4
Die Verschlußschrauben1,2,3,5 kön- V1 V2
nen auch durch einen Meßstutzen G 1/8
V1 V2
DIN ISO 228 ersetzt werden.

M/CD • Edition 02.10 • Nr. 222 345
4
1 2 3 Screw plugs 1,2,3 and 5 may also be 1 2 3 5
replaced by a measuring socket G 1/8

DIN ISO 228. 4
Die Verschlußschrauben1,2,3 können Les bouchons filetés 1,2,3 peuvent Les bouchons filetés 1,2,3,5 peuvent Verdeckte Verbindungsbohrung für Sy-
auch durch einen Meßstutzen G 1/8 aussi être remplacés par une prise aussi être remplacés par une prise de stemzubehör. / Concealed connecting bore
DIN ISO 228 ersetzt werden. de pression G 1/8 DIN ISO 228.Le pression G 1/8 DIN ISO 228. for system accessories. / Orifice masqué
Screw plugs 1,2,3 may also be re- viti di chiusura 1, 2,3 possono essere Le viti di chiusura 1,2,3,5 possono es- pour connextion d'accessoires. / Foro
placed by a measuring socket G 1/8 anche sostituite da una pressione G 1/8 sere anche sostituite da una pressione coperto per collegamento accessori.
DIN ISO 228. DIN ISO 228. G 1/8 DIN ISO 228.
1 … 12
Einbaumaße/Dimensions/Cotes d'encombrement/Dimensioni [mm]
space requirements for fitting solenoid

Encombrement pour changement
Ingombro per sostituzione bobina

Platzbedarf für Magnetwechsel
space requirements for fitting solenoid
Encombrement pour changement
Ingombro per sostituzione bobina

Platzbedarf für Magnetwechsel
e
d
de l´électroaimant
e
d
de l´électroaimant
Rp
Rp
c
c
a
b
f a f
b g
DMV 507-520/11 DMV 525/11
Typ Rp Pmax. Imax. Öffnungszeit Einbaumaße/Dimensions/ Gewicht

Type [VA] ~(AC) Opening time Cotes d'encombrement/Dimensioni Weight
Type 240 V Durée d'ouverture [mm] Poids
Tipo Tempo aperutra a b c d e f g Peso [kg]
DMV-D 507/11 Rp 3/4 45 0,20 <1s 93 141 35 134 232 73 --- 2,1
DMV-D 512/11 Rp 1 1/4 65 0,28 <1s 124 174 45 150 254 99 -- 4,6
DMV-D 520/11 Rp 2 90 0,37 <1s 124 201 45 190 333 99 -- 5,6
DMV-D 525/11 Rp 2 110 0,46 <1s 162 239 88 255 400 103 123 12,1
DMV-DLE 507/11 Rp 3/4 45 0,20 20 s 93 141 35 160 232 73 -- 2,2
DMV-DLE 512/11 Rp 1 1/4 65 0,28 20 s 124 174 45 179 254 99 -- 4,7
DMV-DLE 520/11 Rp 2 90 0,37 20 s 124 201 45 218 323 99 -- 5,7
DMV-DLE 525/11 Rp 2 110 0,46 20 s 162 239 88 275 400 103 123 12,3
Doppelmagnetventil durch geeigneten Schmutzfänger vor Verunreinigungen schützen, Sieb ist eingebaut.
Protect double solenoid valve from fouling using suitable dirt traps. Sieve is installed.
Il faut protéger les électrovannes par un filtre approprié, mais un tamis est déjà monté à l'entrée de la vanne.
Proteggere l'elettrovalvola doppia con adeguati filtri da sporco, una reticella è già montata.
Verschluß- und Verbindungsschrauben sachgemäß anziehen.

Werkstoffpaarung Druckguß – Stahl beachten!
Tighten plugs and union screws properly.
ISO 7005-2 Make sure of proper material combinations, e.g. diecast – steel!
Serrer les vis fermeture et de fixation comme il convient.
Respecter l'appariement des materiaux moulage sous pression –acier!
Stringere in modo appropriato sia le viti di collegamento che quelle di chisura.
Prestare attenzione alla pressofusione in acciaio nell'abbinamento dei materiali.
[Nm] max. Drehmomente/Systemzubehör M4 M5 M6 M8 G1/8 G1/4 G1/2 G3/4

max. torque/System accesories
max. couple/Accessoires du système 2,5 Nm 5 Nm 7 Nm 15 Nm 2,5 Nm 7 Nm 10 Nm 15 Nm
max. coppie/Accessorio di sistema

Gerät darf nicht als Hebel benutzt werden!

M/CD • Edition 02.10 • Nr. 222 345
Nnby/
Do not use unit as lever!
Ne pas utiliser la vanne comme un levier!
à
L'apparecchio non deve essere usato come leva!

à
W2 W3
ENW Rp 1/2 3/4 1 1/4 2
Unby/ Nnby/ Mmax. 105 225 475 1100 [Nm] t ≤ 10 s
Tmax. 50 85 160 250 [Nm] t ≤ 10 s
2 … 12
Option Option Option Opzione
Elektrischer Anschluß Electrical connection Raccordement électrique Allacciamento elettrico
Anschluß über PG 11 an Schraub- Connection via PG11 to screw Sur bornes à vis par entrée de Allacciamento a morsetti tramite
klemmen. terminals. câble PG11. passacavo PG11.
M2 O M3
3 2 4
P1 N P2 PE
W2 W3
Gewindeflanschausführung Threaded flange version Version à bride filetée Esecuzione con flangia filettata
DMV - D(LE) 507/11 (DN 20) - DMV - D(LE) 507/11 (DN 20) - DMV - D(LE) 507/11 (DN 20) - DMV - D(LE) 507/11 (DN 20) -
DMV - D(LE) 525/11 (DN 50) DMV - D(LE) 525/11 (DN 50) DMV - D(LE) 525/11 (DN 50) DMV - D(LE) 525/11 (DN 50)
Ein- und Ausbau Mounting and dismounting Pose et dépose Montaggio e Smontaggio
1. Schraube A und B lösen - 1. Loosen screws A and B 1. Deserrer les vis A et B sans 1. Allentare le viti A e B
nicht ausschrauben. do not remove. les dévisser totalement. non svitare.
Bild 1 und 2 Figs 1 and 2 Figures 1 et 2 Figure 1 e 2
2. Schraube C und D aus- 2. Remove screws C and D. 2. Dévisser les vis C et D 2.Svitare le viti C e D
schrauben. Figs 1 and 2 Figures 1 et 2 Figure 1 e 2
Bild 1 und 2 3. Remove double solenoid valve 3. Extraire l´électrovanne double 3.Tirare fuori la valvola elettro-
3. Doppelmagnetventil zwischen between the threaded flanges. entre les brides filetées. magnetica doppia fra le flange
den Gewindeflanschen heraus- Figs 3 and 4 Figures 3 et 4 filettate. Figure 3 e 4
ziehen. 4. After mounting, perform 4. Après pose, procéder à un 4. Dopo il montaggio, effettuare il
Bild 3 und 4 leakage and functional tests. contrôle de l´étanchéité. controllo di tenuta e di
4. Nach Einbau Dichtheits- und funzionamento.
Funktionskontrolle.
1 2
C A A C
D B B D
3 4
M/CD • Edition 02.10 • Nr. 222 345
3 … 12
Plombierung Lead seal
Plombierungsöse 2 in der Ver- Lead seal eye 2 in 1.5 mm dia.

schlußklappe Ø 1,5 mm. sealing valve.
Plombierungsöse 3 in der Kreuz- Lead seal eye 3 in 1.5 mm capstand
lochschraube Ø 1,5 mm. headed screw.
Nach Einstellung des gewünschten After setting the requested pressure

Drucksollwertes. setpoint:
1. Schutzklappe 1 schließen. 1. Close protective valve 1.
2. Draht durch 2 und 3 ziehen, 2. Route wire through 2 and 3,
Bild 2. Fig. 2. 2
3. Plombe um Drahtenden drücken, 3. Press lead around wire ends, 05/98
Drahtschlaufe kurz halten. keep wire loop short.
Plombage Piombatura
Oeillet de plombage 2 Ø 1,5 mm Occhiello per piombatura nel co-

dans le capuchon. perchietto Ø 1,5 mm.
Oeillet de plombage 3 Ø 1,5 mm Occhiello per piombatura nella vite
dans la vis à tête percée. a testa tonda forata Ø 1,5 mm.
3 1
Après le réglage. Dopo la regolazione del valore di
1. Remettre le capuchon 1. pressione nominale desiderato:
2. Passer le fil de plombage dans 1. chiudere il coperchietto
les trous 2 et 3 Fig 2. 2. tirare il filo attraverso i punti 2 e
3. Plomber en laissant une petite 3 (Fig.2)
boucle. 3. piombare le estremità del filo la-
sciando corto l'anello passante.
DMV - D 507/11 - 525/11 DMV - D 507/11 - 525/11 DMV - D 507/11 - 525/11 DMV - D 507/11 - 525/11
DMV-DLE 507/11 - 525/11 DMV-DLE 507/11 - 525/11 DMV-DLE 507/11 - 525/11 DMV-DLE 507/11 - 525/11
Hauptmengeneinstellung nur an Main flow setting only possible Réglage du débit principal pos- Regolazione portata principale
V1 möglich! at V1! sible uniquement sur V1! possibile solo su V1!
Hauptmengeneinstellung erfolgt Set main volume on open valve. Le réglage du débit principal doit La regolazione della portata princi-
am geöffneten Ventil. Set valve V1 during operation. Check être réalisé vanne ouverte. pale avviene a valvola aperta.
Einstellung am Ventil V1 im Betrieb setting values continuously. Le réglage se fait sur V1, installation La regolazione su valvola 1 è da
durchführen, Einstellwerte ständig Smallest setting volume flow: en marche. Il est souhaitable de effettuare in fase di esercizio e da
kontrollieren. contrôler le débit pendant le réglage. controllare costantemente i valori
Kleinster Einstellvolumenstrom: Débit principal mini.: tarati. Portata volumetrica con
regolazione al minimo:
O O O O O O O O
Vmin. / mini.> 0.1 x Vmax. / maxi. Vmin. / mini.> 0.1 x Vmax. / maxi. Vmin. / mini.> 0.1 x Vmax. / maxi. Vmin. / mini.> 0.1 x Vmax. / maxi.
Eine Umdrehung entspricht ca. 0,5mm Hub

1 rotation corresponds to approx. 0.5 mm stroke
Un tour correspond à environ 0,5 mm de course
Un giro corrisponde a una corsa di ca. 0,5 mm.
¢
ÇW
Ç!q
V1 njo/0njoj nby/0nbyj/
O O
max./maxi. min./mini. Vmin./mini.> 0.1 x Vmax./maxi
M/CD • Edition 02.10 • Nr. 222 345
4
\n!!0i^
4 … 12
DMV-DLE DMV-DLE DMV-DLE DMV-DLE
° start
Schnellhubeinstellung V Rapid stroke adjustment V° start ° start
Réglage course rapide V Regolazione scatto rapido
° start
V
Werkseinstellung DMV-DLE: Factory setting DMV-DLE: Réglage en usine DMV-DLE: Regolazione in fabbrica del DMV-
Schnellhub nicht eingestellt Rapid stroke not adjusted Course rapide non réglée DLE: Scatto rapido non regolato
1. Einstellkappe E von der Hy- 1. Unscrew the adjustment cap E 1. Dévisser le capuchon de 1. Svitare dallídraulico la
draulik abschrauben. from the hydraulic brake. réglage E du frein hydraulique farfalla E.
2. Einstellkappe drehen und als 2. Turn the adjustment cap and 2. Tourner le capuchon de 2. Fare ruotare la valvola a
Werkzeug benutzen. use as a tool. réglage et l'utiliser comme farfalla utilizzandola come
3. Linksdrehen = Vergrößerung 3. Turn a-clockwise = increase outil. attrezzo.
des Schnellhubes (+). rapid stroke (+). 3. Rotation à gauche = 3. Rotazione antioraria =
augmentation de la course aumento dello scatto
rapide (+). rapido (+).
[m3 /h]
Werkseinstellung
Factory setting
Réglage d'usine
Regolazione in fabbrica
Schnellhub
Fast stroke
Course rapide
Scatto rapido
[s] t
E
M/CD • Edition 02.10 • Nr. 222 345
5 … 12
Austausch Hydraulik oder Ein- Replacing hydraulic brake unit Remplacement du frein hydrauli- Sostituzione dell'idraulico o del
stellteller or adjustment plate que ou du disque de réglage piattello di regolazione
1. Anlage ausschalten. 1. Switch off firing system. 1. Mettre l'installation hors ten- 1. Disinserire l'impianto
2. Sicherungslack über der 2. Remove locking varnish from sion. 2. Rimuovere la lacca di sigillo sopra
Senkkopfschraube A entfer- countersunk screw A. 2. Eliminer le vernis de blocage la vite a testa svasata A.
nen. 3. Unscrew countersunkscrew A. au-dessus de la vis à tête fraisée 3. Svitare la vite a testa svasata
3. Senkkopfschraube A aus- 4. Unscrew socket headscrew B. A. A.
schrauben. 5. Raise adjustment plate C or 3. Dévisser la vis à tête fraisée 4. Svitare la vite a testa cilindrica
4. Zylinderkopfschraube B aus- hydraulic brake D. A. B.
schrauben. 6. Remove sealing plug E 4. Dévisser la vis à tête cylindrique 5. Sollevare il piattello C o l'idrau-
5. Einstellteller C bzw. Hydraulik 7. Exchange adjustment plate C B. lico D.
D abheben. or hydraulic brake D 5. Soulever le disque de réglage 6. Rimuovere la tappino di chisura
6. Verschlußstopfen E entfer- 8. Screw in countersunk and C ou le frein hydraulique D. E.
nen. socket head screw. 6. Eliminer le bouchon E. 7. Sostituire il piattello C o l'idrau-
7. Einstellteller C bzw. Hydraulik Only tighten socket head screw 7. Remplacer le disque de réglage lico D.
D austauschen. so that hydraulic brake can just C ou le frein hydraulique D. 8. Riavvitare la vite a testa cilin-
8. Senk- und Zylinderkopf- be turned. 8. Revisser les vis à tête fraisée et drica e stringere la vite a testa
schraube wieder eindrehen. 9. Coat countersunk screw A with à tête cylindrique. Serrer la vis svasata soltanto fino a che
Senkkopfschraube nur so locking varnish. à tête fraisée. l'idraulico possa ancora essere
festziehen, daß Hydraulik 10. Leakage test: 9. Enduire la vis à tête fraisée A fatto ruotare.
noch gedreht werden kann. Pressure tap at sealing de vernis de blocage. 9. Sigillare con la lacca la vite a
9. Senkkopfschraube A mit plug 2: DMV 507-520/11 10. Contrôle d'étanchéité: testa svasata A.
Sicherungslack überziehen. Pressure tap at sealing via la prise de pression 10. Prova di tenuta:
10. Dichtheitsprüfung über plug 3: DMV 525/11 bouchon fileté 2: attraverso il tappo a su
Druckabgriff: pmax. = 500 mbar. DMV 507-520/11. presa di pressione 2:
Verschlußschraube 2: 11. Perform functional test. via la prise de pression DMV 507-520/11.
DMV 507-520/11. 12. Switch on firing system. bouchon fileté 3: attraverso il tappo a su
Verschlußschraube 3: DMV 525/11. presa di pressione 3:
DMV 525/11. pmax. = 500 mbar. DMV 525/11.
pmax. = 500 mbar. 11. Procéder à un contrôle de pmax. = 500 mbar.
11. Funktionskontrolle durchfüh- fonctionnement. 11. Effettuare la prova di funziona-
ren. 12. Mettre l'installation sous ten- mento.
12. Anlage einschalten sion. 12. Reinserire l'impianto.
A B
D
E
M/CD • Edition 02.10 • Nr. 222 345
6 … 12
Magnetwechsel Replacing the solenoid Remplacement de la bobine Sostituzione bobina
Ausführungen mit Versions with adjusting plate Pour les modèles DMV-D 5.../11 Esecuzioni con piatto di regolazio-
Einstellteller DMV-D 5.../11 DMV-D 5.../11or avec disque de réglage ou ne DMV-D 5.../11 oppure con freno
oder Hydraulik DMV-DLE 5../11 hydraulic brake DMV-DLE 5../11 DMV-DLE 5../11 avec frein hy- idraulico DMV-DLE 5../11
draulique
1. Hydraulik bzw. Einstellteller ent 1. Remove hydraulic brake or adjust- 1. Enlever le disque de réglage ou le 1. Togliere rispettivamente il freno
fernen, wie auf Seite 6 : ing plate as described on page 6: frein hydraulique comme page 6: idraulico il piatto di regolazione
"Austausch Hydraulik oder "Replacing the hydraulic brake or "Remplacement du frein hydrauli- come descritto a pag. 6: "sosti-
Einstellteller", Punkt 1 - 5, be- adjusting disk", steps 1 -5. que ou disque de réglage" repère tuzione del freno idraulico o del
schrieben. 1 à 5. piatto di regolazione" - punto
1-5.
2. Magnet auswechseln. 2. Replace solenoid 2. Remplacer la bobine 2. Sostituire la bobina.

Magnet-Nr. und Spannung Important: Make sure that the Attention au N° de la bobine et Prestare assoluta attenzione
unbedingt beachten! solenoid no. and voltage are à la tension! al numero della bobina e alla
correct! tensione!
3. Hydraulik bzw. Einstellteller 3. Remount hydraulic brake or 3. Enlever le disque de réglage ou 3. Rimontare di nuovo rispettiva-
wieder montieren, wie auf Seite adjusting plate as described on le frein hydraulique comme page mente il freno idraulico e il piatto
6 " Austausch Hydaulik oder page 6:"Replacing the hydraulic 6: "Remplacement du frein hy- di regolazione come descritto
Einstellteller", Punkt 7 - 11, brake or adjusting plate", steps 7 draulique ou disque de réglage" a pag. 6 "sostituzione del freno
beschrieben. -11. repères 7 à 11. idraulico o del piatto di regola-
zione" - punto 7-11.
M/CD • Edition 02.10 • Nr. 222 345
7 … 12
Durchfluß-Diagramm / Flow Diagram / Courbe des débits / Diagramma di portata
611
511
411
311
261
211
91
71
61
5
!60
51
!Sq
!3
!3
!2
!Sq
!Sq
!Sq
.
05!
!.
!.
41
!.
q!6
q!3
q!3
q!2
Çq!\ncbs^
3!S
1!S
6!S
8!S
*!62
*!63
*!63
*!61
31
)MF
)MF
)MF
)MF
W.E
W.E
W.E
W.E
EN
EN
EN
EN
21
9
7
6
5
3
Cbtjt!!!!!!!!!,!26¢!D-!2124!ncbs-!uspdlfo
Cbtfe!po!!,!26¢!D-!2124!ncbs-!esz
Cbtf!!!!!!!!!!,!26¢!D-!2124!ncbs-!tfd
Cbtf!!!!!!!!!!,!26¢!D-!2124!ncbs-!tfddp
2
2 3 4 5 6 7 9 21 31 41 51 61 71 91 211 311 411 511 711 911 2111 3111

4
¢
Wo!\n!!0i^!Mvgu!0!Bjs!0!Bsjb!ew!>!2-11
3 4 5 6 7 9 21 31 41 51 61 71 91 211 311 411 511 711 911 2111 3111

¢ 4
Wo!\n!!0i^!Fsehbt0Obuvsbm!hbt0Hb{!Obuvsfm0Hbt!nfubop!ew!>!1-76
Durchflußverluste in [m 3/h] Flow losses in [m3/h] air for in- Perte en débit d'air [m3/h] due Perdite di portata in [m3/h] d'aria
Luft bei Einbau des Feinfilter- stalling microfilter au montage d'un filtre à média con il filtrino fine montato
Einsatzes filtrant fin
DMV 520/11
∆p [mbar] DMV 507/11 DMV 512/11 [m3/h]
[m3/h] [m3/h]
17,5
2 1,20 9,0 21,5
5 1,70 11,0 27,0
10 1,80 13,2 34,5
20 1,90 16,0 45,0
40 2,30 18,4 56,0
70 2,50 22,5
Gasart Dichte
°
V = °
V Luft/air/air/aria x f Type of gas Spec. Wgt.
Type de gaz poids spécifique dv f
Tipo di gas Peso specifico
[kg/m3]

M/CD • Edition 02.10 • Nr. 222 345

Spec. weight air
poids spécifique de l'air Stadtgas/City gas/ 0.58 0.47 1.46
peso specifico aria Gaz de ville/Gas città
f=
Dichte des verwendeten Gases Flüssiggas/LPG/ 2.08 1.67 0.77
poids spécifique du gaz utilisé
peso specifico del gas utilizzato Luft/Air/ 1.24 1.00 1.00
Air/Aria 8 … 12
Ersatzteile / Zubehör Bestell-Nummer Ersatzteile / Zubehör Bestell-Nummer
Spare parts / Accessories Ordering No. Spare parts / Accessories Ordering No.
Pièces de rechange / access. No. de commande Pièces de rechange / access. No. de commande
Parti di ricambio / Accessori Codice articolo Parti di ricambio / Accessori Codice articolo
Verschlußschraube, flach mit 5 Stück/Set Zylinderschraube DIN 912, 8.8 4 Stück/Set

O-Ring 5 Pieces/Set Socket head screw acc.DIN 912, 8.8 4 Pieces/Set
Locking screw 5 Pièces/Set Vis à tête cylindrique DIN 912, 8.8 4 Pièces/Set
Bouchon fileté 5 Pezzi/Set Vite cilindrica DIN 912, 8.8 4 Pezzi/Set
Tappo a vite DMV 507/11 M6 x 30 231 588
G 1/8 230 432 DMV 512-520/11 M8 x 40 231 589
DMV 525/11 M8 x 25 231 590
Schmutzfänger, Sieb
Dirt trap, sieve Meßstutzen mit Dichtring 5 Stück/Set
Collecteur d'impuretés, tamis Set of setscrews 5 Pieces/Set
Filtro antipolvere, reticella Goujon 5 Pièces/Set
DMV 525/11 247 547 Serie di viti per acciaio 5 Pezzi/Set
G 1/8 230 397
Set Zündgasflansch G1/2
G 1/2 start gas flange set Ersatzmagnet
Kit bride taraudée G 1/2 pour Replacement solenoid
vanne d'allumage Aimant de rechange
Set per flangia gas di accensi- Bobina di ricambio
one G 1/2 219 007 DIN 43 650
DMV 507/11 1111 auf Anfrage
Adapter-Set für GW A2 mit DMV 512/11 1211 on request
Anschluß G 1/4 DMV 520/11 1212 sur demande
Adapter set for GW A2 fitted with DMV 525/11 1411 su richesta
G 1/4 port
Kit de montage GW A2 avec Verschlußstopfen V2
raccord taraudé G 1/4 V2 sealing plug
Set adattatore per GW A2 con Bouchon V2
attacco G 1/4 Tappino di chiusura V2
DMV 507/11 - DMV 525/11 222 982 DMV 507/11 -DMV 520/11 231 591
DMV 525/11 231 610
Hydraulikbremse
Hydraulic brake auf Anfrage Teller für Magnetbefestigung
Frein hydraulique on request Disk for attaching solenoid
Freno idraulico sur demande Disque pour la fixation de la bobine
DMV 507/11 - DMV 525/11 su richiesta Piatto per fissaggio bobina
DMV 507/11 - DMV 520/11 231 592
Einsteckscheibe DMV 525/11 231 612
Insert washer
Disque à emboîtement Set Feinfilter, Sieb, Haltering
Dischetto da inserire Set Micro filter, sieve,
DMV 507/11 - DMV 520/11 231 563 supporting ring
DMV 525/11 231 564 Kit Filtre fin, tamis,
bague d'appui
Leitungsdose, Schwarz Set Filtro fine, reticella, l'anellino
Line socket, black DMV 507/11 230 440
Prise, noire DMV 512/11 - DMV 520/11 230 441
Spina, nera DMV 525/11 247 547
GDMW, 3 pol. + E 210 319
Anschlußflansch
Connection flange
Bride de raccordement
Flangia di collegamento
DMV 507 Rp 1/2 222 341
DMV 507 Rp 3/4 222 342
DMV 507 Rp 1 222 001
DMV 512-520 Rp 1 222 343
DMV 512-520 Rp 1 1/4 222 344
DMV 512-520 Rp 1 1/2 221 884
DMV 512-520 Rp 2 221 926
DMV 525 Rp 2 215 384
O-Ring, EN geprüft
O-ring, EN tested
Joint torique, testé EN
O-Ring, collaudato a norme EN
M/CD • Edition 02.10 • Nr. 222 345
DMV 507/11 57 x 3,0 230 443

DMV 512-520/11 75 x 3,5 230 444
DMV 525/11 231 574
9 … 12
Arbeiten am Doppelma- Work on the double so- Seul du personnel spé- Qualsiasi operazione
gnetventil dürfen nur von lenoid valve may only be cialisé peut effectuer effettuata sulle valvole
Fachpersonal durchge- performed by specialist des travaux sur l'électro- doppie deve essere fatta
führt werden. staff. vanne double. solamente da parte di
Flanschflächen schützen. Protect flange surfaces. Protéger les surfaces de Proteggere le superfici
Schrauben kreuzweise Tighten screws cross- brides. Serrer les vis en della flangia. Stringere le
anziehen. wise. croisant. viti in modo incrociato.
Direkter Kontakt zwischen Do not allow any direct Eviter tout contact di- Non è consentito il con-
Doppelmagentventil und contact between the dou- rect entre l'électrovanne tatto diretto fra la valvola
dem aushärtendem Mau- ble solenoid valve and double et la maçonnerie, dopie e murature invec-
erwerk, Betonwänden, hardened masonry, con- les cloisons en béton et chiate, pareti in calce-
Fußböden ist nicht zu- crete walls or floors. planchers en cours de struzzo, pavimenti.
lässig. séchage.
Nennleistung bzw. Druck- Always adjust nominal Régler toujours le débit Effettuare in linea di massima
sollwerte grundsätzlich output or pressure set- nominal ou les pressions la regolazione di potenza
p [mbar] nominale e valori nominali
am Gasdruckregelgerät points on the gas pres- de consigne sur le régu-
einstellen. Leistungsspezi- sure regulator and per- lateur de pression. Limita- di pressione sul regolatore di
V° pressione gas. La regolazione
[m3/ h] fische Drosselung über das formance-specific throt- tion au niveau de DMV, en
Doppelmagnetventil. tling using the DMV specifica di potenza va fatta
fonction du débit.
attraverso la DMV
Bei Teilewechsel auf ein- When changing parts, En cas de remplacement Sostituendo le varie
wandfreie Dichtungen make sure that seals are de pièces, vérifier que parti controllare sempre
achten. in good condition. les joints ne présentent tutte le guarnizioni affin-
aucun défault. ché siano perfettamente
a tenuta.
Rohrleitungsdichtheits- Pipeline leakage test: Contrôle de l'étanchéité Per la prova di tenuta delle
prüfung: Kugelhahn vor close ball valve upstream de la conduite: fermer le tubature:
den Armaturen / DMV of fittings/DMV. robinet à boisson sphéri- chiudere il rubinetto a
schließen. que avant les électrovan- sfera davanti ai corpi
nes / DMV. valvola / DMV.
Nach Abschluß von Ar- On completion of work Une fois les travaux sur Al termine dei lavori ef-
Safety beiten am Doppelmagnet- on the double solenoid l'électrovanne double ter- fettuati su una valvola
ventil: Dichtheitskontrolle valve, perform a leakage minés, procéder toujours elettromagnetica doppia:
first und Funktionskontrolle and function test. à un contrôle d´étanchéité predisporre un controllo
durchführen. et de fonctionnement. sia della tenuta che del
O.K. funzionamento.
führen, wenn Gasdruck gas pressure or power is travaux lorsque la pres- effettuare lavori in presen-
oder Spannung anliegt. applied. No naked flame. sion ou la tension sont za di pressione gas o di
Offenes Feuer vermeiden. Observe public regula- présentes. Eviter toute tensione elettrica. Evitare i
Öffentliche Vorschriften tions. flamme ouverte. Observer fuochi aperti e osservare le
beachten. les réglementations. prescrizioni pubbliche.
M/CD • Edition 02.10 • Nr. 222 345
Bei Nichtbeachtung der If these instructions are En cas de non-respect La non osservanza di quan-
Hinweise sind Personen- not heeded, the result de ces instructions, des to suddetto può implicare
oder Sachfolgeschäden may be personal injury or dommages corporels ou danni a persone o cose.
denkbar. damage to property. matériels sont possible.
Sous réserve de tout modification constituant un progrès technique / Ci riserviamo qualsiasi modifica tecnica e costruttiva 10 … 12
E HC G J
qui suit :

VIE UTILE
DUNGS recommande le
UV-Flammenfühler
10.000 h
Sensore fiamma UV
M/CD • Edition 02.10 • Nr. 222 345
11 … 12
M/CD • Edition 02.10 • Nr. 222 345
12 … 12
D GB F I
Betriebs- und Montagean- Operation and assembly Notice démploi et de Istruzioni di esercizio e di
leitung instructions montage montaggio
Gas- und Luftdruckwächter Gas and air pressure switch Pressostat pour le gaz et l'air Pressostato Gas e aria
GW…A5 GW…A5 GW…A5 GW…A5
GW…A5/1 GW…A5/1 GW…A5/1 GW…A5/1
Max. Betriebsdruck / Max. operating Umgebungstemperatur

pressure/ Pression de service maxi. Max. °C Ambient temperature
pressione di esercizio +70 Température ambiante
GW 3/10/50/150 A5
Temperatura ambiente
pmax. = 500 mbar (50 kPa) 0
GW 500 A5 –15 °C … +70 °C
-15
[mbar] pmax. = 600 mbar (60 kPa)
Druckwächter/ Pressure Switch/ Mediumstemperatur

Pressostat/ Pressostato °C Medium temperature
+70
Typ/Type/Type/Tipo Température du fluide
GW…A5 Temperatura fluido
nach / acc. / selon / secondo 0
–15 °C … +70 °C
-15
EN 1854 EN 1854
Einstellbereiche Lagertemperatur
Setting ranges °C Storage temperature
+80
Plages de réglage
100 – 500 mbar
5 – 150 mbar
Température de stockage
5 – 50 mbar Campi di taratura Temperatura stoccaggio
0
2 – 10 mbar –30 °C … +80 °C
0,7 – 3 mbar
-30
~(AC) eff., min./mini 24 V, Familie 1+2+3

~(AC) max. /maxi. 250 V Family 1+2+3
=(DC) min./mini. 24 V, Famille 1+2+3
=(DC) max. /maxi. 48 V Gas Gaz Famiglia 1+2+3
[V] Nennstrom/nominal current/courant
nominal/corrente nominale
GW 3 A5: ~(AC) 6 A
GW 10…500 A5: ~(AC) 10 A Schutzart
Schaltstrom/current on contact/courant Degree of protection
de commutation/corrente di intervento Protection
GW 3 A5: ~(AC) 4 A cos ϕ 1 Protezione
~(AC) 2 A cos ϕ 0,6
[A] GW 10…500 A5: IP 54 nach / acc. / selon / secondo
IEC 529
EN 1854 ~(AC) max./maxi. 6 A cos ϕ 1 IEC 529 (EN 60529)
~(AC) max./maxi. 3 A cos ϕ 0,6
GW 3…500 A5:
~(AC) eff., min./mini 20 mA
=(DC) min./mini. 20 mA
=(DC) max./maxi. 1 A
Einbaulage / Installation position / Position de montage / Posizione de montaggio

Standardeinbaulage; bei Abweichung Schaltpunktänderung beachten.
Standard installation position; in case of deviation, take the switch point change into account.
Position de montage standard; en case de divergence, veiller à la modification du point de commutation.
Posizione standard; per altre posizioni di montaggio osservare il cambiamento del punto di intervento.
1
GW 3…50 A5 max. ± 0,6 mbar

3
GW 150 A5 max. ± 1 mbar

GW 500 A5 max. ± 3 mbar
2 Bei waagerechtem Einbau schaltet der Druckwächter bei einem höheren Druck.
In the horizontal installation position the switching pressure is increased.
3
Monté horizontalement, le pressostat commute à une pression dénviron.

Con montaggio orizzontale il pressostato scatta ad una pressione superiore.
M/CD • Edition 02.10 • Nr. 227 048
Bei Einbau waagerecht über Kopf schaltet der Druckwächter bei einem niedrigeren Druck.
When the pressure switch is mounted horizontally overhead, its switching pressure decreases.
Monté horizontalement à lénvers, le pressostat commute à une pression moins élevée.
1
Con montaggio orizzontale capovolto il pressostato scatta ad una pressione inferziore.

2
Bei Einbau in einer Zwischeneinbaulage schaltet der Druckwächter bei einem vom eingestellten Sollwert maximal höheren
bzw. niedrigeren Druck.
2
3
When the pressure switch is mounted in an intermediate position, its switching pressure deviates from the setpoint.
Monté dans une position intermédiaire, le pressostat commute à une pression divergeant dún par rapport à la valeur de
1
consigne réglée.
Con il montaggio in una posizione intermedia il pressostato scatta ad una pressione diversa da quella nominale.
1…8
Einbaumaße / Dimensions Meßstutzen ø 9
Cotes d'encombrement / Measuring rozzle 9 mm dia.
Dimensioni [mm] Prise de mesure ø 9
GW…A5 Presa per misuratore ø 9
Nut für O-Ring

Groove for o-ring
Gorge pour joint torique
Scanalatura per anello torico
10,5 x 2,25
48,5
34
2
53,75 ± 0,2
Befestigungslöcher
Druckanschluß optional mit Dämpfungsdüse bei GW…A5/1 Fixing holes
Pressure connection, optionally with damping nozzle for GW…A5/1 Trous de fixation
Raccord de pression en option avec buse d’amortissement pour GW...A5/1 Fori di fissaggio
Presa pressione opzione con ugello di smorzamento per GW...A5/1 12,5
2
3
42,2
44,7 ø 4,2
1
25,2
ø 4,2 ± 0,2
12,5
6,5
18
72
42
Made in Germany
26
IP 54
Dichtung
13,5
Seal
Joint d'étanchéité Steckanschluß für Leitungsdose nach DIN EN 175 301-803
Guarnizione Plug-in socket for cable socket as per DIN EN 175 301-803
Fiche pour boîtier de raccordement selon DIN EN 175 301-803
Attacco a spina per presa a norme DIN EN 175 301-803
Schutzhaube für Steckanschluß
Safety cover for plug-type connection
Capot de protection pour connecteur
Calotta di protezione per collegamento a spina
[Nm] max. Drehmomente / Systemzubehör M4 max. Drehmoment Haubenschraube 1,2 Nm

max. torque / System accessories max. torque cap-head screw
19
max. couple / Accessoires du système 2,5 Nm couple max. pour les vis du couvercle
vite per cappuccio per coppia max.
18
[Nm] max. Drehmomente Dichtschraube in Meßstutzen 2 Nm

Max. torques sealing screw in test nipples
19
Couples maxi. pour la vis d’étanchéité dans la prise de mesure

18
Coppia di serraggio max. per vite di tenuta nel raccordo per misuratore
Geeignetes Werkzeug einsetzen!

Please use proper tools!
23
21
Utiliser des outils adaptés!

Impiegare gli attrezzi adeguati!
Gerät darf nicht als Hebel be-

nutzt werden
Do not use unit as lever.
Ne pas utiliser le pressostat
comme un levier.
3
Lápparecchio non deve essere

usato come leva.
M/CD • Edition 02.10 • Nr. 227 048
2
2…8
Anbaumöglichkeiten Druckanschluß Raccordement
Attachment possibilities O-Ring-Flanschanschluß an der Bride avec joint torique par la partie
Possibilités de montage Unterseite des Druckwächters. basse du pressostat.
Possibilità di montaggio Befestigung Fixation
2 Schrauben M4 x 20, 2 vis M4 x 20 autotaraudeuses.
MB-VEF … B01 selbstfurchend.
GW…A5
➡➡
} DMV-VEF
DMV-D(LE) … /11
DMV-SE
MB-D …
Pressure tap
O-ring-flange connection to under-
side of the pressure switch.
Attachment
Attacco pressione
Attacco a flangia con O-Ring sulla
parte inferiore del pressostato.
Fissaggio
MB-Z …
FRI … /10 2 M4 x 20 bolts, self-tapping. 2 viti M4 x 20 autofilettanti.
:
Anbaumöglichkeiten
Attachment possibilities
Possibilités de montage
Possibilità di montaggio
DMV-…/11
DMV-SE/VEF
1 [GW…A5 + VPS 504] 2 [GW…A5] 3 [GW…A5]

Zulässige Anbaumöglichkeit! Zulässige Anbaumöglichkeit! Zulässige Anbaumöglichkeit!
1 Mount here! Mount here! Mount here!
Possibilité de montage autorisée ! Possibilité de montage autorisée ! Possibilité de montage autorisée !
Possibilità di montaggio am- Possibilità di montaggio am- Possibilità di montaggio am-
missibile! missibile! missibile!
Nicht zulässiger Anbau!

Do not mount here!
Montage non autorisé !
Montaggio non ammesso!
Anbaumöglichkeiten
Attachment possibilities
Possibilités de montage
Possibilità di montaggio
MultiBloc
MB-D, MB-Z, MB-VEF
3
Nicht zulässiger An-
bau!
Do not mount here!
M/CD • Edition 02.10 • Nr. 227 048
Montage non auto-

3 [GW…A5] 4 [GW…A5] risé !
Zulässige Anbaumöglichkeit! Zulässige Anbaumöglichkeit! Montaggio non am-
Mount here! Mount here! messo!
Possibilité de montage auto- Possibilité de montage auto-
risée ! risée !
Possibilità di montaggio Possibilità di montaggio am-
ammissibile! missibile!
3…8
Anbaumöglichkeiten GW…A5 Add-on possibilities GW…A5
Sicherheitsmagnetventil Safety solenoid valve
SV-… 505-520 SV-… 505-520
Druckabgriff GW…A5 Pressure tap GW…A5

Anbau möglich … Fitting possible ...
SV SV SV SV SV SV
505/507 510/512 520 505/507 510/512 520
1 pe pa pa 1 pe pa pa
2 nein pe pe 2 no pe pe
3 nein pe(1) pe 3 no pe(1) pe
4 pa mit pa1) pa 4 pa with pa1) pa

221 630 221 630
horizontal horizontal
Possibilités d’équipement GW…A5 Possibilità di montaggio per GW…A5

Electrovanne de sécurité... Valvola elettromagnetica di sicurezza...
SV-… 505-520 SV-… 505-520
Prise de pression GW…A5 Presa pressione GW...A5

Equipement possible … possibilità di montaggio ...
SV SV SV SV SV SV
505/507 510/512 520 505/507 510/512 520
1 pe pa pa 1 pe pa pa
2 non pe pe 2 no pe pe
3 non pe(1) pe 3 no pe(1) pe
4 pa avec pa1) pa 4 pa con pa1) pa

221 630 221 630
horizontal orizzontale
Druckabgriff 4
Pressure tap 4
Prise de pression 4
Presa pressione 4
Druckabgriff 3
Pressure tap 3
Prise de pression 3 Druckabgriff 1
Presa pressione 3 Pressure tap 1
Prise de pression 1
Presa pressione 1
Druckabgriff 2
M/CD • Edition 02.10 • Nr. 227 048
Pressure tap 2
Prise de pression 2
Presa pressione 2
1)
Bei Druckwächtermontage Flanschanbau beachten!
1)
For pressure switch assembly, pay attention to the flange attachment.
1)
Lors du montage du pressostat, attention à la fixation par bride.
1)
Montando il pressostato fare attenzione alla flangia!
4…8
Elektrischer Anschluß Zur Erhöhung der Schaltleistung Schaltfunktion Bei steigendem Druck:
Electrical connection wird bei DC-Anwendungen Switching function 1 NC öffnet, 2 NO schließt.
Raccordement électrique < 20 mA und 24 V der Einsatz Schéma électrique Bei fallendem Druck:
Allacciamento elettrico eines RC-Gliedes empfohlen. Funzione di commutazione 1 NC schließt, 2 NO öffnet.
EN 60730 pressostato
To increase the switching capac- GW…A5 While pressure is increasing:
DIN EN 175 301-803 ity, we recommend that you use a 1 NC opens, 2 NO closes.
NO RC device for current values While pressure is decreasing:
< 20 mA and 24 V d.c. applica- 1 NC closes, 2 NO opens.
2 tions. 2 NO
3 COM Pression montante:
COM Pour augmenter la puissance de 1 NC ouvre, 2 NO ferme.
rupture, l'utilisation d'un circuit 3 Pression descendante:
1 RC est préconisée pour les 1 NC ferme, 2 NO ouvre
applications à courant continu
1 NC
< 20 mA et 24 V. p Con pressione in salita:
NC
1 NC apre, 2 NO chiude.
Per aumentare la potenza d'inse- Con pressione in discesa:
rimento con applicazioni DC 1 NC chiude, 2 NO apre
< 20 mA e 24 V, consigliamo
l'impiego di un elemento RC.
Zubehör Bestell-Nr. für Gerät / Typ Nennweiten

Accessories Order No. for equipment / type Nominal diameters
Accessoires No. de commande pour appareil / type Diamètres nominaux
Accessorio Nr. ordine per apparecchio / Tipo Diametri nominali
Montage-Set 223 280

Assembly set
Kit de montage
Set dimontaggio
2 x M4 x 20
1 x O-Ring / Joint torique
Adapter pBr 214 975 MB-D … Rp 3/8 – Rp 2

Adapter pBr MB-Z … Rp 3/8 – Rp 2
Adaptateur pBr DMV- … Rp 3/8 – Rp 2
Adattatore pBr
Adapter-Set für GW … A5 mit 222 982 DMV - … Rp 3/8 – Rp 2

Anschluß G 1/4 MB - … 415-420 Rp 3/8 – Rp 2
Apapter-set for GW … A5 fitted
with G 1/4 port
Kit de montage GW … A5 avec
raccord taraudé G 1/4
Set adattatore per GW … A5 con
attacco G 1/4
Adapter auf Gewindeflansch 221 630 MB -… 405-412 Rp 3/8 – Rp 1 1/4

(G 1/8) DMV -… Rp 3/8 – Rp 2
Adapter on threaded flange SV -… 505-520
(G 1/8)
Adaptateur sur bride filetée
(G 1/8)
Adattatore per flangia filettata
(G 1/8)
Leitungsdose 3-pol. + E grau 210 318

GDMW
Line socket 3-pin + E grey
GDMW
Prise 3 pôles + terre grise
GDMW
Presa di rete a 3 poli e terra, grigia
GDMW
M/CD • Edition 02.10 • Nr. 227 048
5…8
Einstellung des Gasdruckwäch- Réglage du pressostat
1
ters
Haube mit geeignetem Werkzeug Elever les vis du capot en utilisant

demontieren, Schraubendreher No. un tournevis No3 respectivement PZ
3 bzw. PZ 2, Bild 1. 2, Figure 1.
Haube abnehmen. Enlever le capot.
Setting the gas pressure switch Regolazione del pressostato

gas
Dismount the hood using a suitable Smontare la calotta con un attrezzo

tool, e.g. screwdriver no. 3 or PZ 2, adeguato, ossia cacciavite nr. 3
Fig. 1. Remove hood. rispettiv PZ 2, figura 1. Togliere la
calotta
IP 54
Made in Germany
Druckwächter am Einstellrad mit Régler le pressostat avec son bou- 2
Skala auf vorgeschriebenen Druck- ton sur la valeur désirée, Figure 2.
sollwert einstellen, Bild 2.
Respecter les recomman-
Anleitung des Brennerher- dations du constructeur
stellers beachten! du brûleur!
Druckwächter schaltet bei fallendem Le pressostat commute par pression

Druck: Einstellung auf ▲. descendante: régler sur ▲.
Haube wieder montieren! Remonter le capot!
Set the pressure switch at the set- Tarare il pressostato, come in figura
IP 54
Made in Germany
ting wheel to the specified pressure 2, sul valore di pressione nominale

setpoint using the scale, Fig. 2. prescritto, agendo sulla rotella della
scala graduata.
2 1
Observe the burner manu- Prestare attenzione alle

facturer's recommenda- istruzioni indicate dal fabbri-
NO NC
tions! cante del bruciatore!
Pressure switch switches as pres- Il pressostato scatta con pressione

sure reduces: Set to ▲. in discesa: regolazione sulla ▲. 2 mb
Remount hood! Rimontare la calotta. 3 ar
GW 10 A5
4
5
10
6
M/CD • Edition 02.10 • Nr. 227 048
9
7 8
6…8
Arbeiten am Druckwäch- Work on the pressure Seul du personnel spécia- Qualsiasi operazione ef-
ter dürfen nur von Fach- switch may only be perfor- lisé peut effectuer des tra- fettuata sul pressostato
personal durchgeführt med by specialist staff. vaux sur le pressostat. deve essere fatta da par-
werden. te di personale compe-
tente.
Kondensat darf nicht Do not allow condensate Eviter l'entrée de conden- Nell' apparecchio non
in das Gerät gelangen. to flow into the equipment. sats dans le pressostat, deve infiltrarsi alcuna
Bei Minustemperaturen, In case of sub-zero tem- une prise en glace par condensa. Alle tempera-
durch Vereisung Fehl- peratures, malfunction or température négative ture negative sarebbe-
funktion/Ausfall mög- equipment failure may be nuirait à son fonctionne- ro possibili disfunzioni
lich. possible due to icing. ment. dovute a formazione di
ghiaccio.
Rohrleitungsdichtheits- Pipeline leakage test: clo- Contrôle de l´étanchéité Per la prova di tenuta
prüfung: Kugelhahn vor se ball valve upstream of de la conduite: fermer delle tubature: chiudere il
dem Druckwächter schlie- the pressure switch. le robinet à boisseau rubinetto a sfera davanti
ßen. sphèrique avant le pres- al corpo pressostato.
sostat.
Nach Abschluß von Ar- On completion of work Une fois les travaux sur Al termine dei lavori effet-
Safety beiten am Druckwäch- on the pressure switch, le pressostat terminés, tuati su un pressostato:
ter: Dichtheitskontrolle perform a leakage and procéder toujours à un predisporre un controllo
first und Funktionskontrolle function test. contrôle d´étanchéité et sia della tenuta che del
O.K. durch-führen. de fonctionnement. funzionamento.
Niemals Arbeiten durch- Never perform work if Ne jamais effectuer des In nessun caso si deb-
führen, wenn Gasdruck gas pressure or power is travaux sous pression et bono effettuare lavori in
oder Spannung anliegt. applied. No naked flame. sous tension. Eviter toute presenza di pressione
Offenes Feuer vermeiden. Observe local regula- flamme ouverte. Observer gas o di tensione elettrica.
Örtliche Vorschriften be- tions. les réglementations. Evitare i fuochi aperti e
achten. osservare le prescrizioni
pubbliche.
Hinweise sind Personen- not heeded, the result de ces instructions, des quanto suddetto può im-
oder Sachfolgeschäden may be personal injury or dommages corporels ou plicare danni a persone
Silikonöle und flüchtige Avoid silicone oils and Eviter les huiles de Evitare oli siliconici e
Silikonbestandteile volatile silicones silicone et les eléments componenti siliconici
(Siloxane) in der (siloxanes) in the de silicone volatils volatili (silossani)
Umgebung vermeiden. environment. (siloxanes) dans nell’ambiente.
Fehlfunktion / Ausfall Malfunction/failure l’environnement. Possibile disfunzione /
möglich. possible. Dysfonctionnement / guasto.
panne possibles.
M/CD • Edition 02.10 • Nr. 227 048
7…8
D GB F I
(PED) und die Richtlinie Directive (PED) and the chauffe-bains à pression pressione (PED) e la direttiva
über die Gesamtener- Energy Performance of (PED) et la directive sur la per l‘efficienza dell‘energia
von Heizungsanlagen zur es in order to ensure a high installations de chauffage, afin la garanzia a lungo termine di
langfristigen Sicherstel- degree of efficiency over a de garantir à long terme des un alto grado di rendimento
lung von hohen Nutzungs- long term and, consequent- taux d‘utilisation élevés et par e con ciò di basso inquina-
graden und somit gering- ly, the least environmental conséquent une charge envi- mento ambientale. Ciò rende
ster Umweltbelastung. Es pollution. It is necessary ronnementale minimum. Il est necessaria la sostituzione
besteht die Notwendig- to replace safety-rele- nécessaire de remplacer les di componenti rilevanti dal
keit sicherheitsrelevante vant components after composants relatifs à la sé- punto di vista della sicu-
Komponenten nach Er- they have reached the curité lorsqu‘ils ont atteint rezza alla scadenza della
reichen ihrer Nutzungs- end of their useful life. la fin de leur vie utile. Cette loro durata di utilizzazione.
dauer auszutauschen. This recommendation recommandation ne s‘ap- Questo suggerimento vale
Diese Empfehlung gilt applies only to heating plique qu‘aux installations solo per impianti di riscal-
nur für Heizungsanla- appliances and not to de chauffage et non aux damento e non per impie-
gen und nicht für Ther- industrial heating proc- applications de processus ghi per processi termici.
mprozessanwendungen. esses. DUNGS recom- thermique. DUNGS recom- DUNGS consiglia detta
DUNGS empfiehlt den mends replacing such mande le remplacement, sostituzione in conformità
Austausch gemäss fol- components according conformément au tableau alla sottostante tabella:
gender Tabelle: to the following table: qui suit :

VIE UTILE
DUNGS recommande le rem-
placement au bout de :
UV-Flammenfühler
10.000 h
Sensore fiamma UV
M/CD • Edition 02.10 • Nr. 227 048
8…8
OIL PUMP TYPE E 1001
GEAR SIZES 4-6-7 E 1001
E 1001 - 11 - Ed 11 - Sept. 2002
This is a general specification leaflet ; for specific applications not PUMP

covered herein, contact Suntec. IDENTIFICATION
(Not all model combinations are available
The SUNTEC E 1001 oil pump incorporates a pressure regulating valve with Consult your Suntec representative)
cut-off function. Its design is basically similar to that of J pumps, but E pumps
can also be used with heavy oil.
E : Pressure regulation
APPLICATIONS
Gear set capacity
(see pump capacity curves)
- Light, medium and heavy oil.
- One or two-pipe system. Strainer
- Normally associated with in-line solenoid valve. C : 170 µm
N : 550 µm
PUMP OPERATING PRINCIPLE Shaft rotation

and nozzle location
The gear set draws oil from the tank through the built-in filter and transfers it to (seen from shaft end)
the valve that regulates the oil pressure to the nozzle line. All oil that does not A : clockwise rotation/
right hand nozzle.
go through the nozzle line will be dumped through the valve back to the return B : clockwise rotation/
line in two pipe installation or, if it is a one-pipe installation, back to the suction left hand nozzle.
port in the gear-set. In that case, the by-pass plug must be removed from the C : anti clockwise rotation/
return port and the return port sealed by steel plug and washer. left hand nozzle.
D : anti clockwise rotation/
The valve also has a cut-off function as follows : right hand nozzle.
During starting period when the gear-set speed is increasing, all the oil passes
through a special flat on the piston, back to the return. Once the speed reaches
a certain value and the flow can no longer pass through this flat, then the E 6 N C 1 001 6 P
pressure increases rapidly overcoming the valve spring force and opens the
valve.
Flange mounting
During the stop sequence, the gear-set speed slows down and the valve closes
when the gear-set capacity is lower than the flat flow. 001 : standard model
with cut-off function
The cut-on and cut-off speeds depend on the gear-set size and set pressure.
Bleed : Revision number
6 : for E4 and E6
Bleeding in two pipe operation is automatic, but it may be accelerated by 5 : for E7
loosening the plug in a pressure gauge port.
In one pipe operation, a pressure port must be opened to bleed the system. Installation
P : by-pass plug installed in return port
for two-pipe operation
Vacuum
Inlet
Oil under suction gauge port
Oil under pressure Gear set

By-passed oil
returned to tank,
or to suction
Back
to suction
Pressure
To nozzle
adjustment
Pressure
By-pass By-pass
gauge port
plug plug
removed inserted
Return ONE PIPE TWO PIPE
plugged INSTALLATION INSTALLATION Return
SUNTEC INDUSTRIES FRANCE - 1, rue Lavoisier - BP 102 - 21603 LONGVIC Cedex - Tel. (33) 3 80 70 60 70 - Fax (33)3 80 70 61 11- http://www.suntec.fr
Pump capacity
Capacity (L/h)
TECHNICAL DATA 400
General 300 E7
Mounting Flange mounting according to EN 225.
Connection threads Cylindrical according to ISO 228/1 200
Inlet and return G 1/2 10 15 20 25 30 Pressure
Nozzle outlet G 1/4 Capacity (L/h) (bars)
300
Pressure gauge port G 1/8
Vacuum gauge port G 1/2
E6
Valve function Pressure regulating and cut-off
200
Strainer Open area : 45 cm ²
Opening size : C = 170 µm E4
N = 550 µm
100
Shaft Ø 11mm according to EN 225. 10 15 20 25 30 Pressure
By-pass plug Inserted in return port for 2 pipe system; (bars)
Viscosity = 200 cSt
to be removed with a 3/16" Allen key for 1 pipe system. 20 cSt
5 cSt - Rated speed = 2850 rpm
Weight 4 kg
Data shown take into account a wear margin. Do not
oversize the pump when selecting the gear capacity.
Power consumption
Power (W)
900
Hydraulic data
800
Nozzle pressure range 14 - 30 bars 700
E7
Delivery pressure setting 20 bars 600
Operating viscosity 2,8 - 450 mm²/s (cSt)
500
Oil temperature 0 - 90°C in the pump.
400
Inlet pressure 1,5 bars max.
300
Return pressure 1,5 bars max. 10 15 20 25 30 Pressure
Power (W) (bars)
Suction height 0,45 bars max. vacuum to prevent air separation from oil.
700
Rated speed 3600 rpm max.
600
Torque (@ 45 rpm) 0,30 N.m E6
500
400
E4
300
200
100
10 15 20 25 30 Pressure
Viscosity = 200 cSt (bars)
20 cSt
5 cSt - Rated speed = 2850 rpm
PUMP DIMENSIONS Example shows "C" rotation and nozzle outlet.
88 80 99
48 92
24

Suction or
Pressure
vacuum gauge port
gauge port
28
91
A
Ø41 Ø54 Ø10,5
Return and Vacuum
A
47
128
internal gauge port
by-pass plug or suction

A-A Nozzle outlet Pressure
10 adjustment
22 Ø 11

37 59 max 43
We reserve the right to change specifications without prior notice. E 1001 - 11 - Ed 11 - Sept. 2002
OIL PUMP TYPE AJ
GEAR SIZES 4-6 AJ
AJ - 11 - Ed 7 - Jan. 2004
This is a general specification leaflet; for specific applications not PUMP

covered herein, contact Suntec. IDENTIFICATION
(Not all model combinations are available
The SUNTEC AJ oil pump is the basic model incorporating a pressure Consult your Suntec representative)
regulating valve with cut-off*.
AJ : basic valve
APPLICATIONS
Gear set capacity
(see pump capacity curves)
- Light oil.
- One or two-pipe system. Shaft rotation
- Normally associated with in-line solenoid valve. and nozzle location
(seen from shaft end)
A: clockwise rotation /
PUMP OPERATING PRINCIPLE right hand nozzle.
B: clockwise rotation /
The gear set draws oil from the tank through the built-in filter and transfers it to left hand nozzle.
the valve that regulates the oil pressure to the nozzle line. All oil that does not C: anti clockwise rotation /
left hand nozzle.
go through the nozzle line will be dumped through the valve back to the return D: anti clockwise rotation /
line in two pipe installation or, if it is a one-pipe installation, back to the suction right hand nozzle.
port in the gear-set; in that case, the by-pass plug must be removed from the
vacuum gauge port and the return port sealed by steel plug and washer. Pressure range
C : 10-20 bars
The valve also has a cut-off function* as follows : E : 10-30 bars
During starting period when the gear-set speed is increasing, all the oil passes
through a bleed slot in the piston, back to the return. Once the speed reaches
AJ 6 C C 1 000 3 P
a certain value and the flow can no longer pass through this bleed slot, then the
pressure increases rapidly overcoming the valve spring force and opens the valve.
During the stop sequence, the gear-set speed slows down and the valve closes Flange mounting
when the gear-set capacity is lower than the bleed slot flow. 000 : standard model
The cut-on and cut-off speeds depend on the gear-set size and set pressure. cut-off function
002 : by-pass nozzle
Bleed : no cut-off function
Bleeding in two pipe operation is automatic, but it may be accelerated by 003 : Ø 8 mm shaft
cut-off function
loosening the plug in a pressure gauge port.
In one pipe operation, a pressure port must be opened to bleed the system. Revision number
Installation
* Owing to the presence of the nozzle by-pass hole, AJ 1002 models have no cut- P : by-pass plug installed
off function. Cut-off must be provided by an external solenoid valve. in vacuum gauge port
for two-pipe operation
Pressure
gauge port
Pressure To nozzle
adjustment
Gear set
Back
to suction
By-pass By-pass
plug plug Oil under suction
removed inserted
Oil under pressure

Vacuum By-passed oil
gauge port returned to tank,
or to suction
ONE PIPE Return TWO PIPE
INSTALLATION plugged Return Inlet INSTALLATION
SUNTEC INDUSTRIES FRANCE - 1, rue Lavoisier - BP 102 - 21603 LONGVIC Cedex - Tel. 33 3 80 70 60 70 - Fax 33 3 80 70 61 11 - http://www.suntec.fr
TECHNICAL DATA Pump capacity
Capacity (L/h)
350
General
300
Mounting Flange according to EN 225
Connection threads Cylindrical according to ISO 228/1
Inlet and return G 1/4 (see "Dimensions") 250
Nozzle outlet G 1/8 AJ 6
Pressure gauge port G 1/8
Vacuum gauge port G 1/8 200
Valve function Pressure regulating and cut-off*
(* except for 1002 models).
150
Strainer Open area : 30 cm2 AJ 4
Opening size : 120 x 150 mm2
Shaft AJ 1000/1002 : Ø 11mm (7/16") 100
AJ 1003 : Ø 8 mm according to EN 225. 5 10 15 20 25 30 Pressure
(bars)
By-pass plug Inserted in vacuum gauge port for 2 pipe system; Viscosity = 5 cSt - rated speed = 2850 rpm
to be removed with a 4 mm Allen key for 1 pipe system.
Data shown take into account a wear margin.
Weight 1,7 kg Do not oversize the pump when selecting the
gear capacity.
Hydraulic data Power consumption

Power (W)
600
Nozzle pressure range C : 10 - 20 bars
E : 10 - 30 bars
AJ 6
Delivery pressure setting 12 bars 500
Operating viscosity 2,8 - 75 mm²/s (cSt)
Oil temperature 0 - 60°C in the pump.
400
Inlet pressure 2 bars max.
Return pressure 2 bars max.
AJ 4
Suction height 0,45 bars max. vacuum to prevent air separation from oil. 300
Rated speed 3600 rpm max.
Torque (@ 45 rpm) 0,30 N.m
200
100
5 10 15 20 25 30 Pressure
(bars)
Viscosity = 5 cSt - Rated speed = 2850 rpm
PUMP DIMENSIONS Example shows "C" rotation and nozzle outlet.
71 A 41 51

B 118°

E
Ø 6,5
21
Ø54 Ø10,5 74
15
35 E
G1/4
E-E
13 21
13,5 13,5
Inlet and Return
D 70
C 92 with direct sealing
A B C D (sealing washers
(mm) (mm) Ø (mm) (mm) can be used too)
AJ 1000 80 42 11(7/16") 10 Suction Nozzle outlet Vacuum gauge port and
internal by-pass plug
AJ 1002 80 42 11(7/16") 10
AJ 1003 42 15 8 7
Return Pressure gauge port Pressure adjustment
We reserve the right to change specifications without prior notice. AJ - 11 - Ed 7 - Jan. 2004
THERMAX LIMITED THERMAX
Heating SBU, C&H Division SUSTAINABLE SOLUTIONS
D-13, M.I.D.C. Industrial Area, R. D. Aga Road ENERGY & ENVIRONMENT
Chinchwad, Pune - 411019, INDIA
Tel.: +91 - 20 - 27470436, 27475941/ 42, 66122100
Boilers & Heaters Water & Waste Solutions
Fax: +91 - 20 - 27472049
Absorption Cooling Air Pollution Control
E-mail: heating.enquiries@thermaxindia.com
Captive Power Chemicals
REGIONAL OFFICES  New Delhi  Mumbai  Kolkata  Chennai  Ahmedabad  Bangalore  Hyderabad  Pune INTERNATIONAL OFFICES  UK  USA 
UAE  Germany  Belgium  Denmark  Russia  Saudi Arabia  Thailand  Malaysia  Phillipines  China  Brazil  Peru  Chile  Bangladesh  Srilanka  Kenya 
In view of our constant endeavor to improve the quality of our products, we reserve the right to alter or change specifications without prior notice. All photographs shown in this publication are representative in
purpose and are to be used for reference purpose only. Whilst this information is given in good faith, no warranty or representation is given concerning such information which must not be taken for establishing any
contractual or other commitment binding on Thermax Ltd. For actual details and specifications, please refer the Thermax offer document.

Thermopac / Deltatherm Revomax / Revomax Plus

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REVOMAX / REVOMAX PLUS ( RXA , RXD )

REVOMAX / REVOMAX PLUS

(FUEL : OIL / GAS FIRED)

COOLING & HEATING DIVISION CD 34/177

PRESSURE: 10.54 & 17.5 KG/CM2G

FUEL: COAL (INDIAN, IMPORTED) / WOOD / LIGNITE /

PUBLICATION NO. : PIFDCM0035 REV : 01

ADDRESS TEL NO. FAX NO.

COOLING & HEATING DIVISION CD 34/177

AVENUE CHARLES THIELEMANS, 32(0) -

C/O. PT, MITRABINA REKANIAGA, +62-21-83787473

P O BOX 17156, JEBEL ALI,

THERMAX EUROPE LTD

COOLING & HEATING DIVISION CD 34/177

BLDG. NO. 114, FLAT NO. 68 00-73-272-543582 00-73-272-543582

THERMAX INC, Phone: +1 248 207 0541

C/O, PRO-ACTIVE MH RESOURCES 00-60-3-21619801/03/04 00-60-3-21612685

C/O, MIZAMI NIGERIA LTD., 00-234-805-1992790 /

THERMAX LIAISON OFFICE

C/o. GULF POWER INTERNATIONAL, 00966 55 391 5403

C/O LALAN ENGINEERING LTD., 00 – 94716823020

C/O. UNIMEX INTER-TRADE INC., 0062 24537851,

THERMAX HONGKONG LIMITED 00-852 2961 4041 00-852 2961 4042

COOLING & HEATING DIVISION CD 34/177

MODEL : RXA – 02,03,04,05,06

(FUEL : OIL / GAS FIRED)

COOLING & HEATING DIVISION CD 34/177

(FUEL : OIL / GAS FIRED)

COOLING & HEATING DIVISION CD 34/177

CHAPTER 1 : PREFACE ................................................................................................................................ 2

CHAPTER 2 : TECHNICAL SPECIFICATIONS ........................................................................................ 3

CHAPTER 3 : REVOMAX / REVOMAX PLUS IN GENERAL.................................................................. 6

CHAPTER 6 : BOILER HOUSE................................................................................................................... 10

CHAPTER 8 : FUEL STORAGE & HANDLING....................................................................................... 12

CHAPTER 10 : WATER SUPPLY................................................................................................................ 22

CHAPTER 12 : ELECTRICAL POWER SUPPLY ..................................................................................... 26

COOLING & HEATING DIVISION 1 CD 34/177.

This manual is prepared with a view to:

a. assist you in making a proper installation,

b. assist you in understanding the construction and operation of the boiler,

c. assist you in starting and stopping the boiler,

d. guide you on routine maintenance required, and,

e. help you in locating the exact fault, and setting it right.

We have a team of Service Engineers to guide you in proper installation of your

COOLING & HEATING DIVISION 2 CD 34/177.

CHAPTER 2: TECHNICAL SPECIFICATIONS

S.N Description Unit RXA-02 RXA-03 RXA-04 RXA-05 RXA-06

10. Pressure parts - Non IBR

11. Electric supply - 415 / 380 (± 6%)V , 50(± 3%)Hz,

Blower (3000 rpm) kW 0.75 0.75 0.75 1.5 1.5

Water pump motor

COOLING & HEATING DIVISION 3 CD 34/177.

S N. Description Unit RXD-04 RXD-06 RXD-850

COOLING & HEATING DIVISION 4 CD 34/177.

COOLING & HEATING DIVISION 5 CD 34/177.

COOLING & HEATING DIVISION 6 CD 34/177.

CHAPTER 4: "DO"S AND "DON'T"S FOR REVOMAX / REVOMAX

COOLING & HEATING DIVISION 7 CD 34/177.

14. A leaky gasket can cause unscheduled shut-down in boiler operation. It is

15. Economiser air vent line should be rising vertically up.

For gas fired unit

COOLING & HEATING DIVISION 8 CD 34/177.

COOLING & HEATING DIVISION 9 CD 34/177.