Jinhai BWTS

FINAL PACKAGE
GEA CRM No.: 30034667

Product: Ballast Master
Vessel Name: MSC Bianca
IMO: 9770749
Revision 1
Copyright © 2017 by Trojan Technologies All Rights Reserved
Trojan MarinexTM holds several patents for the system and all adaptations/changes that are in conflict with our patents and property rights are
illegal without our written consent. All warranties will be invalid if the customer makes changes on the system without approval.
Trojan Marinex™ Original Instructions

TABLE OF CONTENTS
DEVICE LIST
Trojan Marinex™ BWT - Device List
TECHNICAL OVERVIEW
Technical Specification - Trojan Marinex BWT
Technical Data Sheet
P&ID - MX0303
ELECTRICAL DRAWINGS
Wire Diagram Overview - MX0305
Wire Diagram Interconnect - MX0306
Wire Diagram Power Distribution Cabinet - 507585G
Power Distribution Cabinet Assembly - 507587G
Control Cabinet Assembly - 507581G
Wire Diagram Control Cabinet - 507579
Junction Box Assembly - 507885G
MANUFACTURER’S MANUALS
Trojan Marinex BWT - Operation and Maintenance Manual
Process Master FEP300 Electromagnetic Flowmeter
Bray Controls - Operation and Maintenance Manual - Resilient Seated Butterfly Valves
Bray - Operation and Maintenance Manual - Series 6A Electro-Pneumatic Positioner
Bray - Operation and Maintenance Manual - Series 92/93 Pneumatic Actuator
Drain Pump Service Manual
CERTIFICATES
DNV Type Approval Certificate - Trojan Marinex
DNV Type Approval Certificate - Flow Transmitter

IMPORTANT CONTACTS
Visit us at http://www.gea.com and select
Service to access our Service Hotline. Select
Marine Application and your country to be
directed to a service representative.
HEAD OFFICE - CANADA

Trojan Technologies
3020 Gore Road,
London, Ontario,
Canada, N5V 4T7
Tel.: +519 457 3400
Fax: +519 457 3030
http://www.trojanmarinex.com
If you are unable to reach your local

representative and have a technical emergency,
contact Trojan Marinex Service:
Email: service@trojanmarinex.com

DEVICE LIST
PID Code (Reference P&ID Scope of Drawing
Scope ID Quantity Description Usage Size/Type Nominal Bore Power MX0303 Part-No Supply Reference/Comments
Trojan
1 2 Treatment Unit - BWT 1000 1000 -- Horizontal Right/60Hz 1000S-WRN6B Marinex MX0288
ASSEMBLED SCOPE ID 1 Trojan
2 2 Filter Motor Power by Marinex PDC M1100 (1000S-WVN6B) Marinex MX0288
Inlet ASSEMBLED SCOPE ID 1 Trojan
3 2 Pressure Sensor -- Power by Marinex PDC PT1100 (1000S-WVN6B) Marinex MX0288
Outlet ASSEMBLED SCOPE ID 1 Trojan
4 2 Pressure Sensor -- Power by Marinex PDC PT1101 (1000S-WRN6B) Marinex MX0288
5 2 Temperature Sensor -- Power by Marinex PDC TT1100 (1000S-WRN6B) Marinex MX0288
6 1 UVI Sensor -- Power by Marinex PDC AE1100/AT1100 (1000S-WRN6B) Marinex MX0288
7 2 Pressure Gauge -- N/A PI1100 (1000S-WRN6B) Marinex MX0288
Low ASSEMBLED SCOPE ID 1 Trojan
8 2 Level Sensor -- Power by Marinex PDC LS1100 (1000S-WRN6B) Marinex MX0288
9 2 Level Sensor -- Power by Marinex PDC LS1101 (1000S-WRN6B) Marinex MX0288
10 2 Mounting Leg kits -- N/A Horizontal (1000S-WRN6B) Marinex MX0289
11 2 Fresh Water Fill Valve 1" BSPP Female Power by Marinex PDC FV1103 (1000S-WRN6B) Marinex MX0289
12 2 Filter Chamber Drain Valve Power by Marinex PDC FV1106 (1000S-WRN6B) Marinex MX0303
13 2 UV Chamber Drain Valve Power by Marinex PDC FV1101 (1000S-WRN6B) Marinex MX0303
14 2 Drain Pump DN32 Power by Marinex PDC P1201 (1000S-WRN6B) Marinex MX0289
120VAC +/-5%, 60Hz, 1ᶲ Trojan
15 2 CC ASSY MRX, Inline +PE Customer Power Supply 507581-001 Marinex MX0300
460VAC +/-5%, 60Hz 3ᶲ Trojan
16 2 Power Distribution Cabinet -- Delta + PE Customer Power Supply 507587-1000460 Marinex MX0301
Trojan
17 2 Junction Box Power by Marinex PDC N/A Marinex MX0288
Trojan
18 2 Ballast Inlet, Butterfly valve, pneumatic actuation Waferbody DN400 Power by Marinex PDC FV1000 507311-400WPF Marinex MX0303
Trojan
19 2 Deballast Inlet, Butterfly valve, pneumatic actuation Waferbody DN400 Power by Marinex PDC FV1001 507311-400WPF Marinex MX0303
Trojan
20 2 Proportional Butterfly outlet valve, pneumatic actuation Waferbody DN400 Power by Marinex PDC FCV1200 507311-400WPP Marinex MX0303
Proportional butterfly backwash valve, pneumatic Trojan
21 2 actuation Waferbody DN200 Power by Marinex PDC FV1102 507311-200WPP Marinex MX0303
Trojan
22 2 Backwash Swing Check valve DN200 NA CV1102 507357-20016EPDM Marinex MX0303
Trojan
23 2 Drain Swing Check Valve DN50 NA CV1201 507357-05016EPDM Marinex MX0303
Trojan
24 2 Flow Meter EN1092-1, PN10…16 Power by Marinex PDC FE1200/FT1200 907800-40015000x Marinex MX0303
Trojan
25 2 Aux Control Cabinet 120+/-5%, 60Hz, 1ᶲ +PE Customer Power Supply 507590 Marinex MX0307
TECHNICAL OVERVIEW
TECHNICAL SPECIFICATION
Trojan MarinexTM BWT

Inline Lamp Driver Configuration
Product Overview
General Description
Specifically designed for the marine environment, the
Trojan Marinex BWT is unique, integrating two treatment
processes, filtration and UV disinfection in one single unit.
With a small footprint, lower power draw, and minimum
pressure loss, the system is well suited to both newbuild
and retrofit installations. With a wide operational range,
the system performace is not impacted by temperature or
salinity.
Operation is fully-automated and can be controlled

through the ship’s automation system, or through a
touchscreen interface provided with the system.
During ballasting operations, water is treated with filtration and UV. During deballasting
operations, water is only treated with UV.
The Trojan Marinex BWT consists of the following principal components;
Treatment Unit
• TrojanUV Solo Lamp™ Technology
• Custom-designed Trojan Marinex filtration system
• Automatic lamp cleaning system to ensure maximum UV output
• Automatic drain and fill system to inhibit corrosion of wetted components
• Junction box for all cable and control connections
Electrical and Control Cabinets

• Two wall mounted cabinets house main system power, breakers, PLC and other system control
components
• Distribute power to all components of the Treatment Unit
Environmental Advantages of Trojan Marinex

• Chemical-free operation and cleaning
• Inherently safe, does not produce hazardous gases or create carcinogenic disinfection by-products
• Non-corrosive, no risk to protective coatings
Version 4 July 2017 1

System Design and Features
Treatment Unit Design
The Trojan Marinex product suite includes seven models treating a range of flowrates. The design
of each model has been optimized for performance at the maximum flow in very challenging
water quality conditions.
Filter Technology
The Trojan Marinex filtration system was specifically designed to address the unique challenges of
ballast water treatment, balancing removal rates and operability. Over five years of testing has
been conducted at IMO and USCG approved test facilities treating marine, brackish and
freshwater. Engineered with increased surface area, inherent filter redundancy, and a highly
efficient cleaning system to provide uninterrupted operation even in very challenging water
conditions.
Automatic Filter Backwash System

Each Treatment Unit is equipped with an automatic filter backwash system. The system
systematically targets individual filter elements, adjusting back pressure based on the cleanliness
of each element to recover the filter to a clean state without manual intervention. The treatment
process is not impacted during a backwash sequence and the remaining filter elements remain
operational to treat ballast water.
UV Disinfection
UV light provides rapid, effective inactivation of ballast water organisms through a physical
process. When organisms are exposed to the germicidal wavelengths of UV light, they are
rendered incapable of reproducing.
Leveraging the TrojanUV Solo Lamp Technology, the Trojan Marinex BWT is engineered to stabilize
flow around the UV lamps and optimize for maximum disinfection performance. The proprietary
lamp technology provides consistently lower power draw, regardless of salinity, temperature, or
water quality, long lamp life and proven performance with over 50 million operating hours
throughout many water treatment applications.
Lamp power is maintained at 100% throughout ballasting and deballasting operations. This
minimizes the operator involvement, setup and risk of inadequate treatment during rapidly changing
water quality conditions.

Inline TrojanUV Solo Lamp Driver
Mounted directly to the Treatment Unit, the Inline Lamp Driver provides power to each TrojanUV
Solo Lamp. The factory sealed units eliminate the need for additional cabinets, cooling and lamp
cabling.
Each inline lamp driver provides:
• Advanced controls to maximize the lamp life and UV output
• High electrical efficiency (>95%) and reduces wasted energy and active cooling requirements
• LED indicators enable crew to easily monitor status
Ultraviolet Intensity (UVI) Sensor

Every model is equipped with a UVI sensor, approved to a European standard (DVGW), to monitor
the UV output of the lamps. In the event of low UV output, the system initiates a lamp cleaning
cycle. If the condition is not resolved after a cleaning cycle an alarm occurs to warn that operating
conditions are outside of the approved limits.
Automatic Lamp Cleaning System

Each TrojanUV Solo Lamp is housed in a quartz sleeve that can become fouled during regular
operation, reducing the amount of UV light available for treatment. The chemical-free cleaning
system removes any potential fouling without interrupting treatment operations. Lamp cleaning
occurs during startup, at the end of all treatment cycles and during a low UVI alarm. One group of
lamps is cleaned at a time and treatment continues during cleaning.
The lamp cleaning system consists of a wiper plate, which is magnetically coupled to a drive
cylinder. The system is powered by hydraulic fluid and is hermetically sealed and all connections
are located on the outside of the Treatment Unit (non-wetted area).
Level Sensors
The Treatment Unit is equipped with level sensors (one at the top, and one at the bottom). The
sensors are used to indicate water level in the Treatment Unit.
Pressure Sensors
Two pressure sensors, one on the inlet and one on the outlet, measure the pressure differential
across the filtration system and monitor for over pressurization.
Temperature Sensor
A temperature sensor monitors the Treatment Unit to prevent prolonged high temperature
conditions. The Treatment Unit can remain powered throughout periods with little or no flow
causing temperatures in the Treatment Unit to rise. If a high temperature condition occurs, a
cooling sequence will be initiated to maintain the temperature below the setpoint.
Power Distribution and Control Cabinets

The main system power and breakers are housed inside the Power Distribution Cabinet. One
Power Distribution Cabinet is used to provide power to each Treatment Unit.

Inside the Control Cabinet are the electronic components that control and monitor the entire
system, such as the programmable logic controller (PLC) and the touchscreen. The touchscreen
serves as the system’s operation and monitoring interface, providing access to all aspects of
operation and status at a glance. The Control Cabinet features built-in USB port, providing easy
transfer of data from the internal memory. One Control Cabinet is used to control and monitor up
to four Treatment Units installed on the same vessel.
Remote Control and Monitoring

In addition to the main Control Cabinet, the system can be monitored and controlled remotely
through the Ship Automation System or using optionally supplied touchscreen interfaces.
The Auxiliary Control Cabinet provides the ability to monitor and control up to four Treatment
Units via an Ethernet connection. The cabinet features a large touchscreen interface and is
designed to be wall mounted. Alternately, a stand-alone touchscreen for integration into an
existing ship panel can be provided.
Monitoring
The system automatically monitors and logs key components of the treatment process when the
BWTS is operational or by-passed. IMO and USCG regulations stipulate this data must be stored
for two years. GPS location can be logged by receiving a signal from the vessel’s GPS antenna
through the Ship Automation System. Data is easily retrievable electronically via a .CSV file.
Safety Features
The UV portion of the Treatment Unit has safety features that have been developed to prevent
personal injury:
• Power Disconnect – Electrical power to the UV lamp is safely isolated when the inline lamp driver is
removed.
• Emergency Stop – E-Stop buttons are provided on the Power Distribution Cabinet and the Control
Cabinet
• Door stays – each cabinet is equipped with hardware to secure the door in the open position when
power is off for maintenance purposes.
Assembly & Manufacturing

During assembly, each Treatment Unit is pressure tested beyond its working pressure to ensure it
exceeds the designed working pressure and meets good manufacturing principles. Additionally,
key components are factory tested to ensure good working order, including UV lamps, inline lamp
drivers, filters and wiper drive cylinders.

Treatment Process Overview
System Start-Up
The system start-up sequence begins when an operation mode is selected. The UV lamp initiation
(warm-up) sequence begins. In ballasting mode, the system will request the operator to turn on
the pump and a filter backwash will occur. Once completed, a ‘Ready-To-Treat’ signal will be sent
to the vessel.
Treatment
Operation Mode: Ballasting
Filtration is the first stage of treatment to remove particles and organisms from entering the
ballast tanks. Water than flows through the UV chamber targeting all remaining organisms.
Treated water is directed to the ballast water tanks.
Ship Automation System
Ready Ballast System Request Stop Ready

for Flow Pump Run Ready to Treat Request to Stop
To Treat Pump
Filtration + UV System
System Startup Offline
Treatment Shutdown
Operation Mode: Deballasting

Water is treated with only UV then discharged overboard.
Ship Automation System
System Stop Ready

Request Ready Ballast
Ready Request to Stop
to Treat for Flow Pump Run
To Treat Pump
System
System Startup UV Treatment Offline
Shutdown
Operation Mode: Tank Stripping

If local water is used during the stripping operation, the combined flow from the ballast tank
and local water is piped to the deballast inlet and treated with UV only, similar to deballasting
mode. The maximum flow rate during stripping is 1/3 (one-third) the TRC.

System Shutdown
When the system has received the stop request the Treatment Unit will begin the shutdown
sequence. The outlet valve is closed and the UV lamps are turned off. Once completed, a ‘Ready-
to-Stop-Pump’ signal will be sent to the vessel. When the operator stops the pump, the inlet valve
closes and the system will transition into the draining sequence. Once the draining sequence is
complete, the Treatment Unit will re-fill with technical or potable water to inhibit corrosion of
wetted components.
Offline
The system will stay in this state until a ballast, deballast or stripping mode has been requested,
or if a system alarm is activated while in the offline state.

Version 4.0, June 2017
Technical Data Sheet - Standard Product - Inline Driver Configuration
BWT 150 BWT 250 BWT 500 BWT 750 BWT 1000 BWT 1250 BWT 1500
General
Treatment Rated Capacity (TRC) (m3/hr) 150 250 500 750 1000 1250 1500
3
Backwash Flow (min) (m /hr) 50 50 100 100 150 150 150
Combined Flow (treated+backwash) (m3/hr) 200 300 600 850 1150 1400 1650
Ballast Pump Recommendation Treated Flow + Backwash Flow with min 2.5 bar at the inlet of the Trojan Marinex BWT
System Pressure Loss (with clean filters) 0.2 bar

Maximum Installed Power (kW) 9.2 14.2 26.2 33.2 44.2 57.2 64.2
Control Cabinet: Power Distribution Cabinet (Select One):

120 - 240 VAC ± 5% - 400 VAC ± 5%, 3 Phase DELTA + PE, 50 Hz
Operating Voltages and Frequencies 50/60 Hz Single Phase + PE - 440 VAC ± 5%, 3 Phase DELTA + PE, 60 Hz
- 460 VAC ± 5%, 3 Phase DELTA + PE, 60 Hz
- 480 VAC ± 5%, 3 Phase DELTA + PE, 60 Hz
Flange Standard FLANGE, ISO 7005-1 PN 10 TYPE 03
Inlet / Oulet Flange Sizes (DN) 150 200 300 400 400 500 500
Backwash Flange Sizes (DN) 100 100 150 150 200 200 200
Drain Flange Sizes (DN) 32 32 32 32 32 32 32
Technical or Potable Water Fill Connection 1 Inch BSPP
Ambient Temperature 0° C to 55° C
Temperature for Wetted Components No slush or ice. Treatment not impacted by varying water temperatures.
Treatment Unit (TU)
Material 316L Stainless Steel or Better
Maximum Operating Pressure (bar) 6
Number of Lamps 14 24 48 62 84 110 124
TM
TrojanUV Solo Lamp (Low Pressure Amalgam), 500 W
UV Technology Inline Lamp Driver mounted directly to Treatment Unit
Automatic Chemical-Free Cleaning
Number of Filter Elements 8 12 24 36 48 55 69
Filter Mesh 32 µm, Super Duplex
Automatic Backwash Cleaning. 0.25 bar pressure differential triggers a cleaning cycle. ≤ 0.1 bar pressure differential stops a
Filter Cleaning
cleaning cycle.
Vertical Orientation
2.2 x 1.0 x 1.3 2.3 x 1.1 x 1.6 2.4 x 1.1 x 1.7 2.5 x 1.6 x 2.0 2.6 x 1.7 x 2.2 2.7 x 1.9 x 2.4 2.7 x 2.0 x 2.4
Dimensions H × W × D (meters)
Horizontal Orientation
1.4 x 1.8 x 1.3 1.4 x 2.0 x 1.6 1.5 x 2.2 x 1.7 1.8 x 2.4 x 2.0 2.0 x 2.4 x 2.2 2.2 x 2.5 x 2.4 2.4 x 2.5 x 2.4
Dimensions H × W × D (meters)
Weight - Dry (kg) each 760 1300 1500 2100 3100 3400 4600
Weight - Wet (kg) each 1300 2200 2600 4100 5500 7700 8900
Technical or Potable Water Fill Volume m3 (estimated) 0.6 0.9 1.1 2.0 2.4 4.3 4.3
Filter Motor
Quantity Per Treatment Unit 1
Weight (kg) 25
Construction and Standard Colour1 Squirrel cage induction motor, IP65, TUFF-316 Canadian GRAY (10-0322-05)
Powered by Trojan Marinex BWT Power Distribution Cabinet

Supply Voltage (VAC) and Frequency
(380 – 420 VAC± 5%, 3 Phase, 50Hz or 280 - 440 VAC± 5%, 3 Phase, 60Hz)
Power (kW) 0.18
Motor RPM Dependent on Power Frequency; 50Hz – 1405 RPM; 60Hz - 1700 RPM
Type of Duty S1 (IEC) 100%

Thermal Class F
Installation Location Installed on Treatment Unit
7
Drain Pump
Weight (kg) 55
Squirrel cage induction motor, IP55, Nickel Aluminum Bronze Pump
Construction and Standard Colour1
Motor Colour: Munsell Blue 8B 4.5/3.25
Powered by Trojan Marinex BWT Power Distribution Cabinet
Supply Voltage (VAC) and Frequency
(400 VAC± 5% , 3 Phase, 50Hz or 460 VAC± 5%, 3 Phase, 60Hz)
Power (kW) 1.5
Motor RPM Dependent on Power Frequency; 50Hz – 2901 RPM; 60Hz - 3515 RPM
Type of Duty S1 (IEC) 100%
Thermal Calss F
Drain Valves
Valve Ball Valve, 3 PC, Full Port
Valve Body Type Threaded 1” NPT
Construction and Standard Colour1 Valve body, ball and stem: A995-4A DUPLEX, Seals: 15% RPTFE, Non Wetted Parts: SS304;
Maximum Working Pressure (bar) 68
Actuator Pneumatic, Single acting, Spring return, Fail Closed
Air Supply Maximum 8.25 BAR, Minimum 5.5 BAR
Air Supply Tube Size (mm) 6
Power Supply Powered by Trojan Marinex BWT Power Distribution Cabinet (24V DC)
Fill Valve
Valve Ball Valve, 3 PC, Full Port
Valve Body Type Threaded 1” NPT, Adapted to 1” BSPP for customer connection
Construction Valve body, ball and stem: A995-4A DUPLEX, Seals: 15% RPTFE, Non Wetted Parts: SS304
Maximum Working Pressure (bar) 68

Actuator Pneumatic, Single acting, Spring return, Fail Closed
Air Supply Maximum 8.25 BAR, Minimum 5.5 BAR
Air Supply Tube Size (mm) 6
Power Supply Powered by Trojan Marinex BWT Power Distribution Cabinet (24V DC)
Control Cabinet (CC)
Quantity Per Treatment Unit Minimum - 1 per 4 Treatment Units (same model); Maximum - 1 per Treatment Unit
Dimensions H × W × D (m) 0.7 x 0.6 x 0.3
Weight (kg) each 70
Construction and Standard Colour Wall mounted, IP 54, Powder Coated Mild Steel, RAL 7035
Supply Voltage (VAC) and Frequency 120 - 240 VAC ± 5% 50/60 Hz Single Phase + PE
Installation Location Within 100 meters of treatment unit.
Communication protocol Modbus TCP/IP or RS485
Programmable Logic Controller (PLC) Type Siemens ET 200 SP
Human Machine Interface Type Siemens TP 900 Comfort 23cm Touchscreen
8
Power Distribution Cabinet (PDC)
Quantity Per Treatment Unit 1 1
Dimensions H × W × D (m) 1.1 x 1.2 x 0.3 1.1 x 1.4 x 0.3
Weight (kg) each 150 175
Construction Wall mounted, IP 54, Powder Coated Mild Steel, RAL 7035
Select One At Time of Order:
400 VAC ± 5%, 3 Phase DELTA + PE, 50 Hz
Supply Voltage (VAC) 440 VAC ± 5%, 3 Phase DELTA + PE, 60 Hz
Installation Location Within 100 meters of treatment unit.
NOTES:
1. Standard colours of mechanical equipment are subject to change based on availability.
2. This document is provided for information purposes only and is subject to change. It is not to be used for detailed design or integration activities.
9
ELECTRICAL DRAWINGS
P10 P11 C1 C4 W1
P7 P12 P6 F1 F8 F12
P1 C3 C1 C2
C4
F1 F8 F9 F10 F11
F13 F14 F15 F16

F12
F17 F18 F19 F20
F2 F3 F4
W1 F5 F6 F7
W2 W3
W4 W5
P23 P18
P22 P17
P10
P26 P21 P16
P11
P25 P20 P9
P12 P7 P24 P19 P8

MANUFACTURER’S
MANUALS
Trojan Marinex™ BWT
Operation and Maintenance
User Manual
Original Instructions
Edition 7
© Trojan Technologies, 2017. All rights reserved. Printed in Canada. DC280101-07-04

2 Original Instructions
Table of Contents
Section 1 Specifications ....................................................................................................................... 7
Section 2 Safety Information ................................................................................................................ 9
2.1 Use of Hazard Information ........................................................................................................... 9
2.2 Precautionary Labels ................................................................................................................... 9
2.3 Safety Precautions..................................................................................................................... 11
2.4 Safety Features.......................................................................................................................... 13
Section 3 General Information............................................................................................................ 15
3.1 Patents and Permissions ........................................................................................................... 15
3.2 Abbreviations and Acronyms ..................................................................................................... 15
3.3 System Overview ....................................................................................................................... 16
3.3.1 Treatment Unit .................................................................................................................. 17
3.3.2 Control Cabinet (CC) ........................................................................................................ 20
3.3.3 Power Distribution Cabinet (PDC) .................................................................................... 20
3.3.4 Auxiliary Control Cabinet (Optional).................................................................................. 21
3.3.5 System Operation Modes ................................................................................................. 21
3.3.6 Monitoring ......................................................................................................................... 22
3.3.7 Alarm Conditions............................................................................................................... 22
3.4 General Overview ...................................................................................................................... 23
3.4.1 Water Quality Effects on Ballast Operation....................................................................... 23
3.5 Shipment and Storage ............................................................................................................... 24
3.5.1 Shipping Contents............................................................................................................. 24
3.5.2 How the Equipment is Shipped......................................................................................... 24
3.5.3 Storage Requirements before the Install .......................................................................... 24
3.5.4 Treatment Unit Weight ...................................................................................................... 25
3.5.5 Electrical Cabinet Weights and Dimensions ..................................................................... 25
Section 4 Lockout Tag Out.................................................................................................................. 27
4.1 Lockout Tag Out Procedure....................................................................................................... 27
4.1.1 Equipment Shutdown........................................................................................................ 27
4.1.2 Deactivate Energy Sources .............................................................................................. 27
4.1.3 Lockout Tag Out Energy Sources..................................................................................... 28
4.1.4 Verify the Lockout ............................................................................................................. 28
4.2 Remove the Lockout Tag Out .................................................................................................... 28
Section 5 Startup and Shutdown ....................................................................................................... 29
5.1 Pre-start Checklist...................................................................................................................... 29
5.2 Power on procedure for the Trojan Marinex BWT ..................................................................... 29
5.3 Power off procedure for the Trojan Marinex BWT ..................................................................... 29
5.4 Lay-up Procedure ...................................................................................................................... 29
5.5 Emergency Shutdown Procedure for the Trojan Marinex BWT ................................................. 30
Section 6 Operation............................................................................................................................. 31
6.1 Human Machine Interface (HMI)................................................................................................ 31
6.1.1 Home Screen .................................................................................................................... 31
6.1.2 Navigation Bar .................................................................................................................. 32
6.1.3 Multi-System Control Slide Out ......................................................................................... 32
6.1.4 System Brightness Adjustment Slide Out ......................................................................... 32
6.2 Screens...................................................................................................................................... 33
6.2.1 System Overview Screen.................................................................................................. 33
6.2.2 Treatment Unit Overview .................................................................................................. 34
6.2.3 System Control Slide Out Tab .......................................................................................... 35
6.2.4 Operator Settings .............................................................................................................. 36
6.2.5 P&ID Tag Settings ............................................................................................................ 37
6.2.6 Alarm Summary Screen .................................................................................................... 38
6.2.7 Alarm History Screen ........................................................................................................ 39
Original Instructions 3
Table of Contents
6.2.8 Information Screen ............................................................................................................40
6.3 System Control...........................................................................................................................40
6.3.1 Local Control .....................................................................................................................40
6.3.2 Remote Control .................................................................................................................40
6.3.3 SAS Control.......................................................................................................................41
6.4 Ballast Procedure (Local Control Mode) ....................................................................................41
6.4.1 Start Ballast Operations.....................................................................................................41
6.4.2 Stop Ballast Operations.....................................................................................................42
6.5 Deballast Procedure (Local Control Mode) ................................................................................43
6.5.1 Start Deballast Operations ................................................................................................43
6.5.2 Stop Deballast Operations.................................................................................................44
6.6 Stripping Procedure (Local Control Mode) .................................................................................45
6.6.1 Start Stripping Operations .................................................................................................45
6.6.2 Stop Stripping Operations .................................................................................................45
6.7 Maintenance Mode.....................................................................................................................46
6.8 Pause Procedure for the Trojan Marinex BWT ..........................................................................46
6.8.1 Automatic Pause ...............................................................................................................46
6.8.2 Manual Pause....................................................................................................................47
6.9 Log In .........................................................................................................................................47
6.10 Downloading Monitoring Data from Data Logger .....................................................................47
Section 7 Maintenance.........................................................................................................................49
7.1 Maintenance Schedule...............................................................................................................49
7.2 Tools and Materials ....................................................................................................................49
7.2.1 Torque Chart .....................................................................................................................50
7.2.2 Assembly Fluids ................................................................................................................50
7.3 Manual Technical or Potable Water Fill......................................................................................51
7.3.1 UV Lamp Cleaning - Maintenance Mode...........................................................................51
7.3.2 Backwash - Maintenance Mode ........................................................................................52
7.4 Depressurize and Drain Treatment Unit.....................................................................................52
7.5 TrojanUV Solo Lamp ..................................................................................................................52
7.5.1 Storage of Used UV Lamps...............................................................................................52
7.5.2 Safety Information for UV Lamps ......................................................................................52
7.5.3 Remove and Install a UV Lamp.........................................................................................53
7.5.4 Clean UV Lamps Manually ................................................................................................54
7.5.5 Remove a UV Cartridge ....................................................................................................55
7.5.6 Install a UV Cartridge ........................................................................................................55
7.5.7 Replace the Wiper Seals ...................................................................................................56
7.6 UVI Sensor .................................................................................................................................58
7.6.1 Remove and Replace the UV Sensor and Sensor Window ..............................................58
7.7 Remove and Replace the Level Sensor.....................................................................................61
7.8 Remove and Replace the Temperature Sensor.........................................................................62
7.9 Replace the Air Eliminator..........................................................................................................63
7.9.1 Verify the Air Eliminator Is Working ...................................................................................64
7.10 Replace the Pressure Sensor ..................................................................................................64
7.11 Filter .........................................................................................................................................65
7.11.1 Replace a Filter Element .................................................................................................65
7.11.2 Clean the Filter Element ..................................................................................................66
7.11.3 Backwash Pads (Top) .....................................................................................................67
7.11.4 Backwash Pad (Bottom) ..................................................................................................68
7.12 Inline UV Lamp Driver LED Fault Indication ............................................................................69
Table of Contents
Section 8 Troubleshooting.................................................................................................................. 71
Section 9 Replacement Parts ............................................................................................................. 77
9.1 Scheduled Maintenance Parts ................................................................................................... 77
9.2 Recommended On Board Spares ............................................................................................. 77
9.3 Identifying the Configuration of your BWTS............................................................................... 78
9.4 Replacement Parts Overview .................................................................................................... 78
9.5 Filter System .............................................................................................................................. 79
9.5.1 Gear Motor........................................................................................................................ 79
9.5.2 Drive Plate Cover.............................................................................................................. 80
9.5.3 Filter Assembly ................................................................................................................. 81
9.5.4 Filter Element ................................................................................................................... 82
9.6 UV System ................................................................................................................................. 83
9.6.1 UV Lamp Cartridge Assembly........................................................................................... 84
9.7 Instrumentation, Technical Fill and Air Vents ........................................................................... 86
9.7.1 UV Sensor......................................................................................................................... 89
9.7.2 M12 Sensor Cable ............................................................................................................ 90
9.7.3 H-Drive Power Cable ........................................................................................................ 90
9.8 Drain System ............................................................................................................................ 90
9.8.1 Drain Pump ...................................................................................................................... 92
9.9 Power Distribution Cabinet ........................................................................................................ 92
9.10 Control Cabinet ........................................................................................................................ 92
Table of Contents
Section 1 Specifications
Specifications are subject to change without notice.
Specifications
BWT 1000
BWT 1250
BWT 1500
Model
BWT 150
BWT 250
BWT 500
BWT 750
Flow
Treatment Rated Capacity
150 m3/hr 250 m3/hr 500 m3/hr 750 m3/hr 1000 m3/hr 1250 m3/hr 1500 m3/hr
(As per Type Approval Certificate)
Equipment Limitations
The UV Intensity, as measured by the UV Sensor, must be equal to or greater than
Minimum UVI
2.0mW/cm2
Salinity Salinity is not a limiting condition of the system
Ambient Temperature Range 0 °C to 55 °C
Temperature for Wetted
No slush or ice. The treatment process is not impacted by varying water temperatures
Components
pH The process of UV treatment is not impacted by pH
Maximum Operating Pressure 6 bar
Specifications
Section 2 Safety Information
Please read this entire manual before operating this equipment. Pay attention to all danger, warning and
caution statements in this manual. Failure to do so could result in serious personal injury or damage to the
equipment.
Make sure that the protection provided by this equipment is not impaired. Do not use or install this
equipment in any manner other than that specified in installation manual.
2.1 Use of Hazard Information
DANGER
Indicates a potentially or imminently hazardous situation which, if not avoided, will result in death or serious
injury.
WA R N I N G
Indicates a potentially or imminently hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION
Indicates a potentially hazardous situation which, if not avoided, could result in minor or moderate injury.
NOTICE
Indicates a situation that is not related to personal injury.
2.2 Precautionary Labels

Read all labels and tags attached to the instrument. Personal injury or damage to the instrument could
occur if not observed.
Electrical equipment marked with this symbol may not be disposed of in European public disposal
systems. In conformity with European local and national regulations (EU Directive 2002/96/EC),
European electrical equipment users must now return old or end-of life equipment to the Producer for
disposal at no charge to the user.
Note: For recycling, please contact the equipment producer or supplier for instructions on how to
return end-of-life equipment, producer-supplied electrical accessories, and all auxiliary items for
proper disposal. No equipment is to be returned without authorization. Local recycling programs may
be used. For the manufacturer recycling UV lamp program or producer-supplied electrical
accessories and auxiliary items, contact the equipment supplier for proper disposal instructions.
Hg This symbol indicates there is Mercury present.
This is the safety alert symbol. Obey all safety messages that follow this symbol to avoid potential
injury. If on the instrument, refer to the instruction manual for operation or safety information.
This symbol indicates that a risk of electrical shock and/or electrocution exists.
This symbol indicates that the marked item has stored energy. Obey procedures to wait 5 (five)
minutes after disconnecting main power to allow stored energy to dissipate.
This symbol indicates that the marked item is pressurized. Obey all procedures to safely release
pressure.
This symbol indicates a potential pinch hazard.
Safety Information
This symbol indicates a fork lift hazard.
This symbol indicates to maintain adequate clearances to prevent any impact if equipment swings
during lift.
This symbol indicates that a trained and competent lifting operator should be used to move the
equipment.
This symbol indicates a potential crush hazard.
This symbol indicates there is a potential UV hazard. Proper protection must be worn.
UV
This symbol indicates that the marked item can be hot and should not be touched without gloves.
This symbol indicates the presence of devices sensitive to Electrostatic Discharge (ESD). Proper care
must be taken to prevent damage to the equipment.
This symbol indicates that the marked item should not be touched.
This symbol indicates that a risk of person injury exists from a hazardous energy source, and that all
appropriate lockout tag out procedures must be obeyed.
This symbol indicates safety glasses with side protection must be worn as a minimum added
protection.
This symbol indicates a safety glasses with side protection is required for protection against UV
exposure.
This symbol indicates that a full face shield is required for protection against intense UV exposure.
This symbol indicates gloves must be worn.
This symbol indicates safety boots must be worn.
This symbol indicates that the operator must read all available documentation to perform required
procedures.
Safety Information
2.3 Safety Precautions
Read the safety precautions in this section before doing maintenance, service or repair. Obey the
instructions in the safety precautions. Failure to follow the instructions in the safety precautions can result in
serious injury or death.
DANGER
Arc Flash and Shock Hazard - Live Electrical Circuit Present. Hazardous Voltage.
• Failure to follow these instructions will result in electrical shock, injury or death from electrocution.
• Equipment should be accessed by competent personnel only.
• Devices inside this equipment contain stored energy.
• NEVER work inside this equipment until at least 5 (five) minutes after disconnecting main power to
allow stored energy to dissipate.
• Lockout tag out all sources of power before performing any inspection, repair, or maintenance.
There may be more than one source of power!
DANGER
Pressurized Device - Impalement Hazard.
• Failure to follow these instructions will result in serious injury or death due to forcible ejection of
materials from UV chamber.
• Inspection, repair and maintenance must be performed by competent personnel only.
• ALWAYS follow lockout tag out procedures, as required by Operation and Maintenance Manual.
• NEVER perform any physical inspection, repair, maintenance or service on UV chamber unless UV
chamber has been isolated, depressurized and open to atmosphere.
• NEVER stand in front of UV lamp section while UV chamber is undergoing a hydrostatic pressure
test. Stand to the side of the UV chamber while looking for leaks.
• If a leak is observed, depressurize immediately, drain, repair and retest.
WA R N I N G
Body Crush Hazard.
• Failure to follow these instructions could result in serious injury or death due to improper lifting
procedures, underrated lifting equipment, and moving parts.
• ALWAYS secure with safety device.
• ALWAYS stay clear of elevated loads.
• ALWAYS comply with local safety regulations.
CAUTION
Burn Hazard.
• Failure to follow these instructions may result in minor or moderate injury due to burns.
• If accidental exposure occurs, immediately cool affected area. Consult physician.
• NEVER touch hot surface.Allow UV lamps to cool for a minimum of 10 (ten) minutes before
handling.
Safety Information
CAUTION
UV Light Hazard.
• Failure to follow these instructions could cause serious burns to unprotected eyes and skin.
• ALWAYS use UV protective gear, including gloves, clothing, and face shield when UV light is
UV present.
• NEVER look directly at illuminated UV lamp, even with protective gear.
• NEVER illuminate UV lamp if personnel may be directly exposed to UV light.
CAUTION
Slip and Fall Hazard.
• Failure to follow these instructions may result in injuries from a slip and fall.
• ALWAYS ensure safe footing.
• ALWAYS clean up spills promptly.
• ALWAYS comply with site-specific safety protocols and procedures.
NOTICE
A health risk exists.
This system uses ultraviolet light to reduce the concentration of pathogens to a noninfectious level.
Failure to observe maintenance instructions or the alarm messages will diminish the effectiveness of
this system. This will result in the effective disinfection no longer being guaranteed and the
requirement of the water supply regulations no longer being met.
NOTICE
Mercury Chemical
• UV lamps contain a small amount of mercury in either elemental or bound amalgam state,
depending on lamp type. These lamps are similar to fluorescent and compact fluorescent lamps
(CFL). Always comply with local regulations governing the disposal of lamps containing mercury
and the waste associated with breakage.
Hg
• NEVER use a vacuum cleaner to clean up broken lamps containing mercury. Vacuuming could
spread mercury-containing powder or vapor.
• Thoroughly collect broken glass and trace amounts of mercury and place into a sealable bag or
container. For further reference see the U.S. EPA guidelines
http://www.epa.gov/cfl/cleaning-broken-cfl.
• If you have further questions about the safe clean-up of mercury containing lamps, contact the
TrojanUV Technical Assistance Center at tac@trojanuv.com.
Safety Information
NOTICE
Personal Protective Equipment Required.
• ALWAYS use appropriate eye, hand, and foot protection.
• ALWAYS wear UV-C safety glasses when around equipment or a UV-C face shield when inspecting
open running equipment.
• ALWAYS follow plant safety procedures and protocols.
• ALWAYS take all necessary precautions when working around, operating, or working on this
equipment, if contamination of components is expected within this application due to effluent
biological or chemical contaminants.
NOTICE
Only competent personnel should undertake operation, repairs, maintenance, or servicing of
equipment described in this manual. Maintain the continuity of the lockout tag out between shifts. If you
do not understand the information or procedure explanations in this manual, STOP and contact your
Service Provider for assistance.
Warning: This product may contain chemicals known to the State of California to cause cancer and birth defects or
other reproductive harm.
Note: Dispose of contaminated parts/components as per country requirements.
2.4 Safety Features

The Ballast Water Treatment (BWT) system has safety features that prevent personal injury:
• Emergency Stop push button: The Control Cabinet and Power Distribution Cabinet are both equipped
with an E-Stop that will stop all operations, however power remains at the Control Cabinet.
Safety Information
Section 3 General Information
The information in this manual has been carefully checked and is believed to be accurate. However, the
manufacturer assumes no responsibility for any inaccuracies that may be contained in this manual. In no
event will the manufacturer be liable for direct, indirect, special, incidental or consequential damages
resulting from any defect or omission in this manual, even if advised of the possibility of such damages. In
the interest of continued product development, the manufacturer reserves the right to make improvements
in this manual and the products it describes at any time, without notice or obligation.
3.1 Patents and Permissions

The products described in this document may be protected by one or more patents in The United States of
America, Canada and/or other countries. For a list of patents owned by Trojan Technologies, go to:
www.trojantechnologies.com/patents.
No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by
any means without written permission of Trojan Technologies.
3.2 Abbreviations and Acronyms

Table 1 describes the abbreviations and acronyms included in this manual.
Table 1 Abbreviation/Acronyms
Abbreviation/Acronyms Description
ACC Auxiliary Control Cabinet
BSPP British Standard Parallel Pipe
BSPT British Standard Pipe Taper
BWMS Ballast Water Management System
BWT Ballast Water Treatment
CC Control Cabinet
HMI Human Machine Interface
I/O Input/Output
L/min Liters per minute
m/s Meters per Second
m3/h Cubic Meters per Hour
mW/cm2 Milliwatt per square centimeter
NPT National Pipe Taper (Thread)
P&ID Piping and Instrumentation Diagrams
PDC Power Distribution Cabinet
PLC Programmable Logic Controller
SAS Ship Automation System
TRC Treatment Rated Capacity
UV Ultraviolet
General Information
3.3 System Overview
The Trojan Marinex BWT system combines filtration and UV disinfection in a single Treatment Unit. This
reduces the need for complex interconnecting piping and the associated pressure loss. The small footprint
of the integrated system increases flexibility in locating the system within the vessel.
The operation of the system is fully automated by a PLC which interfaces with the flow meter, ballast pump
and valve line up to control treatment.
HORIZONTAL INSTALLATION VERTICAL INSTALLATION
1 4 5
2 3 6
Figure 1 Treatment Unit (Connection View)

1 Technical/Potable Water Fill 4 Outlet Flange
2 Ballast Inlet Flange 5 Backwash Outlet Flange (with studs)
3 Deballast Inlet Flange 6 System Drain Flange
General Information
3.3.1 Treatment Unit
The Treatment Unit houses the primary treatment technology, filter elements and UV lamps, as well as the
sensors required for systems control. The automatic filter backwash system and UV lamp cleaning system
is also housed with the Treatment Unit.
2
3
1
5
10
8 6 9
Figure 2 Treatment Unit

1 Filter Backwash Motor 6 Level Sensors
2 Air Vent 7 Drain Valves
3 Inline Lamp Driver 8 Drain Pump
4 Pressure Gauge (Inlet) 9 Junction Box
5 Technical/Potable Fill Valve 10 UVI Sensor
Figure 3 Inline TrojanUV Solo Lamp and Filter

1 TrojanUV Solo Lamp Assembly 2 Filter Element
General Information
The Inline Lamp Drivers provide power to the UV Lamps. The Inline Lamp Driver has high electrical
efficiency (>95%) and reduces wasted energy and cooling requirements. On-board digital signal
processors simplify diagnostics, improve reliability, UV lamp life and UV output. The Inline Lamp Drivers
are mounted directly on to the Treatment Unit and use the surrounding air as its source for cooling.
Figure 4 Lamp Connection View Figure 5 Power Cable Connection View
The Junction Box is the connection point from the PDC to the Treatment Unit. The Junction Box is
mounted to the Treatment Unit. All devices and instruments that are attached to the treatment unit are
wired to Junction Box by the manufacturer.
Figure 6 Junction Box
General Information
3.3.1.1 Automatic UV Lamp Cleaning System
1
2

1 Hydraulic Drive Cylinder 4 Guide Rod
2 Gland Plate 5 Stop Plate
3 Wiper Plate
Over time, the UV lamps can become fouled, reducing the amount of UV light available for treatment. Debris
is prevented from building up on the lamps using a chemical-free wiper system.
The UV lamp cleaning system consists of a hydraulic drive cylinders, which moves a wiper plate from one
end of the lamp to the other. The drive cylinder is hermetically sealed to prevent the possibility of fluid
loss.The wiper plate holds a number of wiper seals, which clean several lamps simultaneously. One bank of
lamps is cleaned at a time, reducing disruption to the treatment process.
The cleaning process initiates automatically. In standard operation, the lamps will be cleaned at the start
and end of a treatment cycle. A cleaning sequence will also be initiated automatically based on operation
time or if there is a low UVI reading. The cleaning sequence can also be manually initiated from the control
panel.
A cleaning sequence consists of actuating the wiper plate from its home position to the end of the lamp and
back to the home position. The cleaning cycle is finished when the last UV lamp wiping mechanism reaches
its home position.
General Information
3.3.2 Control Cabinet (CC)
The Control Cabinet contains the electronic control components that control the BWT system. The Control
Cabinet consists of two main components, the Programmable Logic Controller (PLC) and the Human
Machine Interface (HMI). The PLC is programmed with specific code to carry out the automated processes
and monitoring functions. The HMI for the controller uses touchscreen technology, it allows access to
various functions and settings, including automatic and manual controls. The touchscreen serves as the
systems’ monitoring window. An operator can view all aspects of operation and status at a glance.
3
4
2 5
1
6
Figure 8 Control Cabinet

1 Disconnect Switch 4 Human Machine Interface
2 Ethernet 5 USB
3 Local/Remote/SAS Control Selector Switch 6 Emergency Stop
3.3.3 Power Distribution Cabinet (PDC)

The Power Distribution Cabinet contains the main system power and breakers.
Figure 9 Power Distribution Cabinet

1 PDC Powered Light 3 Emergency Stop
2 Drivers On Light 4 Disconnect Switch
General Information
3.3.4 Auxiliary Control Cabinet (Optional)
The Auxiliary Control Cabinet provides the ability to monitor and control up to four (4) Treatment Units. The
major component in this cabinet is the HMI.
Figure 10 Auxiliary Control Cabinet

1 Human Machine Interface
3.3.5 System Operation Modes

Ballast Mode
Operator turns on
Trojan Marinex BWT Trojan Marinex BWT
Operator Selects Pump (SAS sends
signals Operator to Opens Ballast
Ballast Mode Ballast Pump
turn on Ballast Pump Inlet Valve
Run Signal)
Trojan Marinex BWT

Operator Starts
System Start-Up Trojan Marinex BWT
Treatment (SAS Filtration + UV
(Lamp Cleaning, signals Operator
sends request Treatment
Warm-Up, to begin treatment
to treat signal)
Filter Backwash)
Trojan Marinex BWT

Operator Stops
completes Shutdown Trojan Marinex BWT
Treatment Operator Shuts
Sequence (Lamp requests Ballast
(SAS sends Down Ballast Pump
Cleaning, Filter Pump Off
stop request)
Backwash)
Trojan Marinex BWT

drains and fills Trojan Marinex BWT
with technical is Offline.
or potable water.
General Information
Deballast Mode
Trojan Marinex Operator Starts

Trojan Marinex BWT
Operator Selects System Starts Up Treatment (SAS
signals Operator to
Deballast Mode (Lamp Cleaning sends request to
begin treatment
Warm-Up treat signal)
Operator turns on
Trojan Marinex BWT Trojan Marinex BWT
Pump (SAS sends
signals Operator to Opens Deballast UV Treatment
Ballast Pump Run
turn on Ballast Pump Inlet Valve
Signal)
Operator Stops Trojan Marinex BWT

Trojan Marinex BWT
Treatment completes Shutdown Operator Shuts
requests Ballast
(SAS sends Sequence (Lamp Down Ballast Pump
Pump Off
stop request) Cleaning)
Trojan Marinex BWT

drains and fills Trojan Marinex BWT
with technical is Offline.
or potable water.
Stripping Mode
Operation in stripping mode is the same as deballast mode. During stripping operations, the maximum
flow rate is limited to one third (1/3) the Treatment Rated Capacity (TRC).
3.3.6 Monitoring
The BWT system automatically monitors and logs key components of the treatment process. The data is
stored for a 2 year period. The data logging will occur when the BWT system is operational or bypassed.
Data is easily retrievable electronically.
3.3.7 Alarm Conditions

Equipment alarms have been broken into three categories:
• Critical Alarms - Impact safety and operation of the vessel
• Major Alarms - Impacts the operations of the ballast water treatment equipment
• Minor Alarm - Potential impact to the operation of the ballast water treatment system
General Information
3.4 General Overview
3
5
Figure 11 Ballast Operation - Example

1 Ballast Inlet 4 Inlet Piping
2 Deballast Inlet 5 Backwash Piping
3 Outlet Drain Piping (not shown)
1. Ballast inlet - When the ballast inlet valve is opened the water flows through the filter system first and
then through the UV chamber.
2. Deballast inlet - When the deballast inlet valve is opened the water flows directly into the UV chamber
bypassing the filter system.
3. Outlet - Ballast and deballast flow is regulated through the outlet by a proportionally controlled valve to
maintain the designed flow rate, the water will either exit to sea or to the ships ballast tanks depending
on the treatment mode.
4. Inlet piping - The inlet piping is used to connect the ballast and deballast inlets.
5. Backwash piping - The backwash piping is used for discharging debris and backwash water during a
ballast operation.
6. Drain piping - The drain piping is used for draining sea water during system shutdown or maintenance.
3.4.1 Water Quality Effects on Ballast Operation

The Trojan Marinex BWT system will regulate flow based on the set point entered, up to the treatment
rated capacity of the system. In typical water quality conditions, the differential pressure operating range of
the system varies between 0.1 bar and 0.25 bar. A filter backwash cycle is initiated at a differential
pressure of 0.25 bar, to reduce the differential pressure to below 0.1 bar. The amount of time in between
filter backwash cycles will vary with local water quality conditions. It is possible, and acceptable, for the
system to remain in a continuous filter backwash cycle under challenging water conditions.
In very challenging water conditions, the differential pressure across the system may be higher.
Depending upon the ballast water pump, it is possible that the system may experience a decreased flow in
this condition. When the differential pressure reaches 3 bar, a critical alarm occurs and the system shuts
down.
Under normal operating conditions, with a properly sized ballast water pump, the Trojan Marinex BWT
system will be able to maintain its maximum treatment rated capacity both in and out of a cleaning cycle.
General Information
3.5 Shipment and Storage

The following instructions outline the duties and responsibilities of the contractor on receiving the BWT
system. The contractor assumes responsibility for the system equipment after it has arrived at the project
site.
These instructions define the minimum requirements for care of the system equipment prior to the system
being commissioned. Additional care must be demonstrated by the contractor, as necessary, to ensure that
the equipment is not damaged.
3.5.1 Shipping Contents

• Treatment Unit
• Cabinets
• Inline Lamp Drivers
• Any optional peripheral equipment (i.e. Valves, flow meter)
3.5.2 How the Equipment is Shipped

The system components are packed in wooden crates or on skids, labeled with the component name(s),
part number(s). Other labels identify components which are fragile or breakable and components which
must be kept dry.
On receiving the equipment, inspect for physical damage. Contact your nearest manufacturer's
representative to report missing components or damage.
3.5.3 Storage Requirements before the Install

It is recommended to store the equipment indoors and in a dry area. Heating is not necessary during
storage.
Storage area conditions:
• Ambient air temperature between -40 ºC to 55 ºC (-40 ºF to 130 ºF).
• Relative humidity from 10% to 90%, non-condensing.
• Free from dust and dirt ingress.
• Must not contain corrosive or explosive gases.
• Vermin free.
If indoor storage is not possible, the Treatment Unit may be stored outdoors under the following conditions:
• Equipment is stored on high ground that is not susceptible to flooding.
• Equipment is elevated a minimum of 300 mm (12 inches) above the ground or as appropriate to
prevent flooding.
• Equipment is completely covered with waterproof tarps to prevent exposure to the elements (e.g., rain,
snow, sand, dust etc.). Tarps must be tight fitting, attached securely and examined regularly. Water and
snow accumulation should be removed regularly.
• Equipment stored in crates should not be exposed to direct sunlight.
• Equipment can be stored in sea containers.
General Information
3.5.4 Treatment Unit Weight

Dry Weight (kg) Wet Weight (kg)
Treatment Unit Size
(Approximate) (Approximate)
BWT 150 760 1300
BWT 250 1300 2200
BWT 500 1500 2600
BWT 750 2100 4100
BWT 1000 3100 5500
BWT 1250 3400 7700
BWT 1500 4600 8900
3.5.5 Electrical Cabinet Weights and Dimensions

Power Distribution Cabinet (PDC)
BWT 150 - BWT 750 BWT 1000 - BWT 1500

Weight (kg) 150 175
Dimensions (m) 1.1 x 1.2 x 0.3 1.1 x 1.4 x 0.3
Control Cabinet (CC)
BWT 150 - BWT 750 BWT 1000 - BWT 1500

Weight (kg) 70
Dimensions (m) 0.7 x 0.6 x 0.3
Auxiliary Control Cabinet (ACC)
BWT 150 - BWT 750 BWT 1000 - BWT 1500

Weight (kg) 20
Dimensions (m) 0.3 x 0.4 x 0.2
General Information
Section 4 Lockout Tag Out
DANGER
Obey all warning and caution statements. Refer to Section 2.
Read and understand the Operation and Maintenance Manual before operating this equipment. Read
all user documentation before performing operations, inspections, repair, or maintenance on this
equipment.
equipment described in this section of the manual. If you do not understand the information or
procedure explanations in this manual, STOP and contact your Service Provider for assistance.
The procedure in Section 4.1 is the minimum lockout requirement. Use additional precautions, as needed.
Obey all site-specific protocols.
4.1 Lockout Tag Out Procedure
4.1.1 Equipment Shutdown
Locate and identify the main energy source for the Trojan Marinex BWT.
1. Ensure that no hazards will be created by equipment shutdown.
2. Shut down all equipment that will need lockout tag out.
3. Ensure that all moving parts come to a complete stop.
4.1.2 Deactivate Energy Sources
A hazardous energy source is any energy source that can cause serious personal injury or death. The
potential hazardous energy sources in this manual are:
1. Identify and deactivate the main isolating device of each energy source:
• Electrical energy (Incoming power)
• Water pressure (Potential energy)
• Thermal (Thermal energy)
UV
• UV Light (Radiation Energy)
• Mechanical (Kinetic Energy)
2. Disconnect all electrical equipment from power:

• Disconnect all electrical equipment
• Power off and disconnect electrical power to hard-wired equipment
3. Dissipate stored electrical energy in capacitors.

4. Close all shut-off valves.
Lockout Tag Out
4.1.3 Lockout Tag Out Energy Sources
1. Use a multi-lock scissor adaptor to lockout each energy source.

2. Attach a completed lockout tag. Include the required information:
• Person and company applying the lockout
• Reason for the lockout
• Date of the lockout
3. Apply a personal lock.
4.1.4 Verify the Lockout
1. Ensure that the meter is working correctly with a test before and after measuring the de-energized
source:
a. Test the voltmeter to a known, energized 24 VAC/120 VAC source.
b. Use the same voltmeter to test the locked-out energy sources to verify that there is no voltage.
c. Test the voltmeter again to a known, energized 24 VAC/120 VAC source.
2. Ensure that the stored energy sources have dissipated.

3. Try to start the de-energized equipment.
4.2 Remove the Lockout Tag Out

When the work is finished, the lockout tag out can be removed.
1. Ensure that no hazards will be created by removal of the lockout.
2. Obey manufacturer’s instructions and safe work procedures to energize and start the equipment.
3. Clean up the work area.
Section 5 Startup and Shutdown
DANGER
equipment.
5.1 Pre-start Checklist

Make sure that:
• The Treatment Unit is fully assembled — including but not limited to: all cables, Inline Lamp Drivers,
TrojanUV Solo Lamp™ Assembly.
• There are no water leaks.
• The air vent(s) are operating correctly.
• The drainage or water bypass provisions are obeyed until disinfection starts.
• Cabinet doors are latched and secure.
5.2 Power on procedure for the Trojan Marinex BWT

1. Turn “ON” supply power.
2. Turn Power Distribution Cabinet (PDC) disconnect switch to “ON”.
3. Turn Control Cabinet (CC) disconnect switch to “ON”.
5.3 Power off procedure for the Trojan Marinex BWT

Note: This procedure is to be used to disconnect power to the system prior to servicing. It is not part of the
standard system stop procedure during normal operation.
1. Before powering off the treatment equipment ensure the system is in an offline state.
2. Turn the Control Cabinet (CC) disconnect switch to “OFF”.
3. Turn the Power Distribution Cabinet (PDC) disconnect switch to “OFF”.
4. Turn “OFF” the supply power to the PDC.
5.4 Lay-up Procedure

If the ballast water treatment equipment is not going to be operated for more than 4 weeks it is
recommended to follow our layup procedure.
1. Manually drain the ballast water treatment system.
2. Remove filters and follow filter cleaning procedure (Section 7.11.2).
3. Replace filters.
4. Fill system back up with technical or potable water.
Startup and Shutdown
5.5 Emergency Shutdown Procedure for the Trojan Marinex BWT

NOTICE
All ship installations are unique and is recommended to develop specific instructions for ballasting/deballasting to
identify special risks in emergency stop conditions.
In the event of an emergency, press the Emergency stop button (E-stop) located at the Control Cabinet
(CC) or the Power Distribution Cabinet (PDC).
Pressing the E-stop button will shut down the BWT System and remove power to the Treatment Unit
including the Inline Lamp Drivers, backwash motor, drain pump, automatic UV cleaning system and all
instrumentation. At this time all valves controlled by the Trojan Marinex BWT system will transition to a
closed state.
Main power will still be available at the Control Cabinet (CC) and Power Distribution Cabinet (PDC).
Note: It is recommended to turn off the pump or open a bypass valve prior to pressing the E-stop to avoid
having increased pressure in the ship’s piping.
Section 6 Operation
DANGER
equipment.
6.1 Human Machine Interface (HMI)

The HMI uses touchscreen technology and is found on the front of the Control Cabinet and on the Auxiliary
Control Cabinet. Avoid using writing tips of pens, pencils or other sharp objects to make selections on the
screen. Use only a clean, dry fingertip or the eraser tip of a pencil.
6.1.1 Home Screen

The Home Screen displays performance information on all ballast water treatment systems operating on
the vessel. Up to 4 systems can be controlled and monitored either individually or simultaneously from this
screen.
1 2 3 4 5 6 7 8
14 9
10
13
11
12
Figure 12 Home Screen

1 Control Mode (Local/Remote/SAS) 8 Alarm History/Summary
2 Alarm Indication 9 Differential Pressure
3 Ballast Mode Selection 10 System Flow Rate
4 Deballast Mode 11 Flow Set Point
5 Stripping Mode Selection 12 Navigation Bar Slide Out Tab
6 Multi-System Control Side Out Tab 13 Screen Brightness Adjustment Slide Out Tab
7 Description/P&ID Toggle Button 14 Treatment Unit Overview Selection
Operation
6.1.2 Navigation Bar
The Navigation Bar is used to navigate through the different screens in the system by touching one of the
icons on the bar.
General navigation rules:
• Push the icons located on the bottom the screen to view and control various functions of the system.
• If a field requires an alphabetic or numeric value, select the field or button to show an alphanumeric
touch pad. Then push the alphanumeric buttons on the screen to enter the value.
• Push the Home button on any screen to go back to the system overview screen.
Figure 13 Navigation Bar
6.1.3 Multi-System Control Slide Out

The Multi-System Control is available if more than one Ballast Water Treatment System is installed. The
controls allow all systems to be simultaneously controlled.
6.1.4 System Brightness Adjustment Slide Out

Allows the operator to adjust the brightness of the HMI screen and switch between Day and Night modes.
Operation
6.2 Screens
Screens are navigated to by pressing the icons located at the bottom of the screen.
Contains ballast and deballast multiple system operations and operational summaries of the Trojan
Marinex BWT systems.
Allows access to a single Trojan Marinex BWT system. Ballast and deballast operations can be
performed in this screen.
Allows access to the sensor configurations in the event of a sensor replacement. Operator Log-in
required.
Allows access to the P&ID tags for the Trojan Marinex BWT system. P&ID tags can be changed in this
screen. Operator Log-in required.
Allows access to the maintenance functions such as the maintenance backwash and manual lamp
wiping of the Trojan Marinex BWT system. Operator Log-in required.
Contains adjustable system settings for the Service Technician. Log-in required.
Contains adjustable system settings for the Service Technician. Log-in required.
Contains Trojan Marinex BWT system performance data. Data logger time & date range can also be
changed in this screen.
Contains the Trojan Marinex I/O list for the Service Technician to perform diagnostics. Log-in required.
Contains the program revisions, system runtime hours and the system time and date stamp.
6.2.1 System Overview Screen

System Status: Displays the status of the Trojan Marinex BWT.
• System Standby: appears when the system is in an operational mode (ballasting/deballasting) and
alarms are not present that would prohibit the automatic startup of the system.
• System Not Ready for Auto: appears when the system is in a ‘No Mode’ state and/or alarms are
present prohibiting the automatic startup of the system and/or all valves are not closed.
Operation
6.2.2 Treatment Unit Overview
The Treatment Unit Overview screen displays a single Trojan Marinex BWT system in its current
operational state. In this screen, the operator will have control of all system functions while having the
ability to monitor the system performance.
2 3 4 5 6
Figure 14 Treatment Unit Overview

1 Control Status Display 5 Treatment Unit Selection Tab (Only if multiple
systems are installed)
2 Control Mode Display 6 System Status Message Bar
3 Operation Mode Display 7 System Performance Summary
4 Treatment Unit Level Status Display 8 System Control Slide Out Tab
Operation
6.2.3 System Control Slide Out Tab
The system control slide out tab allows the operator to select a mode of operation and perform a system
function manually while remaining on the Treatment Unit Overview screen. When system is treating, the
Pause and Stop buttons are displayed.
Figure 15 System Control Slide Out Tab

1 Start Ballast Operation 5 Manual Drain Selection
2 Start Deballast Operation 6 Manual UV Lamp Wipe
3 Start Stripping Operation 7 Manual Backwash
4 Manual Fill Selection
Operation
6.2.4 Operator Settings

The Operator Settings screen is used to set the full scale values of the transducers in the system in the
event of a sensor is replaced. Operator Log in information is required to access screen.
Figure 16 Operator Settings Screen
Operation
6.2.5 P&ID Tag Settings

The P&ID Tag Settings screen is used to set the P&ID tags of the Valves and Transducers in the system
for use with the P&ID tag button on the screen Navigator bar. Operator Log in information is required to
access screen.
Figure 17 P&ID Tag Settings Screen
Operation
6.2.6 Alarm Summary Screen
The Alarm Summary screen is used to display the current alarms in the system. The operator will have the
ability to acknowledge and reset alarms on this screen. The RESET ALARMS push button resets all
alarms that are currently not being triggered.
1 2 3 4
Figure 18 Alarm Summary Screen

1 Active Alarms 3 Reset Acknowledged Alarms
2 Alarm History 4 Acknowledge Individual Alarms
Operation
6.2.7 Alarm History Screen
The Alarm History screen will display all the previous alarms that occurred during system operations; all
alarms will be sorted by time and date.
Figure 19 Alarm History Screen
Operation
6.2.8 Information Screen

The Information Screen is used to check PLC and HMI revision levels and system runtime hours of the
Trojan Marinex BWT system.
1
Figure 20 Information Screen
1 Exit Runtime Application (Service Technician access only)
6.3 System Control

On the front of the Control Cabinet, a selector switch is available to select the control location of the system.
The control functions available at the selector switch are Local, Remote and SAS Control.
6.3.1 Local Control

When the equipment is in the Local Control Mode the selector switch on the Control Cabinet will be in the
local position. The system will have full control at the Control Cabinet. The Control Mode will be displayed
on any Auxiliary Control Cabinet or SAS system that is connected to the Trojan Marinex BWT system
indicating that it is in Local Control mode.
6.3.2 Remote Control

When the equipment is in Remote Control Mode, the selector switch on the Control Cabinet is in the
remote position. Limited control of the equipment can be performed through the Auxiliary Control Cabinet
(optional). An Auxiliary Control Cabinet can control and monitor up to 4 BWT systems. When in Remote
Control, an indication signal is given to HMI in the Control Cabinet and to the SAS system indicating that it
is in remote control mode.
Operation
6.3.3 SAS Control

When the equipment is in SAS Control Mode, the selector switch on the Control Cabinet is in the SAS
position. Limited control of the equipment can be performed through the SAS system. The SAS system
can control and monitor up to 4 BWT systems. When the system is in the SAS mode an indication will be
displayed on the Control Cabinet HMI and the Auxiliary Control Cabinet HMI indicating that it is in SAS
control.
6.4 Ballast Procedure (Local Control Mode)

If controlled by the Control Cabinet and Auxiliary Control Cabinet
Note: Follow ship’s network programmer operating instructions if SAS is used as the primary Remote Control of the
6.4.1 Start Ballast Operations

1. Follow the power on procedure. Refer to Section 5.2.
2. To initiate a start-up sequence; push the ballast mode start icon on the System Overview screen of the
HMI. Refer to Figure 15.
3. If the system is already filled with technical or potable water, a prompt will appear notifying the operator
to “Turn Pump On”.
If the system is not full, the operator must wait until the message “Turn Pump On” appears prior to starting
the ballast pump to allow the treatment unit to fill.
When the ballast pump is turned on, the start-up backwash will begin and the start-up sequence will start.
Note: Water will be directed through the filters and will flow out through the backwash overboard discharge. Water will
not be sent to the ballast tanks until the start-up sequence is complete and the Ready To Treat acknowledgment
has been selected. The start-up sequence can take up to 7-12 minutes depending on the UVI value.
4. The start-up sequence will continue to run until the UV lamps are finished warming up. The start-up
sequence consists of
• Treatment unit filling
• UV lamp warm up
• UV lamp warm up wipe
• Filter cleaning*
*The ballast pump must be ON for filter cleaning to occur.
Operation
5. When the start-up sequence is complete, the following message will appear on the Control Cabinet
and the Auxiliary Control Cabinet.
6. Select YES to continue to ballast. At this time, water will be directed towards the ballast tank(s).
Note: If NO is selected, the Trojan Marinex BWT system will continue to backwash until the operator confirms they
are ready to treat by pressing YES.
7. The Trojan Marinex BWT system is fully automated and will automatically regulate flow to not exceed
the treatment rated capacity as specified in the Type Approval Certificate.
6.4.2 Stop Ballast Operations

1. Push the STOP button on the Control Cabinet or Auxiliary Control Cabinet HMI screens. A shutdown
sequence will be initiated when the STOP button is pressed.
2. When the STOP button is pressed, a shutdown backwash timer will appear displaying the time left in
the shutdown backwash.
3. The shutdown sequence will continue until the Treatment Unit has been drained and then refilled with
technical or potable water. The shutdown sequence consists of:
• Outlet valve closing
• Shutdown Backwash
• UV Lamp Shutdown and Wipe
• Treatment unit draining
• Treatment unit technical or potable water refill
Operation
4. Near the end of the shutdown sequence, a message will appear on the HMI prompting the operator to
turn off ballast pump. If the ballast pump is not turned OFF, the BWT system will continue to Backwash
until the pump is turned OFF.
5. Once the treatment has been refilled, the BWT system will enter the offline state.
6. Rectify any system alarms.
6.5 Deballast Procedure (Local Control Mode)

If controlled by the Control Cabinet and Auxiliary Control Cabinet.
6.5.1 Start Deballast Operations

2. To initiate a start-up sequence; push the deballast mode start icon on the System Overview screen of
the HMI.
sequence consists of:
• UV lamp warm up
Operation
4. When the start-up sequence is complete, the following message will appear on the Control Cabinet
and the Auxiliary Control Cabinet.
5. Select YES to continue to deballast. If YES is selected and the pump is not turned on, a prompt will
appear notifying the operator to “Turn Pump On”. Once the pump is turned on water will be directed
towards the overboard discharge.
Note: If NO is selected, the Trojan Marinex BWT system will remain ready for water processing.
the treatment rated capacity as specified in the Type Approval Certificate.
6.5.2 Stop Deballast Operations

2. When the STOP button is pressed, a message will appear on the HMI telling the operator to turn off the
Ballast Pump.
• UV lamp shut down wipe
• Treatment unit potable water refill
Operation
6.6 Stripping Procedure (Local Control Mode)

If controlled by the Control Cabinet and Auxiliary Control Cabinet.
6.6.1 Start Stripping Operations

2. To initiate a start-up sequence; push the stripping mode start icon on the System Overview screen of the
HMI.
sequence consists of:
• UV lamp warm up
4. When the start-up sequence is complete, the following message will appear on the Control Cabinet and
the Auxiliary Control Cabinet.
5. Select YES to continue to stripping. If YES is selected and the pump is not turned on, a prompt will
appear notifying the operator to “Turn Pump On”. Once the pump is turned on water will be directed
towards the overboard discharge.
Note: If NO is selected, the Trojan Marinex BWT system will remain ready for water processing.
1/3 of treatment rated capacity as specified in the Type Approval Certificate.
6.6.2 Stop Stripping Operations

Operation
2. When the STOP button is pressed, a message will appear on the HMI telling the operator to turn off the
Ballast Pump.
• UV lamp shut down wipe
• Treatment unit potable water refill
6.7 Maintenance Mode

In maintenance mode, the operator can manually control the Automatic UV Cleaning System and the filter
backwash system to improve the performance of the BWT system. Having manual control of the wiping
system will allow the operator to verify the operation of the Automatic UV Cleaning System following system
maintenance. The maintenance backwash allows the operator to improve the performance of the filters
when not in an operation mode. The operator has the ability to manually activate the drain and fill system in
maintenance mode.
At the Control Cabinet, switch the mode selector switch to Local control. To enable maintenance mode,
access the navigational bar at the bottom of the screen and select the Maintenance icon. To enable
maintenance mode, select the disable/enable icon next to maintenance mode.
Note: Maintenance mode cannot be enabled during ballast or deballast operation.
6.8 Pause Procedure for the Trojan Marinex BWT

Note: Follow ship's network programmer operating instructions if SAS is used to control the Trojan Marinex
BWTS.
When the system is paused, it will remain in a ready state until it is signaled to resume treatment.
6.8.1 Automatic Pause

The system will automatically pause if the Ballast Pump is stopped.
Stopping the ballast pump removes the Permissive Run signal, causing the outlet valve to close and the
system will remain in the Ready for Flow state until the pump has been turned on or the Ballast Water
Treatment system is stopped.
Operation
6.8.2 Manual Pause

Treatment can be interrupted by the operator using either the local, remote or SAS control.
Using the Local or Remote HMI:
1. Operator presses the Pause Button
2. Ballast Water Treatment system will signal Operator to Stop the Ballast Pump
3. System will remain in the Ready for Flow state until the Resume button is pressed or the Ballast Water
Treatment system is stopped.
6.9 Log In
The user interface has two access levels:
• Operator: Login required to access Operator, P&D and Maintenance Screens.
• Service: Log in is required to access system settings configured during installation and commissioning.
Note: The operator may be instructed to log in on behalf of the Service Technician for troubleshooting
purposes.
6.10 Downloading Monitoring Data from Data Logger

Procedure:
1. Plug a USB Flash Drive into the USB port on the front of the Control Cabinet.
2. Select the DataLog screen from the Navigation Bar (Figure 26)
3. Select the desired date range to be downloaded and select the Export button.
4. Once the download is complete a notification will appear on the HMI screen.
5. Remove the USB stick from the USB port.
6. Load data using Microsoft Excel or equivalent program to import, view and print content.
Operation
Section 7 Maintenance
DANGER
equipment.
7.1 Maintenance Schedule

Scheduled maintenance and inspections can extend the life of the system and prevent problems. Routine
maintenance may include partial disassembly to access components for cleaning and visual evaluation.
During any maintenance activity, the manufacturer recommends inspection of all components that can be
seen.
Interval Task
Replace gear oil in Filter Motor Gearbox.
5 Year
Replace Drive Seal Bushing.
10,000 Operating Hours* Replace UVI Sensor (Section 7.6.1).
Earlier of 12,000 Operating
Replace TrojanUV Solo Lamp Sleeve Assembly (Section 7.5.3).
Hours or 10 Year
All other components are to be replaced as required. Components should be visually inspected for damage and wear upon
removal.
*The Trojan Marinex™ BWT system has a UVI calibration timer. The timer is set for 10000 hours of operation on the UVI sensor.
The UVI calibration timer has 2 alarms that are associated with it, a UVI calibration timer warning at 500 hours before the
calibration timer expires used to warn the ship and make sure that a replacement UVI sensor is available for when the
calibration timer completes. The Second Alarms is “UVI Calibration Time Exceeded: UVI Sensor out of calibration”, this is used
to document when the sensor is out of compliance and lets the ship know that they UVI sensor is no longer reliable and needs
to be replaced.
7.2 Tools and Materials

Symbols Description Symbols Description
Ladder O-ring lubricant (e.g. Dow Corning 111)
Hex key A n t i- s e i z e
F lui d
Anti-seize fluid
Lifting hoist (Properly sized and rated for

Mild acidic solution
equipment weight)
Lint-free cloth (Kimwipes®) Wiper seals
Maintenance
Symbols Description Symbols Description
Clean water Thread sealant (567 Loctite)

LOCTITE
567
Cotton swabs Clip-Pliers
ISOPROPYL
ALC O H O L
Isopropyl alcohol Allen socket wrench
Open end wrench Wrench
8
Adjustable wrench Lamp Driver Installation Tool
7.2.1 Torque Chart

Table 2 Torque Chart
Torque Torque
Bolt Size
(N·m)
M4 1.4 12(in-lbs)
M5 2.6 23(in-lbs)
M6 5.6 50(in-lbs)
M8 11.3 100(in-lbs)
M10 22 195(in-lbs)
M12 50 37(ft-lbs)
M14 72 53(ft-lbs)
M16 108 80(ft-lbs)
M18 156 115(ft-lbs)
M20 217 160(ft-lbs)
M22 292 215(ft-lbs)
M24 362 267(ft-lbs)
M30 610 450(ft-lbs)
7.2.2 Assembly Fluids

• O-ring lubricant (e.g. Dow Corning 111)
• Anti-seize for fasteners (e.g. Loctite Food Grade Anti Seize)
• Thread sealant used on tapered fittings (e.g. Loctite 567)
Maintenance
7.3 Manual Technical or Potable Water Fill

Manual filling of the Treatment Unit is required to perform maintenance on the UV lamp wipers and to test
the operation of the Automatic UV Cleaning System.
Prerequisites:
• Ensure the Treatment Unit is sealed and all bolts are torqued to its proper torque value.
Materials:
Procedure:
1. At the Control Cabinet HMI, access the Treatment Unit Overview screen (Figure 12).
2. Open the Navigation Menu at the bottom of the screen and access the maintenance screen by
pressing the maintenance icon.
3. Open the Fill valve in the maintenance screen and manually open the Technical or Potable water
source valve attach to the treatment unit.
4. Allow the treatment unit to fill until the “Treatment Unit not filled” indication is extinguished.
5. Close the fill valve and continue on with scheduled maintenance.
7.3.1 UV Lamp Cleaning - Maintenance Mode

In maintenance mode, the operator has the ability to wipe the UV lamps to test the operation of the
hydraulic cylinder and hydraulic drive assembly. It is recommended to test the function of the wiping
system following completion of any maintenance to the UV Lamp Cleaning System.
To wipe the UV lamps in maintenance mode, access the maintenance screen through the navigation bar at
the bottom of the screen. Manually open the technical or potable water fill valve and fill the treatment unit
until the low level indication is extinguished. Once filled, close the fill valve and select the UV cartridge
number that is being worked on and manually extend/retract the wiper.
The cartridge numbering starts from the deballast inlet to outlet from 1 cartridge to a maximum of 6. Refer
to Figure 21 for an example of the cartridge numbering.
Figure 21 Cartridge Number
Maintenance
7.3.2 Backwash - Maintenance Mode

A maintenance backwash requires a BWT system operator at the local control and a ballast pump
operator. It is important to establish communications to both operators in order to complete a maintenance
backwash safely. In the event of an emergency, open the bypass valve to prevent pressure build up.
At the Control Cabinet HMI, access the Maintenance screen and locate the maintenance backwash icon.
Select the icon and verify the backwash valve opens to 100%. Once the valve is opened, communicate to
the pump operator to turn on the ballast pump. If an Auxiliary Control Cabinet is installed, a message will
be displayed on the remote HMI instructing the pump operator to turn on the pump. When the ballast pump
is activated the maintenance backwash will clean the filters for 30 minutes unless stopped manually by the
BWT system operator.
To stop the maintenance backwash, communicate to the ballast pump operator to stop the pump. Once the
ballast pump is off, press the cancel icon to end the maintenance backwash. Verify the backwash valve
closes and no alarms appear on the HMI.
Note: Prior to a maintenance backwash operation ensure all overboard discharge valve lineups are
complete.
7.4 Depressurize and Drain Treatment Unit

Prior to performing a maintenance routine, it is a requirement to properly drain and depressurize the BWT
system.
Materials:
Procedure:
1. Bring the Trojan Marinex BWT system to the OFFLINE state. Refer to Section 5.3.
2. At the Control Cabinet HMI screen, open the maintenance screen from the navigation menu located at
the bottom of the screen.
3. In the maintenance screen, open the Filter Chamber drain valve and UV Chamber drain valve.
4. Turn on the drain pump and allow the Treatment Unit to depressurize and drain prior to conducting
maintenance to the Trojan Marinex BWT system.
5. When the Treatment Unit is fully drained, turn off the drain pump and return all drain valves to the
closed position.
7.5 TrojanUV Solo Lamp
Hg UV
7.5.1 Storage of Used UV Lamps

Put used UV lamps into the replacement UV lamp shipping container, or a similar container. It is preferable
that the original packing materials be used where possible, or materials adequate to prevent breakage
during storage and transportation.
7.5.2 Safety Information for UV Lamps
Employees handling UV lamps should be aware of the risk of mercury release in the event of UV lamp
breakage and should always use the appropriate level of care to prevent accidental breakage.
Maintenance
The manufacturer recommends the purchase of a mercury spill containment kit. The kit should be made
accessible on site in the event of UV lamp breakage. Mercury spill containment kits are readily available
and should include detailed instructions for the safe cleanup of mercury releases. If UV lamp breakage
occurs indoors, keep people out of the immediate area of the spill and obey the clean up instructions
detailed in the mercury spill containment kit.
7.5.3 Remove and Install a UV Lamp
Hg UV
Prerequisites:
• Depressurize and drain the Trojan Marinex BWT system. Refer to Section 7.4
• Shutdown the Trojan Marinex BWT system. Refer to Section 5.3.
• Apply Lockout Tag Out devices as necessary. Refer to Section 4.1.
• Wait ten minutes to allow UV Lamps and Inline Lamp Drivers to cool.
Tools:
Materials:
• UV Lamp Assembly
Procedure:
1. Remove the Inline Lamp Drivers to gain access to the UV lamps.
2. Wearing clean gloves pull out a lamp by the tip of the lamp assembly.
3. As the lamp is being extracted from the treatment unit, support the lamp at the midsection and
continue to remove the lamp until it clears the top of the cartridge.
4. Carefully set each lamp aside in an enclosed box to reduce the chance of breakage.
Maintenance
5. To reinstall lamps, ensure each lamp is lightly lubricated with clean water and gently reinsert lamps
through the lamp inserts of the lamp cartridge. Align the lamp with its wiper insert and apply light
pressure to fully seat the lamp into position.
4
3
2
5
1
Figure 22 Inline Lamp Driver Installation

1 Inline Lamp Driver 4 TrojanUV Solo Lamp Sleeve Assembly
2 M6 Bolt 5 Gland Plate
3 Lock Washer
7.5.4 Clean UV Lamps Manually
UV
Clean UV Lamps to remove fouling or build up that occurred from extended operations. Build-up on the
lamps blocks UV light, and can result in higher UV lamp operating temperatures and decreased UV lamp
efficiency.
NOTICE
Do not use abrasive materials to clean the UV lamp. Abrasive materials will scratch and damage the lamps.
Prerequisites:
• Remove Inline Lamp Drivers.

• Remove UV Lamps.
Materials:
Procedure:
1. Wipe down the outside of the UV lamp with a mild acidic solution (i.e. vinegar) and a lint-free cloth.
Wipe up and down the length of the lamp. Do not wipe across or around the lamp. Wipe until all the
build-up on the lamp is removed.
2. Rinse the outside of the lamp thoroughly with clean water.
3. Install the lamp.
Maintenance
7.5.5 Remove a UV Cartridge

Remove a UV Cartridge to access the internal components of the Automatic UV Cleaning system and to
replace the wiper seals.
Prerequisites:
• Remove all Inline Lamp Drivers.

• Remove all UV lamps.
Tools:
Materials:
Procedure:
1. Follow Inline Lamp Driver and UV Lamp removal procedures prior to removing the UV lamp cartridge.
2. Insert a lifting strap through the lamp insert holes to prepare for lamp cartridge removal.
3. Connect the chain hoist to the lifting straps and apply tension.
4. Remove all hex cap securing bolts from the UV cartridge and remove the cartridge.
Note: Lift the UV Cartridge slowly to make sure wiper plate and stop plate do not catch on unit during
removal.
7.5.6 Install a UV Cartridge

Prerequisites:
• Remove a UV Cartridge. Refer to Section 7.5.5

Tools:
Materials:
A n t i- s e i z e
F lui d
• UV Cartridge O-ring
Procedure:
1. Inspect UV Cartridge O-ring for signs of wear or damage. Replace if necessary.
2. Lubricate the UV Cartridge O-ring and install into the O-ring groove on the Treatment Unit.
3. Make sure the Cartridge guides on the stop plate of the UV Cartridge are attached securely
(Figure 24).
Maintenance
4. Align the Cartridge guides on the UV Cartridge with the guide rods on the Treatment Unit. Slowly insert
the UV Cartridge into position.
Note: Lift the UV Cartridge slowly to make sure wiper plate and stop plate do not catch on unit during
installation.
5. Use anti-seize fluid on all retaining bolts and tighten in star pattern.
6. Reinstall UV lamps (Section 7.5.3) and Inline Lamp Drivers.
7. Fill Treatment Unit and test Automatic UV Lamp Cleaning System. Check for leaks.
7.5.7 Replace the Wiper Seals
Replace the wiper seals when the wiper seals are worn and not effectively cleaning the lamp sleeves.
Prerequisites:
• Remove a UV Cartridge. Refer to Section 7.5.5

Tools:
8 mm
8
Materials:
Procedure:
1. Remove wiper holder from wiper plate.

2. Place wiper seal into holder, lip pointing down as shown in Figure 24.
3. Install wiper holder in wiper plate.
4. When service is complete, assemble prerequisites in reverse order of disassembly.
Maintenance
4
5
Figure 23 UV Cartridge - Exploded View

1 Hydraulic Drive 4 Stop plate
2 Wiper plate 5 Cartridge Guides
3 Hydraulic cylinder
Wiper lip points down towards

direction of stop plate
Figure 24 Wiper Plate Detail
1 Wiper Plate 3 Wiper Holder
2 Wiper Seal 4 Wiper Lip
Maintenance
7.6 UVI Sensor
UV
The Treatment Unit is equipped with a UVI sensor to monitor the UVI intensity of the lamps. In the event of
low UVI intensity, an alarm condition is initiated to warn of the potential for insufficient treatment.
7.6.1 Remove and Replace the UV Sensor and Sensor Window

Clean the UV sensor as a part of scheduled maintenance or when a low UVI alarm occurs. The UVI
Sensor alarm will need to be reset.
Prerequisites:
Tools:
Materials:
ISOPROPYL
ALC O H O L
• UV sensor window O-ring (if required)

• UV sensor window (if required)
• UV sensor (if required)
Procedure:
Maintenance
UV Sensor Removal:
1 2
1
Note: If water is draining at a high rate from the sensor port this could
indicate a broken sensor window.
UV Sensor Window Removal and Seal Replacement:
1 2
1
2 1
3
2
Note: Inspect sensor window gasket for wear or damage. Replace if Note: Inspect sensor window O-ring for wear or damage. Replace if
required. required.
Maintenance
3 Alcohol
1
Alcoh
ol
Install:
1. Assemble components in reverse order of disassembly.
3. If replaced with new UVI Sensor, reset UVI Calibration Timer on Operator Screen. Refer to Figure 16.
Maintenance
7.7 Remove and Replace the Level Sensor

The level sensor is used to indicate low water level conditions in the Treatment Unit.
Prerequisites:
Tools:
Materials:
• Level Sensor
Procedure:
1. Disconnect Level Sensor cable.
2. Remove the Level Sensor from the Treatment Unit.
3. Tighten clockwise into Treatment Unit until threads bottom out on the Treatment Unit.
4. Connect Level Sensor cable.
Figure 25 Low-Level Sensor Assembly

1 Level Sensor
Maintenance
7.8 Remove and Replace the Temperature Sensor

The Treatment Unit is equipped with a temperature sensor to monitor high temperature conditions.
Prerequisites:
Tools:
Materials:
• Temperature Sensor
Procedure:
Remove:
1. Disconnect Temperature Sensor cable.
2. Remove the Temperature Sensor from the Treatment Unit.
Install:
1. Tighten clockwise into Treatment Unit until threads bottom out on the Treatment Unit.
2. Connect Temperature Sensor cable.
Figure 26 Temperature Sensor Assembly

1 Temperature Sensor
Maintenance
7.9 Replace the Air Eliminator

Prerequisites:
Tools:
30 mm
Materials:
LOCTITE
567
• Polyurethane tubing
• 3/4” Nipple
• Thread Sealant
• Air Eliminator
Procedure:
1. Apply sealant to threads on the nipple (Figure 27) and thread into the air eliminator to hand tight.
2. Tighten 2 full turns (from hand tight) with wrenches.
3. Apply sealant to threads on other end of the nipple (Figure 27) and thread into Treatment Unit to hand
tight.
4. Tighten 2 full turns (from hand tight) with wrenches.
Figure 27 Air Eliminator (Plastic)

1 Tubing, Polyurethane 10mm OD 2 Nipple, 3/4 NPT
Maintenance
7.9.1 Verify the Air Eliminator Is Working

During filling, remove tubing and check manually for air flow.
7.10 Replace the Pressure Sensor

The Treatment Unit is equipped with two pressure sensors. One sensor is located on the inlet and the other
sensor is located on the outlet. These sensors work together to sense differential pressure across the
system. When the differential set-point is detected a backwash sequence is initiated.
Prerequisites:
• Depressurize and drain the Trojan Marinex BWT system. Refer to Section 7.4.
Tools:
Materials:
• Pressure Sensor
Procedure:
1. Install the pressure sensor by threading the pressure sensor into the Treatment Unit until it bottoms.
2. Connect the pressure sensor cable.
Figure 28 Pressure Sensor

1 Pressure Sensor 3 Threaded connection (to Treatment Unit)
2 Cable connection
Maintenance
7.11 Filter
7.11.1 Replace a Filter Element
Prerequisites:
Tools:
Materials:
Procedure:
1. Use a wrench to remove the filter motor cover mounting bolts (Figure 29). Lift the filter motor cover
using the three (3) lifting eyebolts.
1
2

1 Filter Motor Cover 3 Hex Bolts
2 Filter Motor
2. Remove the countersunk retaining plate bolts with 4mm Allen key to extract the retaining
plate.(Figure 30)
Maintenance
1
2
3
4

1 Filter Element 3 Retaining Plate
2 Retaining Plate Bolt 4 Flush Arm
3. Remove the filter elements. Rotate the flush arm by hand if required to access filters.
4. Inspect top and bottom O-rings on the filter element and replace if damaged. Apply lubricated O-ring
when re-installing the filter elements.
5. To install, complete steps 1 to 4 in reverse order.
7.11.2 Clean the Filter Element

It is recommended that the filter element be cleaned when the High Differential Pressure alarm is
triggered, or any time the filter is removed for other maintenance purposes.
Upon removal, contaminants on the surface of the element, will begin to corrode, potentially damaging the
element. It is therefore important to clean a contaminated element promptly upon removal from the
Treatment Unit.
Prerequisites:
• Remove Filter Element. Refer to Section 7.11.1.

• Inspect Filter Element for debris and damage.
Note: Debris will be caught on the inside of the filter element.
Tools:
• Pressure Washer
• Bleach
Materials:
Maintenance
Procedure:
1. Soak the filter element for 24 hours in 1 to 25 ratio of bleach to water.
2. After the soaking period, use a pressure washer to dislodge any debris.
Note: Cleaning the Filter Element should be done from the outside to inside.
3. Record the maintenance work in the maintenance log.
4. When service is complete, assemble in reverse order of disassembly.
7.11.3 Backwash Pads (Top)

Prerequisites:
Tools:
Materials:
• Backwash Pad(s)
Procedure:
1. Use a wrench to remove the filter motor cover mounting bolts (Figure 29). Lift the filter motor cover
using the three (3) lifting eyebolts.
2. At the base of the flush arm loosen the (3) socket head cap screws until the flush arm detaches. Refer
to Figure 31.
3. Remove the flush arm through the inlet weldment.
4. At the end of each flush arm remove the socket head cap screw that keeps the backwash pad in place.
5. Replace the old backwash pad with the replacement and reinstall compression spring with the socket
head cap screw.
6. Repeat steps 4 and 5 for each flush arm (if applicable).
7. Replace top flush arm assembly and install (3) socket head cap screws.
Maintenance
8. Replace filter motor cover taking care not to damage sealing O-ring and tighten fasteners.
1 3
Figure 31 Flush Arm Assembly Top

1 Flush Arm 3 Socket Head Cap Screw (x3)
2 Backwash Pad 4 Compression Spring
7.11.4 Backwash Pad (Bottom)

Prerequisites:
Tools:
Materials:
• Backwash Pad(s)
Procedure:
1. Remove the backwash piping from the bottom plate.
2. Remove all bottom plate securing bolts and remove the bottom plate.
3. Remove the bottom flush arm assembly by unscrewing the (3) socket head hex cap set screws located
at the collar of the flush arm.
4. Replace all bottom flush arm assembly components.
Maintenance
5. Re-seal the Treatment unit with the bottom plate and backwash piping.
Figure 32 Flush Arm Assembly Bottom

1 Backwash Pad 3 Flush Arm
2 Compression Spring
7.12 Inline UV Lamp Driver LED Fault Indication

LED Color LED State Description
Red On (Solid) Driver failure
On (Flashing) - 0.5 seconds “ON”, 0.5 seconds “OFF” Lamp Failure
Green On (Solid) Lamp and Driver OK
3
2
Figure 33 LED Fault Indication

1 Status Indication LED 3 Treatment Unit
2 Inline UV Lamp Driver
Maintenance
Section 8 Troubleshooting
DANGER
equipment.
NOTICE
Injury or damage to the equipment caused by improper testing, handling or maintenance is not covered under the warranty of
the manufacturer and is the responsibility of the individual doing the troubleshooting. If there is any question about a
procedure, contact Service before doing the procedure.
Minor Alarm - Indicates the Trojan Marinex BWT system requires maintenance but is operating in
compliance. Minor alarms will remain in the alarms acknowledged and will not reset until the faults have
been remedied. No other actions are required.
Major Alarm: An error has occurred that affects the operation or effectiveness of the system. When a major
alarm is active the system will continue to operate within its capabilities. Major alarms can lead to critical
alarms that can cause the system to shut down unexpectedly. It is necessary to troubleshoot major alarms
as they occur to prevent the system from shutting down unexpectedly or to avoid passing untreated water.
This may require a system shutdown.
Critical Alarm: An error has occurred that has made operation of the system unsafe. When a critical alarm
occurs the system will immediately shut down. This includes the closing of all system controlled valves and
devices. Flow should be shutoff or bypass the BWT system immediately according to ship's operating
procedures. It is necessary to troubleshoot and clear all critical errors before restarting the system.
For the best system operation, resolve every alarm condition as it occurs.
When an alarm occurs, the system does what is necessary to:
• Prevent injury to personnel
• Prevent damage to the vessel
• Prevent damage to the Ballast Water Treatment system
Alarm/Condition Condition Probable Cause Troubleshooting Procedure
Remove actuator and manually move the

valve to an open and closed position. If
Backwash Valve Failed to Close Debris resistance or blockage is detected,
remove valve and check for misalignment
or debris.
Ballast Inlet Valve Failed To Close Verify connections to valve actuator

Actuator not powered
Ballast Inlet Valve Failed To Open Verify power media to the actuator
Major
Deballast Inlet Valve Failed To Close Check or replace valve switches
Defective switch
Deballast Inlet Valve Failed To Open Verify valve cam operation and position
Outlet Valve Failed to Close

Measure valve travel time, increase or
System Bypass Valve Failed to Close Valve travel time decrease setpoint accordingly in HMI
settings.
System Bypass Valve Failed to Open
Troubleshooting
Verify valve cam operation and position;

Inlet valve failure refer to valve manufacturer operations
Ballast Inlet Valve Invalid State and maintenance manual
Major
Incorrect wiring Verify 24VDC signal
Deballast Inlet Valve Invalid State Actuator not powered Verify incoming power

Debris resistance or blockage is detected,
Backwash Valve Failed To Reach remove valve and check for misalignment
Position or debris.
Verify 24VDC signal
Actuator not powered Verify connections to valve actuator

Major
Verify power media to the actuator
Check or replace valve switches

Defective switch
Outlet Valve Failed To Reach Position Verify valve cam operation and position
Measure valve travel time, increase or

Valve travel time decrease setpoint accordingly in HMI
settings.
Deballast inlet valve

failure
Ballast and Deballast Inlet Valve Ballast inlet valve

Major Check or replace valve switches
Open failure
Incorrect Mode of Close one of the valves based on current

operation operation requirement.
Faulty contactor Replace contactor
Drain Pump Contactor Failed to Pump not powered Verify pump power supply
Major
Close
Incorrect wiring Verify pump wiring
Defective pump Replace pump
Disconnect drain lines and clear out

Clogged drain lines
debris
Drain Pump O/L Relay Fault Major
Defective wiring Check wiring to the pump
Defective pump Refer to pump manufacturer O&M manual
Incorrect wiring Verify pump wiring
Defective pump Replace pump

Drain Pump Contactor Failed To
Major Faulty contactor Replace contactor
Open
Overload detected Verify overload relay is not tripped
Lack of Power Verify power source
Lack of Power Verify power source

Filter Motor Contactor Failed to Close
Faulty contactor Replace contactor
Major
Filter Motor Contactor Failed to Open
Incorrect wiring Verify wiring of circuit
Troubleshooting
Debris Verify filter backwash arm spins freely
Lack of power Verify power source

Filter Motor O/L Relay fault Critical
Incorrect wiring Verify wiring of circuit
Flow Meter High Warning Minor Flow rate is too high Check pump spec
Flow Meter High Alarm: System Flow Outlet valve failure See outlet valve troubleshooting
Major
Exceeded
Over sized pump Refer to pump spec
Communication fault Verify 4-20mA signal

Flow Meter Signal Out Of Range Major
Defective sensor Check wiring or replace cable
Inlet Pressure High Warning

Perform a maintenance backwash until
Outlet Pressure High Warning Major Filters clogging
the pressure decreases
Differential Pressure High Warning
System under
Inlet Pressure Signal Out Of Range Check valve lineup to and from system
vacuum
Critical
Outlet Pressure Signal Out of Range Defective Transducer Replace pressure transducer
Check pressure differential. Refer to

Outlet Pressure High Alarm Filters clogged
Maintenance schedule for cleaning filters.
Defective Pressure
Differential Pressure High Alarm Replace pressure transducer
Transducer
Critical
Pump is oversized Review pump specs
Inlet Pressure High Alarm Pressure relief valve

Apply proper pressure setting to the
pressure setting is
pressure relief valve.
not set.
Fouled sensor Clean UVI sensor window; refer to the

window maintenance schedule
Ultraviolet Intensity Low Warning Minor
Refer to the maintenance procedure for
Wiper system failure
removing UV lamps to view the wipers.
Fouled sensor Clean UVI sensor window; refer to the

window maintenance schedule
Ultraviolet Intensity Low Alarm Major
Wiper system failure

Ultraviolet Intensity Signal Out Of
Major
Range Check wiring or replace cable; replace
Sensor malfunction
sensor
Treatment Unit
Check for clogging in the fill line and drain
Temperature Sensor High Warning Major cooling
lines.
malfunctioning
Treatment Unit
Check for clogging in the fill line and drain
Temperature Sensor High Alarm Critical cooling
lines.
malfunctioning
Troubleshooting

Temperature Sensor Signal Out of
Major
Range Check wiring or replace cable; replace
Defective sensor
sensor
Control Cabinet Emergency Stop Incorrect mode of

Critical Verify E-stop is not pressed
Pressed operation
E-stop pressed Check e-stop condition

Control Cabinet: MCR is Off Critical
Power supply fault Check power supply and wiring
Incorrect mode of
PDC: Emergency Stop Pressed Critical Verify E-stop is not pressed
operation
E-stop pressed Check e-stop condition

PDC: MCR is Off Critical
Power supply fault Check power supply and wiring
Sensor or sensor
Remote IO Comm Fault Major Check communication signal wiring
wiring fault
Verify level sensor is operational; replace

Treatment Unit Low Level Fault Critical/Minor Defective switch
level sensor.
Fill valve failure Verify connections to valve actuator
Check or replace power supply

Treatment Unit Temperature Switch
Critical Check or replace valve switches
High Alarm
Treatment Unit
Verify connections to valve actuator
cooling failure
Check or reduce power supply
Defective sensor Verify temperature sensor calibration
Refer to “Treatment Unit Low UV Intensity

Treatment Unit Outside of Approved Low UVI
Fault”
Major
Range
Flow too high Review Pump specs
Bypass valve open Close the bypass valve or stop system

System Bypassed Critical
during operation operation.

resistance or blockage is detected,
Fill valve failure or debris.
Treatment Unit Not Filling Major Verify 24 VDC signal

Verify incoming power

level sensor.
Defective switch
Verify pump operation
Check power supply and wiring
Troubleshooting

UV Chamber drain or debris.
valve failure
Verify 24 VDC signal


Treatment Unit Not Draining Minor Defective switch
level sensor.
Check or replace pump

Defective pump

Discharge valve or debris.
failure
Treatment Unit Not Cooling Major Fill valve not opening Check fill valve operation
UVI sensor
UVI Sensor Calibration Warning Minor calibration is about to Contact Trojan Marinex Service
expire
UVI Sensor Calibration Alarm: UVI UVI sensor

Major Replace UVI sensor
Sensor Calibration Out of Date calibration due
System was
Complete manual drain and fill with
prevented from
System Failed To Properly Shutdown Minor technical or potable water. Complete
completing shutdown
manual lamp cleaning cycle.
procedure.
Check Ethernet connection

Data Logger Failed: System Not
Minor Communication fault
Logging Data Check the data logger power connection
Check 24VDC supply to mode control

contacts
Malfunctioning mode
System Control Mode Alarm –
Minor control switch or PLC Check for damaged or malfunctioning
Defaulted to Local Control Mode
fault mode control switch
Check for damaged wires
Troubleshooting
PLC Faulted
PLC Slot 1 Fault

Replace PLC card; contact Trojan
PLC Slot 2 Fault Major PLC fault
Marinex Service
PLC Slot 3 Fault
PLC Slot 4 Fault
Check SAS communication wiring. Check

SAS Communications Fault Critical Communication fault
control software.
Check ship's SAS network

SAS Flow Signal Fault Major Communication fault
Check communication signal wiring
Wipers did not

complete a full wiper
Wiper ## Fault Minor cycle
H-drive failure Replace H-drive and hydraulic cylinder

Wiper malfunction removing UV lamps to view the wipers to
Wiper ## Not Enabled Minor look for any blockages.
H-drive failure Replace H-drive and hydraulic cylinder
Verify the LED on the Inline Driver is a red

Lamp failure blinking light to confirm lamp failure;
replace lamp.
Lamp String ## Fault Major
Verify the LED on the Inline Driver is solid
Inline Driver failure Red to confirm driver failure; replace
Inline Driver
Section 9 Replacement Parts
Contact Trojan Marinexwith the listed information to order replacement parts.
Provide the:
• Product name and model number (refer to system labels)
• Part number and description of the replacement part or accessory
If a replacement part is not listed, contact your Service Representative for more information.
NOTICE
Shelf life of spare parts
Sensors and electronics have a recommended shelf life of 3 year. Storage past this time may impact the
functionality of the component.
9.1 Scheduled Maintenance Parts

Item Part Number 5 years 10,000 Operating Earlier of 12,000 Operating
Hours Hours or 10 Years
Drive Seal Bushing Refer to 1
Section 9.5.
UVI Sensor 794528 1
TrojanUV Solo Lamp Sleeve 511393-001 Replace all
Assembly
9.2 Recommended On Board Spares

System Models UV Lamps Inline Lamp Drivers
150 2 1
250 2 1
500 2 1
750 4 1
1000 4 1
1250 4 1
1500 4 1
Item Quantity
Pressure Sensor 1 Per Vessel
Level Sensor 1 Per Vessel
Temperature Sensor 1 Per Vessel
Replacement Parts
9.3 Identifying the Configuration of your BWTS
Refer Figure 34 to identify the Design Type of your system prior to selecting replaceable items.
Design Type 1 Design Type 2

Figure 34 BWTS Configuration
9.4 Replacement Parts Overview
5
1 2
Figure 35 Replacement Parts

1 Filter System (Section 9.5) 4 Drain System (Section 9.8)
2 UV System (Section 9.6) 5 Power Distribution Cabinet (Section 9.9)
3 Instrumentation, Technical Fill and Air Vents 6 Control Cabinet (Section 9.10)
(Section 9.7)
Replacement Parts
9.5 Filter System

9.5.1 Gear Motor
Figure 36 Replacement Parts
Component Description Part Number

1 Gear Motor Refer Table 3.
Table 3 Gear Motor Part Numbers
Orientation
Model Vertical Horizontal
50Hz 60Hz 50Hz 60Hz
BWT150
BWT250
BWT500
BWT750 511388-50V 511388-60V 511388-50H 511388-60H
BWT1000
BWT1250
BWT1500
Replacement Parts
9.5.2 Drive Plate Cover
Note: Depending on BWT model provided, the Drive Plate Cover will have one of two configurations.
Refer to the configuration specific to your system.
1
2
3 2
4 3
5 4
5
6
6
7
7
Figure 37 Drive Plate Cover - Configurations

Design Type 1
1 Spacer, Filter Motor MRX STD 506959-001
2 Ring, Drive Seal Back Up 507603
3 Retaining Ring, EXT 50 N 15-7 013292-50N157
4 Bushing, Delrin Filter Drive-2 511279
5 O-ring, 2 1/2 X 1/8 EPDM 002211-230
6 O-ring, 2-1/4 X1/8 Viton 90D 002279-226
7 Bushing, Drive Seal MRX STD 511277-001
Design Type 2
1 Spacer, Filter Motor MRX STD 506959-001
2 Retaining Ring, 55mm External 013298
3 Back-up Ring, Drive Seal MRX 511276
4 Bushing, Bronze Filter Drive 511274
5 O-ring, 2 1/2 X 1/8 EPDM 002211-230
6 O-ring, 1.850 ID X.210 EPDM 002279-226
7 Bushing, Drive Seal MRX STD 511275-001
8 Coupling Bracket, Drive Seal 250i 506398
Replacement Parts
9.5.3 Filter Assembly
2
6
4
Figure 38 Filter Assembly
Design Type 1
Model
Item Component
1 Backwash Pad 507239
2 Compression 506760
Spring
3 O-ring, 6.484 x 002211-260
0.139 EPDM
4 O-ring. 7.475 ID x 002211-431
0.275 EPDM
511047 507482 507618 507815 507785 507983 511346
507784 507985 511347
5 Filter Retaining
507986 511348
Plate
507987 511350
507980 511351
6 O-ring 506333-038 506333-049 506333-033 506333-046 506333-047 506333-010 506333-050
Replacement Parts
Design Type 2
Model
Item Component
BWT 150 BWT 250 BWT 1000 BWT 1250 BWT 1500
1 Backwash Pad 507239
2 Compression Spring 506760
3 O-ring 002211-251 002211-259
4 O-ring 002211-244 002211-252 002211-438
507189 507448 506909 506880-001 507015-001
506880-002 507015-002
5 Filter Retaining Plate
506880-003 507015-003
506880-004 507015-004
506880-005 507015-005
6 O-ring - Filter Plates 506333-038 506333-003 506333-010 506333-010 506333-034
9.5.4 Filter Element
Figure 39 Filter Element

1 O-ring, Filter Top 002211-232
2 Filter Element, Kit (includes 1 and 3) 506742-032
3 O-ring, Filter Bottom 002211-146
Replacement Parts
9.6 UV System
2
1
Figure 40 Lamp Cables

1 Harness, PWR Checkmate 8-drop 511374-008
2 Harness, PWR Checkmate 7-drop 511374-007
Figure 41 UV Lamp Driver Assembly

1 Lamp Driver Assembly, Single Package 511530
Replacement Parts
1
2
Figure 42 UV Lamp Assembly and O-ring

1 Lamp Sleeve Assembly, Inline 500W, Service 511393-001
2 O-ring, 2.359ID x.139 EPDM 002211-229
9.6.1 UV Lamp Cartridge Assembly
1
1
11 3
10
4
8
7 3
5
4
9
5
8 6
7 6

Figure 43 UV Lamp Cartridge Assembly
Replacement Parts
Design Type 1
1 Wiper Drive Kit 507800
2 Guide Rod 507304
3 Wiper Plate Spacer Ring 507268
4 Retaining Ring 5/8 013309-263SS157
5 Cartridge Guide 511573
6 Sleeve Bushing 337850
7 Nut, Hex style 1 M8 316 011072-18RD316
8 Washer, Lock Reg 8 mm 316 012075-AA0080316
9 Washer, Plain 8mm Reg 316 012073-R080316
10 Wiper Holder 507267
11 Wiper Seal 336060
Design Type 2
1 Wiper Drive Kit 507800
2 Guide Rod 507876
3 Cartridge Guide 511573
4 Washer, Plain 8mm Reg 316 012073-R080316
5 Washer, Lock Reg 8 mm 316 012075-AA0080316
6 Nut, Hex style 1 M8 316 011072-18RD316
7 Wiper Holder 506096
8 Wiper Seal 336060
Replacement Parts
9.7 Instrumentation, Technical Fill and Air Vents
Design Type 1
7
5
4
1
Figure 44 Instrumentation Design Type 1 - Vertical Installation
Design Type 1
1 Sensor, Temperature Switch 1/2 NPT 917220
Air Eliminator, Plastic 507578-075
2
Air Eliminator, Stainless Steel 511546
3 Technical Fill Valve 511270-1601PN
4 Switch, Level 3/4 NPT 917222
5 Lug Kit, STRT 8-1/0 AWG 5/16”c 507462
907815-10004BBF
6 Gauge, Pressure 063 1/4BB -1/10
7 Valve, Ball 1/4” FNPT 902472-0401

8 Sensor, Pressure XDCR 1/4 NPT 917219
Refer to
- UVI Sensor
Section 9.7.1
Refer to
- M12 Sensor Cable
Section 9.7.2
Replacement Parts
9
9 2 3 9
2 9
4 8
2
12 8
5
6
11
2
7
7
1
Figure 45 Instrumentation Design Type 2- Vertical Installation
Design Type 2
1 Sensor Kit Assembly Refer to Section 9.7.1
2 Bonded Seal, 1/2” BSPP 316 506401-008
3 Sensor, Temp 4-20mA & PNP G1/2 916688
4 Manifold, Fill Valve 150V HYB 511567
5 Level Switch, 0-20mA. 3/4” BSP 506015
6 Bonded Seal, 1/4” BSPP 316 506401-004
7 Sensor, Press Transducer G 1/4 916642
8 Connection, Tube 1/2 X 1/2 M BSP 316 013359-080816
9 Air Eliminator Assembly, MRX 506734
10 Lug Kit, STRT 8-1/0 AWG 5/16”c 507462
11 Valve, Ball 1/4” FNPT BRZ UN 902472-0401
12 Gauge, Press100 1/4 BTM 0/150 907815-10004BBF
UVI Sensor Refer to Section 9.7.1
- M12 Sensor Cable Refer to Section 9.7.2
Replacement Parts
5 8
4
3 2
9
1
Figure 46 Instrumentation - Horizontal Installation
Design Type 1
1 Valve, Ball 1/4” FNPT 902472-0401
907815-10004BBF
2 Gauge, Press 063 1/4BB -1/10
3 Sensor, Pressure Transducer 1/4 NPT 917219

4 Switch, Level 3/4 NPT 917222
5 Lug Kit, STRT 8-1/0 AWG 5/16”c 507462
6 Sensor, Temperature Switch 1/2 NPT 917221
Air Eliminator, Plastic
7 507578-075
Air Eliminator, Stainless Steel
Refer to
8 UVI Sensor
Section 9.7.1
Refer to
- M12 Sensor Cable
Section 9.7.2
Design Type 2
1 Not Used
2 Gauge, Pressure 907815-10004BBM
Sensor, Pressure Transducer 916642
3
Bonded Seal 506401-004
4 Switch, Level 506015
5 Not Used
Sensor, Temperature Switch 916688
6
Bonded Seal 506041-008
7 Air Eliminator, Plastic 506734
Refer to
8 UVI Sensor
Section 9.7.1
Replacement Parts
Design Type 2
Refer to
- M12 Sensor Cable
Section 9.7.2
9.7.1 UV Sensor
1
2
3
4
5
Figure 47 UV Sensor
Components Description Part Number

1 Gasket, Sanitary 2.5” VITON 820693-007
2 Sensor Adapter 506038
3 O-Ring, 1.257” ID x 0.053” VITON 794611
4 Sensor Window Assy 794530-100
5 UVI Sensor 794528
6 Sanitary Clamp 506285-250
Replacement Parts
9.7.2 M12 Sensor Cable
1
Figure 48 M12 PIN Connections
1 Cable, M12 F 4P HF SHLD 10m 917038-010
9.7.3 H-Drive Power Cable
P1 P31297
DATE CODE
Figure 49 H-Drive Power Cable

1 Cable Assembly, H Wiper 5 Meter 917369-M05
9.8 Drain System
3
2
Figure 50 Drain System - Vertical Installation
Replacement Parts
Model
Item Component BWT BWT BWT BWT BWT BWT BWT
150 250 500 750 1000 1250 1500
Design Type 1
1 Manifold, Double 511421 507772
511566- 511566-
2 Hose Assembly, Flex 1" 511566-16030 511566-16036
16024 16042
4 Valve, Ball 511270-1601PN
5 Gauge, Pressure (Optional) 907856-06304BBF
Design Type 2
1 Manifold, Double 511421 507772
511566-
16042
4 Valve, Ball 511270-1601PN
5 Gauge, Pressure (Optional) 907856-06304BBF
Figure 51 Drain System - Horizontal Installation

Note: Figure is for illustrative purposes only.
Model
Item Component BWT BWT BWT BWT BWT BWT BWT
150 250 500 750 1000 1250 1500
Design Type 1
511566- 511566- 511566-
1* Hose Assembly, Flex 1" 511566-16036 511566-16048
16030 16042 16054
2* Valve, Ball 511270-1601PN
3 Manifold, Single 511371
4 Gauge, Press (Optional) 907856-06304BBF
Replacement Parts
Design Type 2
511566- 511566- 511566-
1* Hose Assembly, Flex 1" 511566-16036 511566-16048
16030 16042 16054
2* Valve, Ball 511270-1601PN
3 Manifold, Single 511427 511371
Manifold, Dual N/A 507772
4 Gauge, Press (Optional) 907856-06304BBF
* System may have more than one hose assembly and valve.
9.8.1 Drain Pump

Frequency
Model 50Hz 60Hz
BWT 150 511419-001 511419-002
BWT 250
BWT 500
BWT 750
507551-001 507551-002
BWT 1000
BWT 1250
BWT 1500
9.9 Power Distribution Cabinet

Refer to the Power Distribution Cabinet Electrical Drawings, Bill of Materials for backplate components
replacement parts.
9.10 Control Cabinet

Refer to the Control Cabinet Electrical Drawings, Bill of Materials for backplate components replacement
parts.
Data Sheet DS/FEP300-EN Rev. K
ProcessMaster FEP300
Electromagnetic flowmeter
The process industry's first choice
Measurement made easy
One solution for all your needs Advanced diagnostics for real-life situations
— The versatile product tailored to meet all your process — Simplified plant trouble shooting increases productivity
applications and process safety
— Status messages in accordance with NAMUR
Versatile and simple configuration — Help texts in the display
— Through glass configuration eliminating the need to
remove the cover and reducing commissioning time Un-paralleled service ability
— Soft key based functionality — Fault finding help texts in the display
— “Easy Set-up” function — Minimized down time with replaceable electronics
cartridge
State-of-the-art memory technology — Universal transmitter reduces spare parts inventory costs
— Revolutionary data storage enables transmitter and storage costs
interchange without the need for reconfiguration
Approvals for explosion protection
ScanMaster in situ verification software option — In accordance with ATEX, IECEx, FM, cFM, NEPSI and
— Allows the customer to perform in-situ verification of the GOST
flowmeter and plant
HART, PROFIBUS PA, FOUNDATION Fieldbus
— Access to all status information
Change from one to two columns

Electromagnetic flowmeter ProcessMaster FEP300 DS/FEP300-EN
The Company Flow performance

ABB is an established world force in the design and Using a higher excitation frequency for the transmitter,
manufacture of instrumentation for industrial process control, ProcessMaster is a flowmeter with an especially short
flow measurement, gas and liquid analysis and environmental response time. With its advanced filtering methods, the device
applications. As a world leader in process automation improves accuracy even under difficult conditions by
technology our worldwide presence, comprehensive service separating the noise from the measuring signal. This leads to
and application oriented know-how make ABB a leading a maximum measuring error of 0.2 % of rate. Self-cleaning,
supplier of flow measurement products. double-sealed polished measuring electrodes enhance the
device's reliability and performance.
Introduction
Easy and quick commissioning
Setting the standard for the process industry
Advanced data storage inside the sensor eliminates the need
ProcessMaster is designed specifically to meet the increased to match sensor and transmitter in the field. The on-board
requirements on advanced flowmeters. The modular design sensor memory automatically identifies the transmitter. On
concept offers flexibility, cost-saving operation and reliability power-on, the transmitter self-configuration function is run and
whilst providing a long service life and exceptionally low replicates all sensor data and TAG specific parameters into
maintenance. the transmitter. This eliminates the opportunity for errors and
Integration into ABB asset management systems and usage leads to an increased startup speed and reliability.
of the selfmonitoring and diagnostic functions increase the
plant availability and reduce downtimes.
Intuitive, convenient navigation
ScanMaster - the diagnostic tool The factory-set parameters can be modified quickly and easily
via the user-friendly display and the non-contact buttons,
Can I rely on the measured values? without opening the housing.
How can I determine the technical condition of my device? The "Easy Set-up" function reliably guides unpracticed users
ScanMaster can answer these frequently asked questions. through the menu step by step.
And ScanMaster allows you to easily check the device for The softkey-based functionality makes handling a breeze - it's
proper functioning either through its Infra-red service port or just like using a cell phone. During the configuration, the
through the HART commands. permissible range of each parameter is indicated on the
display and invalid entries are rejected.
Universal transmitter - powerful and flexible

The backlit display can be easily rotated without the need for
any tools. The contrast is adjustable and the display fully
configurable. The character size, number of lines and display
resolution (number of decimals) can be set as required. In
multiplex operation, several different display options can be
pre-configured and invoked one after the
other.
The smart modular design of the transmitter unit allows for
easy disassembly without the need to unscrew cables or
unplug connectors.
Whether count pulses, 20 mA signals or the status output are
active or passive, the universal transmitter always delivers the
Advanced diagnostic functions correct signal. HART is used as the standard protocol.
Using its advanced diagnostic functions, the device monitors Optionally, the transmitter is available with PROFIBUS PA or
both its own operability and the process. FOUNDATION Fieldbus communication.
Limit values for the diagnostic parameters can be set locally. The universal transmitter simplifies the spare parts inventory
When these limits are exceeded, an alarm is tripped. and reduces the stockholding costs.
For further analysis, the diagnostic data can be read out via
an advanced DTM. Critical states can, thus, be recognized
early and appropriate measures can be taken.
As a result, productivity is increased and downtimes are
avoided. The status messages are classified in accordance
with the NAMUR recommendations.
In the event of an error, a diagnostic-dependent help text
appears on the display which considerably simplifies and
accelerates the troubleshooting procedure. The gives
maximum safety for the process.
2
Assured quality Overview of the ProcessMaster series

ProcessMaster is designed and manufactured in accordance ProcessMaster is available in two series. ProcessMaster 300,
with international quality procedures (ISO 9001) and all which sets the standard in Process Flow measurement and
flowmeters are calibrated on nationally-traceable calibration ProcessMaster 500 with best in class extended functionality
rigs to provide the end- user with complete assurance of both and options. The following table gives an overview.
quality and performance of the meter.
ProcessMaster
FEP300 FEP500
Measuring accuracy
X -
0.4 % (optionally 0.2 %) of rate
Measuring accuracy
- X
0.3 % (optionally 0.2 %) of rate
Batch functions
Presetting counter, overrun correction, - X
external start/stop, batch end contact
Other software functions
X X
Mass units, editable counter,
Two measuring ranges - X
Graphic display
X X
Line recorder function
Diagnostic functions
Detection of gas bubbles or deposits on
- X
electrodes, conductivity monitoring,
temperature monitoring, finger print, trend
Partially filled
ProcessMaster - always the first choice Recognition through partial filling electrode X X
ProcessMaster sets the standard for the process industry. It (TFE)
meets the various requirements of NAMUR. ProcessMaster is Hardware options
a universal device according to the Pressure Equipment Versions for extremely abrasive fluids:
Directive. In compliance with the requirements of NAMUR, the • Ceramic carbide liner, - X
devices are categorized under category III for pipelines. As a • Wolfram carbide electrodes,
result, ProcessMaster can be used universally. This reduces • Double layer electrodes
costs and increases safety. Startup functions
- X
Grounding check
Fieldbus
X X
PROFIBUS PA, FOUNDATION Fieldbus
Verifications / Diagnostic tool
X X
ScanMaster
This data sheet describes ProcessMaster 300.

For ProcessMaster 500 refer to data sheet DS/FEP500
3
Overview – models
Integral mount design
FEP311 FEP315 FEP315
(without explosion protection) (Zone 2 / Division 2) (Zone 1 / Division 1)
1), 3) 2), 3) 2), 4) 2), 5) 1), 3) 2), 3) 2), 4) 2), 3) 2), 4)
G01082-02 G00487-02 G00886-02
Measured error Default: 0.4 % of measured value, 0.2 % of measured value

Nominal diameter range DN 3 ... 2000 (1/10 “ ... 80 ")
Process connection6) Flange in accordance with DIN 2501 / EN 1092-1, ASME B16.5 / B16.47, JIS, AS2129
Nominal pressure PN 10 … 100, ASME CL 150, 300, 600, 900, 1500, 2500
Liner Hard rubber (DN 15 ... 2000), soft rubber (DN 50 ... 2000), PTFE (DN 10 ... 600),
PFA (DN 3 ... 200), ETFE (DN 25 ... 600), Linatex (DN 50 ... 600)
Conductivity > 5 µS/cm (20 µS/cm for demineralized water)
Electrodes Stainless steel, Hastelloy B, Hastelloy C, platinum-iridium, tantalum, titanium, tungsten carbide
Process connection material Steel, stainless steel
IP rating IP 65, IP 67
Measuring medium temperature -25 ... 180 °C (-13 ... 356 °F)
Power supply 100 ... 230 V AC (-15 / +10%), 24 V AC (-30 / +10%), 24 V DC (-30 / +30%)
current output 4 ... 20 mA, active or passive
Pulse output Can be configured locally as active or passive using software
Switch output / switch input Optoelectronic coupler, programmable function
Display Graphical display, configurable
Housing Integral mount design: choice of single-compartment housing or dual-compartment housing.
Communication HART protocol (standard), PROFIBUS PA, FOUNDATION Fieldbus (option)
Explosion protection approvals • ATEX / IECEx zone 1, 2, 21, 22 • NEPSI zone 1, 2
• FM / cFM Cl 1 Div 1 (≤ DN 300), Cl 1 Div 2 • GOST zone 1, 2
Pressure Equipment Directive 97/23/EC Conformity assessment in accordance with category III, fluid group 1
CRN (Canadian Reg.Number) On request
1) Single-compartment housing.
2) Dual-compartment housing.
3) Design level "B" sensor.
4) Design level "B" sensor, all versions made from stainless steel.
5) Design level "C" sensor, DN 25 … 600.
6) For information on flange thicknesses, see the chapters entitled "Dimensions for sensor design level „B“" on page 37 and "Dimensions for sensor design level „C“" on page 43.
Data Sheet Electromagnetic flowmeter

ProcessMaster FEP300
4
Remote mount design

Sensor
FEP321 FEP325 FEP325
(without explosion (Zone 2 / Division 2) (Zone 1 / Division 1)
protection)
1) 2) 1) 1)
G01083-02 G00489-01 G00489-01
Transmitters
FET321 FET325 FET321 FET325 FET325 FET321
(without explosion (Zone 2, Division 2) (without explosion (Zone 1, Division (Zone 2, Division 2) (without explosion
protection) protection) 1) protection)
3) 4) 3) 4) 3) 4) 4) 3) 4) 3) 4)
G01084-02 G01084-02 G01084-02 G00863-02 G01084-02 G01084-02
Sensor
Measured error Default: 0.4 % of measured value, 0.2 % of measured value
Nominal diameter range DN 3 ... 2000 (1/10 “ ... 80 “)
Process connection5) Flange in accordance with DIN 2501 / EN 1092-1, ASME B16.5 / B16.47, JIS 10K
Nominal pressure PN 10 … 100, ASME CL 150, 300, 600, 900, 1500, 2500
Liner Hard rubber (DN 15 ... 2000), soft rubber (DN 50 ... 2000), PTFE (DN 10 ... 600),
PFA (DN 3 ... 200), ETFE (DN 25 ... 600), Linatex (DN 50 ... 600)
Conductivity > 5 µS/cm (20 µS/cm for demineralized water)
Electrodes Stainless steel, Hastelloy B, Hastelloy C, platinum-iridium, tantalum, titanium, tungsten
carbide
Process connection material Steel, stainless steel
IP rating IP 65, IP 67, IP 68, (NEMA 4X)
Fluid temperature -25 ... 180 °C (-13 ... 356 °F)
Transmitters
Power supply 100 ... 230 V AC (-15 / +10 %), 24 V AC (-30 / +10 %), 24 V DC (-30 / +30 %)
current output 4 ... 20 mA, active or passive
Pulse output Can be configured locally as active or passive using software
Switch output / switch input Optoelectronic coupler, programmable function
Display Graphical display, configurable
Housing Field mount housing: choice of single-compartment housing or dual-compartment housing
Communication HART protocol (standard), PROFIBUS PA, FOUNDATION Fieldbus (option)
Approvals
Explosion protection approvals • ATEX / IECEx zone 1, 2, 21, 22 • NEPSI zone 1, 2
• FM / cFM Cl 1 Div 1 (≤ DN 300), Cl 1 Div 2 • GOST zone 1, 2
Pressure Equipment Directive 97/23/EC Conformity assessment in accordance with category III, fluid group 1
CRN (Canadian Reg.Number) On request
1) Design level "B" sensor.

2) Design level "C" sensor, DN 25 … 600.
3) Single-compartment housing.
4) Dual-compartment housing.
5) For information on flange thicknesses, see the chapters entitled "Dimensions for sensor design level „B“" on page 37 and "Dimensions for sensor design level „C“" on page 43.
5
Specification - general
Reference conditions
According to EN 29104
Fluid temperature 20 °C (68 °F) ± 2 K
Ambient 20 °C (68 °F) ± 2 K
temperature
Supply power Nominal voltage acc. to name plate
Un ± 1 %, frequency f ± 1 %
Installation - Upstream >10 x DN, straight section
conditions - Downstream >5 x DN, straight section
Warm-up phase 30 min. Fig. 1
Maximum measuring error Y Accuracy ± of measured value in [%]

X Flow velocity v in [m/s], Q / QmaxDN [%]
Impulse output
- Standard calibration:
Analog output effects
± 0.4 % of measured value,
± 0.02 % QmaxDN (DN 3 … 2000) Same as pulse output plus ± 0.1 % of measured value
± 0.01 mA
- Optional calibration:
± 0.2 % of measured value,
± 0.02 % QmaxDN (DN 10 … 600, 800) Reproducibility, response time
QmaxDN: See table in Section "Flowmeter sizes, flow range" Reproducibility ≤ 0.11 % of measured value,
tmeas = 100 s, v = 0.5 ... 10 m/s
on page 7.
Response time of As step function 0 ... 99 %
current output with 5   200 ms at 25 Hz excitation
damping of frequency
0.02 seconds 5   400 ms at 12.5 Hz excitation
frequency
5   500 ms at 6.25 Hz excitation
frequency
6
Flowmeter sizes, flow range

The flow range end value can be set between 0.02 x QmaxDN and 2 x QmaxDN.
Nominal diameter Min. flow range end value QmaxDN Max. flow range end value
DN " 0.02 x QmaxDN (≈ 0.2 m/s) 0 … ≈ 10 m/s 2 x QmaxDN (≈ 20 m/s)
3 1/10 0.08 l/min (0.02 US gal/min) 4 l/min (1.06 US gal/min) 8 l/min (2.11 US gal/min)
15 1/2 2 l/min (0.53 US gal/min) 100 l/min (26.4 US gal/min) 200 l/min (52.8 US gal/min)
20 3/4 3 l/min (0.79 US gal/min) 150 l/min (39.6 US gal/min) 300 l/min (79.3 US gal/min)
25 1 4 l/min (1.06 US gal/min) 200 l/min (52.8 US gal/min) 400 l/min (106 US gal/min)
32 1 1/4 8 l/min (2.11 US gal/min) 400 l/min (106 US gal/min) 800 l/min (211 US gal/min)
40 1 1/2 12 l/min (3.17 US gal/min) 600 l/min (159 US gal/min) 1200 l/min (317 US gal/min)
50 2 1.2 m3/h (5.28 US gal/min) 60 m3/h (264 US gal/min) 120 m3/h (528 US gal/min)
65 2 1/2 2.4 m3/h (10.57 US gal/min) 120 m3/h (528 US gal/min) 240 m3/h (1057 US gal/min)
125 5 8.4 m3/h (37 US gal/min) 420 m3/h (1849 US gal/min) 840 m3/h (3698 US gal/min)
150 6 12 m3/h (52.8 US gal/min) 600 m3/h (2642 US gal/min) 1200 m3/h (5283 US gal/min)
250 10 36 m3/h (159 US gal/min) 1800 m3/h (7925 US gal/min) 3600 m3/h (15850 US gal/min)
7
Specifications - sensor
ache ich gleich
IP rating Temperature Data

In accordance with EN 60529 The temperature range offered by the device is dependent on
IP 65, P 67, NEMA 4X a number of different factors.
IP 68 (for remote mount design only) These factors include the measuring medium temperature, the
ambient temperature, the operating pressure, the liner
material and the approvals for the explosion protection.
Pipe vibration
In accordance with EN 60068-2-6 Storage temperature
Applicable to sensors in remote mount design and sensors in
-40 ... 70 °C (-40 ... 158 °F)
integral mount design with aluminum transmitter housing.
- In the 10 ... 58 Hz range, max. deflection 0.15 mm (0.006
Minimum permissible pressure depending on measuring
inch)
medium temperature
- In the 58 ... 150 Hz range, max. acceleration 2 g
Installation length Design level "B" sensor

Liner Nominal POperating at Tmedium1)
The flange devices comply with the installation lengths Diameter mbar abs.
specified in VDI/VDE 2641, ISO 13359, or according to
Hard rubber 15 ... 2000 0 < 90 °C (194 °F)
DVGW (process sheet W420, design WP, ISO 4064 short). (1/2 ... 80") < 80 °C (176 °F) 2)
Soft rubber 50 ... 2000 0 < 60 °C (140 °F)
Signal cable (2 ... 80")
For remote mount design only PTFE 10 ... 600 270 < 20 °C (68 °F)
A 5 m (16.4 ft) cable is included in the scope of delivery. (3/8 ... 24") 400 < 100 °C (212 °F)
If more than 5 m (16.4 ft) is required, the cable can be ordered 500 < 130 °C (266 °F)
separately (for ordering information, see the table below or the Thick PTFE, 25 … 80 0 < 180 °C (356 °F)
chapter entitled "Accessories" on page 71). high-temp. 100 … 250 67 < 180 °C (356 °F)
design 300 27 < 180 °C (356 °F)
Signal cable PFA 3 ... 200 0 < 180 °C (356 °F)
(1/10 ... 8")
Application D173D031U01 D173D027U01
ETFE 25 ... 600 100 < 130 °C (266 °F)
Non-Ex (< DN 15)   (1 ... 24")
Non-Ex (≥ DN 15)   Linatex2) 50 ... 600 0 < 70 °C (158 °F)
Zone 2 / Division 2 (< DN (2 … 24“)
15)
 
Zone 2 / Division 2 (≥ DN
15)
  Design level "C" sensor
Liner Nominal POperating at Tmedium1)
Zone 1 / Division 1 Diameter mbar abs.
(all nominal diameters)  
Hard rubber 40 ... 600 600 < 80 °C (176 °F)
(1 1/2 ... 24")
 Application not permitted  Supplied as standard
PTFE 25 ... 600 270 < 20 °C (68 °F)
 Application permitted
(1 ... 24") 400 < 100 °C (212 °F)
500 < 130 °C (266 °F)
On the transmitter design for use in Zone 1, Division 1 (model
FET325), 10 m (32.8 ft) of signal cable is permanently 1) For CIP/SIP cleaning, higher temperatures are permitted for limited time periods; refer to
the table entitled "Maximum permissible cleaning temperature".
connected to the transmitter. 2) For China production site only.
Signal cable length and preamplifier Liner approvals on request; please contact ABB.
A preamplifier is required for cable lengths > 50 m (164 ft).
Maximum signal cable length between sensor and transmitter: Maximum permissible cleaning temperature
Preamplifier Signal cable length CIP cleaning Sensor Tmax Tmax Tamb.
lining minutes
without Max. 50 m (164 ft) for conductivity ≥ 5 µS/cm
Steam cleaning PTFE, PFA 150 °C 60 25 °C
with Max. 200 m (656 ft) for conductivity ≥ 5 µS/cm
(302 °F) (77 °F)
Fluids PTFE, PFA 140 °C 60 25 °C
(284 °F) (77 °F)
If the ambient temperature is > 25 °C, the difference must be

subtracted from the max. cleaning temperature. Tmax - ∆ °C
( ∆ °C = Tamb. - 25 °C).
8
Maximum ambient temperature depending on measuring medium temperature

Note
When using the device in potentially explosive atmospheres, note the additional temperature data in the chapter entitled "Ex
relevant specifications" on page 21.
Integral mount design (standard sensor)

Ambient temperature Measuring medium temperature
Liner Flange material
Minimum Maximum Minimum Maximum
-10 °C (14 °F) 90 °C (194 °F) 4)
Hard rubber Steel -10 °C (14 °F) 60 °C (140 °F)
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
-15 °C (5 °F) 90 °C (194 °F) 4)
Hard rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F)
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
Soft rubber Steel -10 °C (14 °F) 60 °C (140 °F) -10 °C (14 °F) 60 °C (140 °F)
Soft rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F) -15 °C (5 °F) 60 °C (140 °F)
60 °C (140 °F) 90 °C (194 °F)
PTFE Steel -10 °C (14 °F) -10 °C (14 °F)
45 °C (113 °F) 130 °C (266 °F)
-20 °C (-4 °F) 60 °C (140 °F) 90 °C (194 °F)
PTFE Stainless steel -25 °C (-13 °F)
-40 °C (-40 °F) 2) 45 °C (113 °F) 130 °C (266 °F)
60 °C (140 °F) 90 °C (194 °F)
PFA Steel -10 °C (14 °F) -10 °C (14 °F)
45 °C (113 °F) 130 °C (266 °F)
-20 °C (-4 °F) 60 °C (140 °F) 90 °C (194 °F)
PFA Stainless steel -25 °C (-13 °F)
-40 °C (-40 °F) 2) 45 °C (113 °F) 130 °C (266 °F)
60 °C (140 °F) 90 °C (194 °F)
Thick PTFE Steel -10 °C (14 °F) -10 °C (14 °F)
45 °C (113 °F) 130 °C (266 °F)
-20 °C (-4 °F) 60 °C (140 °F) 90 °C (194 °F)
Thick PTFE Stainless steel -25 °C (-13 °F)
-40 °C (-40 °F) 2) 45 °C (113 °F) 130 °C (266 °F)
60 °C (140 °F) 90 °C (194 °F)
ETFE Steel -10 °C (14 °F) -10 °C (14 °F)
45 °C (113 °F) 130 °C (266 °F)
-20 °C (-4 °F) 60 °C (140 °F) 90 °C (194 °F)
ETFE Stainless steel -25 °C (-13 °F)
-40 °C (-40 °F) 2) 45 °C (113 °F) 130 °C (266 °F)
Linatex 1) Steel -10 °C (14 °F) 60 °C (140 °F) -10 °C (14 °F) 70 °C (158 °F)
Linatex 1) Stainless steel -20 °C (-4 °F) 60 °C (140 °F) -20 °C (-4 °F) 70 °C (158 °F)
Integral mount design (high-temperature sensor)3)

PFA Steel -10 °C (14 °F) 60 °C (140 °F) -10 °C (14 °F) 180 °C (356 °F)
-20 °C (-4 °F)
PFA Stainless steel 60 °C (140 °F) -20 °C (-13 °F) 180 °C (356 °F)
-40 °C (-40 °F) 2)
Thick PTFE Steel -10 °C (14 °F) 60 °C (140 °F) -10 °C (14 °F) 180 °C (356 °F)
-20 °C (-4 °F)
Thick PTFE Stainless steel 60 °C (140 °F) -20 °C (-13 °F) 180 °C (356 °F)
-40 °C (-40 °F) 2)
ETFE Steel -10 °C (14 °F) 60 °C (140 °F) -10 °C (14 °F) 130 °C (266 °F)
-20 °C (-4 °F)
ETFE Stainless steel 60 °C (140 °F) -20 °C (-13 °F) 130 °C (266 °F)
-40 °C (-40 °F) 2)
1) For China production site only.
2) For (optional) low-temperature version only.
3) With sensor design level "B" only.
4) The maximum measuring medium temperature is reduced to 80 °C (176 °F) for design level "C" sensors with a hard rubber liner.
9
Note
When using the device in potentially explosive atmospheres, note the additional temperature data in the chapter entitled "Ex
relevant specifications" on page 21.
Remote mount design (standard sensor)

-10 °C (14 °F) 90 °C (194 °F) 4)
Hard rubber Steel -10 °C (14 °F) 60 °C (140 °F)
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
-15 °C (5 °F) 90 °C (194 °F) 4)
Hard rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F)
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
Soft rubber Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14 °F) 60 °C (140 °F)
Soft rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F) -15 °C (5 °F) 60 °C (140 °F)
PTFE Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14 °F) 130 °C (266 °F)
-25 °C (-13 °F)
PTFE Stainless steel 60 °C (140 °F) -25 °C (-13 °F) 130 °C (266 °F)
-40 °C (-40 °F) 2)
PFA Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14 °F) 130 °C (266 °F)
-25 °C (-13 °F)
-40 °C (-40 °F) 2)
Thick PTFE Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14 °F) 130 °C (266 °F)
-25 °C (-13 °F)
-40 °C (-40 °F) 2)
ETFE Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14 °F) 130 °C (266 °F)
ETFE Stainless steel -25 °C (-13 °F) 60 °C (140 °F) -25 °C (-13 °F) 130 °C (266 °F)
Linatex 1) Steel -10 °C (14 °F) 60 °C (140 °F) -10 °C (14 °F) 70 °C (158 °F)
Linatex 1) Stainless steel -20 °C (-4 °F) 60 °C (140 °F) -20 °C (-4 °F) 70 °C (158 °F)
Remote mount design (high-temperature sensor)3)

PFA Steel -10 °C (14 °F) 60 °C (140 °F) -10 °C (14 °F) 180 °C (356 °F)
-25 °C (-13 °F)
-40 °C (-40 °F) 2)
Thick PTFE Steel -10 °C (14 °F) 60 °C (140 °F) -10 °C (14 °F) 180 °C (356 °F)
-25 °C (-13 °F)
-40 °C (-40 °F) 2)
ETFE Steel -10 °C (14°F) 60 °C (140 °F) -10 °C (14 °F) 130 °C (266 °F)
-25 °C (-13 °F)
ETFE Stainless steel 60 °C (140 °F) -25 °C (-13 °F) 130 °C (266 °F)
-40 °C (-40 °F) 2)
1) For China production site only.
2) For (optional) low-temperature version only.
3) With sensor design level "B" only.
4) The maximum measuring medium temperature is reduced to 80 °C (176 °F) for design level "C" sensors with a hard rubber liner.
10
Materials for sensors

Wetted parts Sensor housing
Part Standard Option Design level "B" sensor
Liner PTFE, PFA, ETFE, Linatex
hard rubber, soft
rubber
G01340
Measurement and
Housing
grounding
electrode for: DN 3 ... 400 Pair case, cast aluminum, painted, paint
- Hard rubber Stainless steel Hastelloy B-3 (2.4600), (1/10 ... 16") coat, ≥ 80 µm thick, RAL 9002
1.4571 (AISI 316Ti) Hastelloy C-4 DN 450 … 2000 Welded steel design, painted, paint coat,
- Soft rubber (2.4610), titanium, (18 ... 80") ≥ 80 µm thick, RAL 9002
tantalum, platinum- Terminal box Aluminum alloy, painted, ≥ 80 µm thick,
iridium, gray white, RAL 9002
1.4539 (AISI 904L), Meter tube Stainless steel 3)
tungsten carbide
Cable gland4) Polyamide
- PTFE, PFA, Stainless steel Stainless steel 1.4571
ETFE 1.4539 (AISI 904L) (AISI 316Ti) Stainless steel
Hast. C-4 (2.4610) (in the case of explosion-proof design for
Hast. B-3 (2.4600) ambient temperature of -40 °C [40 °F])
Titanium, tantalum,
platinum-iridium Design level "B" sensor
Grounding plate Stainless steel On request
Protection plate Stainless steel On request
G01342
Non-wetted parts (process connection)
Housing + meter tube
Design level "B" sensor DN 25 ... 400 (1 ... 16") Stainless steel (AISI 316, 316L)
G01340
Design level "C" sensor
Nominal Diameter Standard Option
DN 3 ... 15 Stainless steel1) -
(1/10 ... 1/2")
G01341
DN 20 ... 400 Steel (galvanized)2) Stainless steel 1)
(3/4 ... 16") Housing + meter tube
DN 450 ... 2000 Steel (painted)2) - DN 25 ... 600 (1 ... 24") Steel, painted, paint coat, ≥ 80 µm thick,
(18 ... 80") RAL 9002
Terminal box Aluminum alloy, painted, ≥ 80 µm thick,
gray white, RAL 9002
Design level "B" sensor
The meter tube is made of one of the materials listed below:

G01342
3) 1.4301, 1.4307, 1.4404, 1.4435, 1.4541, 1.4571
Nominal Diameter Standard Option ASTM materials:
Grade TP304, TP304L, TP316L, TP321, TP316Ti, TP317L, 0Cr18Ni9, 00Cr18Ni10,
DN 25 ... 400 Stainless steel - 0CR17Ni14Mo2, 0Cr27Ni12Mo3, 0Cr18Ni10Ti
(1 ... 16") (AISI 316, 316L) 4) Cable gland with M20x1.5 or NPT thread, to be selected via the order number.
Design level "C" sensor
G01341
Nominal Diameter Standard Option

DN 25 ... 600 Steel (painted) 2) -
(1 ... 24")
The process connections are made of one of the materials listed below:
1) 1.4301 (AISI 304), 1.4307, 1.4404 (AISI 316L) 1.4435 (AISI 316L), 1.4541 (AISI 321)
1.4571 (AISI 316Ti), ASTM A182 F304, ASTM A182 F304L, ASTM A182 F316L, ASTM
A182 F321, ASTM A182 F316TI, ASTM A182 F316, 0Cr18Ni9, 0Cr18Ni10,
0Cr17Ni13Mo2, 0Cr27Ni12Mo3, 1Cr18Ni9Ti, 0Cr18Ni12Mo2Ti
2) 1.0038, 1.0460, 1.0570, 1.0432, ASTM A105, Q255A, 20#, 16Mn
11
Overview sensor design level "C" Material load

Limits for the permissible fluid temperature (TS) and
Ambient temp. range: -20 ... 60 °C

permissible pressure (PS) are calculated on the basis of the
Sensor temp. Range: Standard

lining and flange material used in the device (refer to the
name plate on the device).
Flowmeter sensor design level “B”
Carbon steel flange
Electrode design:
DIN flange stainless steel up to DN 600 (24")
Pressure rating
Hard rubber
Sensor Size
PS PS
[bar] [PSI]
Standard
110 1595.4
100 1450.4
PTFE
PN 100
90 1305.3
80 1160.3
DN 25 (1") X X — X X
70 1015.3
DN 32 (1 1/4") X X — X X PN 63
60 870.2
DN 40 (1 1/2") X X X X X
50 725.2
DN 50 (2") X X X X X
DN 65 (2 1/2") DIN PN 10, X X X X X 40
PN 40
580.2
DN 80 (3") DIN PN 16, X X X X X 30 435.1
DN 100 (4") DIN PN 25, X X X X X 20

PN 25
290.1
DIN PN 40 PN 16
DN 125 (5") X X X X X 10
PN 10
145.0
DN 150 (6") X X X X X 0
ASME -30 -10 10 30 50 70 90 110 130 150 170 [°C]
DN 200 (8") CL 150, X X X X X -22 14 50 86 122 158
TS
194 230 266 302 338 [°F]
G00589
DN 250 (10") CL 300 X X X X X Fig. 2
DN 300 (12") X X X X X
DN 350 (14") JIS 10 K X X X X X ASME flange, stainless steel, up to DN 400 (16")
DN 400 (16") X X X X X (CL150/300) up to DN 1000 (40") (CL150)
DN 450 (18") X X X X X PS
[bar]
PS
[PSI]
DN 500 (20") X X X X X 110 1595.4
DN 600 (24") X X X X X 100

CL600
1450.4
90 1305.3
80 1160.3
70 1015.3
60 870.2
50 725.2
CL300
40 580.2
30 435.1
20 290.1
CL150
10 145.0
0
-30 -10 10 30 50 70 90 110 130 150 170 [°C]
-22 14 50 86 122 158 194 230 266 302 338 [°F]
TS G00591
Fig. 3
12
DIN flange, steel, up to DN 600 (24") DIN flange, stainless steel, DN 700 (28") up to
PS PS DN 1000 (40")
[bar] [PSI]
110 PS PS
1595.4
[bar] [psi]
100 1450.4 17 246.5
PN 100
90 1305.3 16 DN 700 PN 16 232.0
1160.3 15 217.5
80
14 203.0
70 1015.3
13 188.5
60 PN 63 870.2 DN 900 PN 16
12 DN 800 PN 16 174.0
50 725.2
11 DN 1000 PN 16 159.5
40 580.2
PN 40 10 145.0
30 435.1 9 DN 900 PN10 130.5
PN 25 DN 800 PN 10
20 290.1 8 DN 700 PN 10 116.0
PN 16
10 145.0 7 DN 1000 PN 10 101.5
PN 10
0 6 87.0
-30 -10 10 30 50 70 90 110 130 150 170 [°C] -30 -20 -10 0 10 20 30 40 50 60 70 80 90 [°C]
-22 14 50 122 122 158 194 230 266 302 338 [°F] 32 TS
-22 -4 14 50 68 86 104 122 140 158 176 194 [°F]
TS G00588 G00219
Fig. 4 Fig. 6
DIN flange, steel, DN 700 (28") up to DN 1000 (40")

ASME flange, steel, up to DN 400 (16") (CL150/300); up to PS PS
DN 1000 (40") (CL150) [bar] [psi]
17 246.5
PS
[bar] 16 232.0
110
15 217.5
100
14 203.0
90 13 DN 700 PN 16 188.5
80 12 174.0
70 11 DN 900 PN 16 159.5
DN 800 PN 16
60 10 145.0
DN 1000 PN 16
9 130.5
50
CL300
8 DN 900 PN 10 116.0
40 DN 800 PN 10
7 DN 700 PN 10 101.5
30
6 DN 1000 PN 10 87.0
20 -10 0 10 20 30 40 50 60 70 80 90 [°C]
CL150 TS
-14 32 50 68 86 104 122 140 158 176 194 [°F] G00220
10
Fig. 7
0
-30 -10 10 30 50 70 90 110 130 150 170 [°C]
-22 14 50 86 122 158 194 230 266 302 338 [°F]
TS G00590
Fig. 5
JIS 10K-B2210 flange

Nominal Material PN TS PS
diameter
32 ... 400 Stainless steel 10 -25 ... 180 °C 10 bar
(1 1/4 ... 16") (-13 ... 356 °F) (145 psi)
32 ... 400 Steel 10 -10 ... 180 °C 10 bar
(1 1/4 ... 16") (14 ... 356 °F) (145 psi)
13
Flowmeter sensor design level “C”

ASME flange, Steel, DN 25 ... 400 (1 ... 24“) Steel casted housing, DN 25 ... 600 (1 ... 24“)
PS PS PS PS
[bar] [psi] [bar] [PSI]
450 6527 40 PN40 580
CL2500
400 5801 35 508
350 5076 30 435
300 4351 25 PN25 363

CL1500
250 3625 20 CL150 290
15 PN16 218
200 2900
CL900
150 2175 10 PN10 145
CL600
100 1450 5 73
50 725 0 0
-10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 °C
0 0 14 32 50 68 86 104 122 140 158 176 194 212 230 248 266 °F
-30 -10 0 10 30 50 70 90 110 130 150 180 °C TS
-22 14 32 50 86 122 158 194 230 266 302 356 °F G01335
TS G01338
Fig. 10
Fig. 8
Welded steel housing, DN 25 ... 600 (1 ... 24“)
ASME flange, stainless steel, DN 25 ... 400 (1 ... 24“)
PS PS
PS PS [bar] [PSI]
[bar] [psi]
CL2500 50 CL300 725
350 5076
300 4351
40 PN40 580
250 3625
CL1500 30 435
200 2900 PN25
20 CL150 290
150 2175
CL900 PN16
100 CL600 1450 10 PN10 145
50 725
0 0
-10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 °C
0 0
-30 -10 0 10 30 50 70 90 110 130 150 180 °C 14 32 50 68 86 104 122 140 158 176 194 212 230 248 266 °F
-22 14 32 50 86 122 158 194 230 266 302 356 °F TS
G01336
TS G01337
Fig. 11
Fig. 9
14
Specifications - transmitter Mechanical properties

IP rating
In accordance with EN 60529 Integral mount Housing made of Housing made of
IP 65, IP 67, NEMA 4X design Aluminium stainless steel
Housing Cast aluminum, Stainless steel CF3M
painted
Vibration
Paint Paint coat ≥ 80 µm -
In accordance with EN 60068-2 thick, RAL 9002
Applicable to transmitters with remote mount design. (light gray)
- In the 10 ... 58 Hz range, max. deflection 0.15 mm (0.006 Cable gland2) Polyamide Polyamide
inch) 1) Stainless steel1) Stainless steel1)
- In the 58 ... 150 Hz range, max. acceleration 2 g 1)
1) Peak load Remote mount design
Housing Cast aluminum, painted
Temperature Data Paint Paint coat ≥ 80 µm thick, RAL 7012 (dark
Ambient temperature gray), front cover / rear cover RAL 9002
(light gray)
Standard: -20 ... 60 °C (-4 ... 140 °F)
Extended: -40 ... 60 °C (-40 ... 140 °F)
Stainless steel1)
Storage temperature range Weight 4.5 kg (9.92 lb)
-40 ... 70 °C (-40 ... 158 °F)
1) In the case of hazardous area design for ambient temperature of -40 °C (40 °F)
2) Cable Gland with M20x1,5 thread or NPT thread with plug to be specified through
modelcode
Electrical data and options
Power supply
Supply voltage 100 ... 230 V AC (-15 % / +10 %),
47 ... 64 Hz
24 V AC (-30 % / +10 %),
47 ... 64 Hz
24 V DC (-30 % / +30 %),
Ripple: < 5 %
Power consumption AC DC
≤ 20 VA 12 W
Inrush current at Inrush current: 5.6 A
230 V: 8.8 A
Screw terminals Maximum 2.5 mm2 (AWG 14)
Isolation of inputs / outputs

The current output, digital outputs DO1 and DO2, and digital
input are electrically isolated from the sensor input circuit and
from each other. The same applies to the signal outputs of the
versions with PROFIBUS PA and FOUNDATION Fieldbus.
Empty conduit detection

This function requires the following:
The conductivity of the measuring medium must
be  20 µS/cm, the signal cable length must be ≤ 50 m (164 ft)
and the nominal diameter DN must be ≥ DN 10. Furthermore,
no preamplifier may be fitted to the sensor.
15
Electrical connections
HART, PROFIBUS PA and FOUNDATION Fieldbus protocols for devices that do not have an explosion-
proof design
A HART FEP311
24 V
+ - + - + - + -
31 32 51 52 81 82 41 42 M1 M2 D1 D2 3 2S E2 E1 1S
FET321
FF+ FF-
1+ 2-
PA+ PA- + -
L N
97 98 41 42
FEP321 < 50 m (200 m)
< 164 ft (656 ft)
PE
B M1 M2 D1 D2 3 2S E2 E1 1S
G01326
A = Transmitter, B = Sensor
Fig. 12: HART-, PROFIBUS PA- and FOUNDATION Fieldbus protocol
Power supply connections Output connections
AC power supply Terminal Function / Notes

Terminal Function / Notes 31 / 32 Current / HART output
L Live / Phase The current output is available in "active" or "passive"
mode.
N Neutral
PE / Protective earth (PE) 97 / 98 Digital communication
PROFIBUS PA (PA+ / PA-) or FOUNDATION
fieldbus (FF+ / FF-) in acc. with IEC 61158-2.
DC power supply
51 / 52 Digital output DO1 active / passive
Terminal Function / Notes Function can be configured locally as „Pulse Output"
1+ + or „Digital Output". Factory setting is „Pulse Output".
2- - 81 / 82 Digital input / contact input
PE / Protective earth (PE) Function can be configured locally as „External
output switch-off“, „external totalizer reset“, „external
totalizer stop“ or „other“.
Sensor cable terminal connections
41 / 42 Digital output DO2 passive
Only on remote mount design. Function can be configured locally as „Pulse Output"
or „Digital Output". Factory setting is „Digital Output",
Terminal Function / Notes Wire color flow direction signaling.
M1 Magnet coil Brown Functional ground
M2 Magnet coil Red
D1 Data line Orange
D2 Data line Yellow
/ SE Shield -
E1 Signal line Violet
1S Schield for E1 -
E2 Signal line Blue
2S Schield for E2 -
3 Measurement potential Green
16
Electrical data
Current / HART output
A I E B I E 700
RB RB 650
+31 +31 V 600

U1 U2 550
-32 -32 500
RB[Ω]
450
G00475-01
400
The current / HART output can be operated in "active" or "passive" mode. 350
A Active: 4 ... 20 mA, HART protocol (standard), load: 250 Ω ≤ R ≤ 650 Ω 300
B Passive: 4 ... 20 mA, HART protocol (standard), load: 250 Ω ≤ R ≤ 650 Ω 250
Supply voltage for the current output: minimum 11 V, maximum 30 V. 200
17 18 19 20 21 22 23 24 25 26 27 28 29 30
U2 [V] G00592
For Ex zone 1 / Div. 1 the maximum load is 300 Ω. Max. permissible load (RB) as a function of the source
voltage (U2)
Fig. 13: (I = internal, E = external)
Digital output DO1

1550
A I E B I E 1450
1350
RB*
19 ... 21 V+ ≤ 30 V+ 1250
51 51 1150
1050
U2 950
- 52 52 -
RB [Ω]
850
Imax = 220 mA
* RB UCE 750
ICE G00476-04
650
550
450
The output can be configured as an "active (A)" or "passive (B)" output (in the case 350
of the transmitter with the dual-compartment housing, the output is configured 250
using the software; in the case of the transmitter with the single-compartment 150
50
housing, it is configured by means of jumpers on the transmitter backplane). 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
U2 [V]
Configuration as "active" output: G00593
- U = 19 ... 21 V, Imax = 220 mA , fmax ≤ 5250 Hz

Max. permissible load (RB) as a function of the source
Configuration as "passive" output
- Umax = 30 V, Imax = 220 mA, fmax ≤ 5250 Hz voltage (U2).  = Permissible range
Configuration as pulse output:
- Max. pulse frequency: 5250 Hz.
- Pulse width: 0.1 … 2000 ms.
- The pulse factor and pulse width are interdependent and are calculated
dynamically.
Configuration as contact output:
- Function: System alarm, empty pipe alarm, max. / min. alarm, flow direction
signaling, other
Digital output DO2

I E The output is always a "passive" output (optocoupler).
R B* Data for the optocoupler:
+U
41 Umax = 30 V, Imax = 220 mA, fmax ≤ 5250 Hz
For maximum load see diagram Fig. 14.
42
Imax = 220 mA
* RB UCE
ICE G00792-01
Digital input DI
I E Data for the optocoupler:
16 V ≤ U ≤ 30 V, Ri = 2 kΩ
Ri = 2 k
81 24V+
82 0V
G00477-01
17
Digital communication
I E I E
PA- FF-
98 98
R R
PA+ FF+
C C
97 97
G00248-01
PROFIBUS PA (PA+ / PA-) FOUNDATION Fieldbus (FF+ / FF-)
U = 9 ... 32 v, I = 10 mA (normal operation), I = 13 mA (in the event of U = 9 ... 32 v, I = 10 mA (normal operation), I = 13 mA (in the event of
an error / FDE) an error / FDE)
Bus connection with integrated protection against polarity reversal. Bus connection with integrated protection against polarity reversal
The bus address can be set via the DIP switches in the device (with
dual-compartment transmitter housing only), the transmitter display or
the fieldbus.
The resistance R and condenser C form the bus termination. They must be installed when the device is connected to the end of the entire bus
cable. R = 100 Ω; C = 1 µF
Connection examples
Digital output DO2
E.g., for system monitoring, max. / min. alarm, empty meter tube or forward / reverse signal, or counting pulses
(function can be configured using software)
I E
R B*
+U
41
42
Imax = 220 mA
* RB UCE
ICE G00792-01
Digital outputs DO1 and DO2

Separate forward and reverse pulses Separate forward and reverse pulses (alternative connection)
I E I E
51 51
52 52
-
V +
24V+
24V
42 42
41 41
G00791
PROFIBUS PA - Connection via M12 plug

Only in non-hazardous areas
Pin assignment
(Front view showing pin insert and pins)
PIN 1 = PA+
PIN 2 = nc
PIN 3 = PA-
PIN 4 = shield
4 3
1 2
G01003-01
Fig. 20
18
Digital communication PROFIBUS PA

The interface conforms to profile 3.01 (PROFIBUS standard, EN
HART protocol 50170, DIN 19245 [PRO91]).
The unit is registered with the HART Communication

Foundation. PROFIBUS DP PROFIBUS PA
100
H2-Bus A 1 F
PA+ PA- PA+ PA- PA+ PA-
G00111
A = Segment coupler (incl. bus supply and termination)

Fig. 22: Example for PROFIBUS PA interface connection
Fig. 21 PROFIBUS PA ID no 0x3430

Alternative 0x9700 or 0x9740
Configuration Directly on the device standard ID no
Software DAT200 Asset Vision Basic Configuration Directly on the device
(+ HART-DTM) Software DAT200 Asset Vision Basic (+
Transmission FSK modulation on current output PROFIBUS PA-DTM)
4 ... 20 mA acc. to Bell 202 standard Transmission signal Acc. to IEC 61158-2
Max. signal amplitude 1.2 mAss Cable Shielded, twisted cable (acc. to IEC
61158-2, types A or B are preferred)
Current output load Min. 250 Ω, max. = 560 Ω
Cable AWG 24 twisted
Bus topology
Max. cable length 1500 m
• Tree and/or line structure
Baud rate 1,200 baud
• Bus termination: passive at both ends of the main bus line
Display Log. 1: 1,200 Hz
(RC element R = 100 Ω, C = 1 µF)
Log. 0: 2,200 Hz
Voltage / current consumption
For additional information, see separate interface
documentation. • Average current consumption: 10 mA
• In the event of an error, the integrated FDE function
System integration (=Fault Disconnection Electronic) integrated in the device
is ensures that the current consumption can rise to a
In conjunction with the DTM (Device Type Manager) available maximum of 13 mA.
for the device, communication (configuration, • The upper current limit is restricted electronically.
parameterization) can occur with the corresponding • The voltage on the bus line must lie in the range of 9 ... 32
framework applications according to FDT 1.21 (DAT200 Asset V DC.
Vision Basic).
Other tool/system integrations (e.g., Emerson AMS/Siemens For additional information, see separate interface
PCS7) are available upon request. documentation.
A free of charge version of the DAT200 Asset Vision Basic
framework application for HART® or PROFIBUS is available System integration
upon request.
ABB provides three different GSD files (equipment master
The required DTMs are contained on the
data) which can be integrated in the system.
DAT200 Asset Vision Basic DVD or in the DTM Library.
Users decide at system integration whether to install the full
They can also be downloaded from www.abb.com/flow.
range of functions or only part.
The change-over is done using the “ID-number selector”
parameter.
ID number 0x9700, GSD file name: PA139700.gsd
ID number 0x9740, GSD file name: PA139740.gsd
ID number 0x3430, GSD file name: ABB_3430.gsd
The GSD files can be downloaded from www.abb.com/flow.

The files required for operation can be downloaded from
www.profibus.com.
19
FOUNDATION Fieldbus (FF) Bus address

The bus address is automatically assigned or can be set in the
Ethernet FOUNDATION Fieldbus H1 system manually.
The identifier (ID) is formed using a unique combination of
100
manufacturer ID, device ID, and device serial number.
HSE-Bus B 1 F
System integration
FF+ FF- FF+ FF- FF+ FF- The following are required:
G00112 • DD (Device Description) file, which includes the device
description.
B = Linking device (incl. bus supply and termination)
• The CFF (Common File Format) file is required for
Fig. 23: Example for FOUNDATION Fieldbus interface connection
engineering the segment. Engineering can be performed
online or offline.
Interoperability test ITK 5.20
campaign no.
The files can be downloaded from www.abb.com/flow.
Manufacturer ID 0x000320
The files required for operation can also be downloaded from
Device ID 0x0124
http://www.fieldbus.org.
Configuration • Directly on the device
• Via services integrated in the
system
• National configurator
Transmission signal Acc. to IEC 61158-2
Bus topology
• Tree and/or line structure
• Bus termination: passive at both ends of the main bus line
(RC element R = 100 Ω, C = 1 µF)
Voltage / current consumption

• Average current consumption: 10 mA
• In the event of an error, the integrated FDE function
(=Fault Disconnection Electronic) integrated in the device
is ensures that the current consumption can rise to a
maximum of 13 mA.
• Upper current limit: electronically restricted.
• The voltage on the bus line must lie in the range of
9 ... 32 V DC.
20
Ex relevant specifications
Electrical connection for operation in zones 1, 21, 22 / Div 1
Flowmeter sensor and transmitter in zone 1 / Div 1
A HART
FEP315
24 V
+ - + - + - + -
31 32 51 52 81 82 41 42 M1 M2 D1 D2 3 2S E2 E1 1S
PROFIBUS PA, FOUNDATION Fieldbus PA PA

FF+ FF-
1+ 2- PA+ PA- + -
L N 97 98 41 42
FEP325 FET325
PE
PA
B M1 M2 D1 D2 3 E2 E1
PA
PA G01327
Fig. 24: HART, PROFIBUS PA and FOUNDATION Fieldbus protocol

N Neutral mode. The configuration must be specified ordering
the meter, because it is not possible to change the
PE / Protective earth (PE) configuration on site.
97 / 98 Digital communication
DC power supply PROFIBUS PA (PA+ / PA-) or FOUNDATION
Terminal Function / Notes Fieldbus (FF+ / FF-) in acc. with IEC 61158-2.
1+ + 51 / 52 Digital output DO1 passive
2- - Function can be configured locally as „Pulse Output"
or „Digital Output". Factory setting is „Pulse Output".
PE / Protective earth (PE)
81 / 82 Digital input / contact input
Function can be configured locally as „External
Sensor cable terminal connections output switch-off“, „external totalizer reset“, „external
Only on remote mount design. totalizer stop“ or „other“. Only available in conjunction
with current output „passive“.
Terminal Function / Notes Wire color 41 / 42 Digital output DO2 passive
M1 Magnet coil Brown Function can be configured locally as „Pulse Output"
M2 Magnet coil Red flow direction signaling.
D1 Data line Orange PA Potential Equalization (PA)
D2 Data line Yellow
/ SE Shield - Note
E1 Signal line Violet The housing for the transmitter and flowmeter sensor must be
1S Schield for E1 - connected to the potential equalization PA. The operator must
E2 Signal line Blue ensure that when connecting the protective conductor (PE) no
2S Schield for E2 - potential differences can occur between protective conductor
3 Measurement potential Green and potential equalization (PA).
A temperature of 70 °C (158 °F) at the cable entry is assumed
for the Ex calculations. Therefore, the cables used for the
supply power and the signal inputs and outputs must have a
minimum specification of 70 °C (158 °F).
For devices with remote mount design for use in
FM / cFM Div. 1 or FM / cFM Div. 2 the signal cable between
the flowmeter sensor and the transmitter must have a
minimum length of 5 m (16.4 ft).
21
Flowmeter sensor in zone 1 / Div 1 and transmitter in zone 2 / Div 2 or outside the hazardous area
FEP325 flowmeter sensor FET325 transmitter FET321 transmitter
(Zone 1 / Div 1) (Zone 2 / Div 2) outside the hazardous area
PA
PA
A HART
24 V
+ - + - + - + -
31 32 51 52 81 82 41 42 M1 M2 D1 D2 3 2S E2 E1 1S
PA /
FF+ FF-
1+ 2-
PA+ PA- + -
L N
97 98 41 42
PE
B M1 M2 D1 D2 3 E2 E1
PA
G01328
Fig. 25: HART, PROFIBUS PA and FOUNDATION Fieldbus protocol

mode.
N Neutral
Fieldbus (FF+ / FF-) in acc. with IEC 61158-2.
DC power supply
51 / 52 Digital output DO1 active / passive
Sensor cable terminal connections
41 / 42 Digital output DO2 passive
M1 Magnet coil Brown PA Potential Equalization (PA)
M2 Magnet coil Red Functional ground
D1 Data line Orange (only with transmitter outside the hazardous area)
D2 Data line Yellow
/ SE Shield - Note
1S Schield for E1 - connected to the potential equalization PA. The operator must
ensure that when connecting the protective conductor (PE) no
E2 Signal line Blue
potential differences can occur between protective conductor
2S Schield for E2 -
and potential equalization (PA).
For devices with remote mount design for use in
FM / cFM Div. 1 or FM / cFM Div. 2 the signal cable between
the flowmeter sensor and the transmitter must have a
minimum length of 5 m (16.4 ft).
22
Electrical data for operation in zones 1, 21, 22 / Div. 1

Devices with HART protocol
When operating in potentially explosive areas, observe the following electrical data for the signal inputs and outputs of the
transmitter. For the correct current output design (active/passive), see the marking contained in the device's terminal box.
Dependent upon the device design, an "active" or a "passive" output will be available. For devices designed for use in Ex Zone 1, the
current output cannot be reconfigured locally. The configuration required for the current output (active/passive) must be specified
when the order is placed.
Model FEP315 or FET325
Operating values Type of protection Ex i, IS
Inputs and outputs UN IN UO IO PO CO COPA LO
[V] [mA] [V] [mA] [mW] [nF] [nF] [mH]
Active current / HART output (Terminals 31 / 32) 20 100 500 210 195 6
Load: 250 Ω ≤ R ≤ 300 Ω UI II PI CI CIPA LI
30 30
[V] [mA] [mW] [nF] [nF] [mH]
60 425 4) 2000 4) 8,4 24 0,065
Passive current / HART output (Terminals 31 / 32) UI II PI CI CIPA LI
Load: 250 Ω ≤ R ≤ 650 Ω 30 30 [V] [mA] [mW] [nF] [nF] [nH]
60 500 4) 2000 4) 8,4 24 170
Passive digital output DO2 (Terminals 41 / 42) UI II PI CI CIPA LI
[V] [mA] [mW] [nF] [nF] [nH]
30 220
4251) 4)
60 2000 4) 3,6 3,6 170
5002) 4)
Passive digital output DO1 (Terminals 51 / 52) 4251) 4)
30 220 60 2000 4) 3,6 3,6 170
5002) 4)
Passive digital input DI (Terminals 81/82)3)
30 10 60 500 4) 2000 4) 3,6 3,6 170
1) For "active" current output

2) For "passive" current output
3) Only available in conjunction with passive current output
4) Intrinsically safe single-channel or multi-channel barriers (supply isolators) with resistance characteristic must be used.
All inputs and outputs are electrically isolated from each other and from the power supply.
Note
The output circuits are designed in such a way that they can be connected to both intrinsically-safe and non-intrinsically-safe
circuits. It is not permitted to combine intrinsically safe and non-intrinsically safe circuits. In the case of intrinsically safe circuits,
potential equalization is required.
The rated voltage of the non-intrinsically safe circuits is UM = 60 V.
Provided that rated voltage UM = 60 V is not exceeded if connections are established to non-intrinsically safe external circuits,
intrinsic safety is still guaranteed.
23
Devices with PROFIBUS PA or FOUNDATION Fieldbus

transmitter. For the correct design (PROFIBUS PA or FOUNDATION Fieldbus), see the marking contained in the device's
terminal box.
For devices in Zone 1 / Div. 1 the bus termination must conform to the FISCO model or the explosion protection regulations,
respectively.
For devices in Zone 2 / Div. 2 the bus termination must conform to the FNICO model or the explosion protection regulations,
respectively.

The fieldbus and the digital output can be connected in zone 1 / Div. 1 in three different variants.
Variant 1: Intrinsically safe fieldbus connection in acc. with FISCO, intrinsically safe connection of the digital output
Operating values Type of protection Ex i, IS and FISCO
Inputs and outputs UN IN Ui Ii Pi Ci CiPA Li
[V] [mA] [V] [mA] [mW] [nF] [nF] [µH]
Passive digital output DO2 (terminals 41 / 42) 30 220 60 200 1) 5000 1) 3,6 3,6 0,17
Fieldbus (terminals 97 / 98) 32 30 17 380 5320 1 1 5
Variant 2: Intrinsically safe fieldbus connection (not in acc. with FISCO!), intrinsically safe connection of the digital
output
Operating values Type of protection Ex i, IS
[V] [mA] [V] [mA] [mW] [nF] [nF] [µH]
Passive digital output DO2 (terminals 41 / 42) 30 220 60 200 1) 5000 1) 3,6 3,6 0,17
Fieldbus (terminals 97 / 98) 32 30 60 500 5000 1 1 5
Variant 3: Fieldbus connection in acc. with FNICO (Zone 2, Div. 2), connection of digital output (Zone 2, Div. 2)
Operating values Type of protection Ex n, NI and FNICO
[V] [mA] [V] [mA] [mW] [nF] [nF] [µH]
Passive digital output DO2 (terminals 41 / 42) 30 220 - - - - - -
Fieldbus (terminals 97 / 98) 32 30 60 500 1) 5000 1) 1 1 5
1) Single-channel or multi-channel barriers (supply isolators) with resistance characteristic must be used.
All inputs and outputs are electrically isolated from each other and from the supply power.
Note
The output circuits are designed in such a way that they can be connected to both intrinsically-safe and non-intrinsically-safe
circuits. It is not permitted to combine intrinsically safe and non-intrinsically safe circuits. In the case of intrinsically safe circuits,
potential equalization is required.
The rated voltage of the non-intrinsically safe circuits is UM = 60 V. Provided that rated voltage UM = 60 V is not exceeded if
connections are established to non-intrinsically safe external circuits, intrinsic safety is still given.
24
Temperature data
Note
The maximum permissible measuring medium temperature depends on the liner and flange material, and is limited by the
operating data in Table 1 and the Ex relevant specifications in Tables 2 ... n.
Table 1: Measuring medium temperature as a function of lining and flange material for models FEP315 and FEP325
Materials Measuring medium temperature (operating values)
Lining Flange Minimum Maximum
-10 °C (14 °F) 90 °C (194 °F)
Hard rubber Steel
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
-15 °C (5 °F) 90 °C (194 °F)
Hard rubber Stainless steel
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
Soft rubber Steel -10 °C (14 °F) 60 °C (140 °F)
Soft rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F)
PTFE Steel -10 °C (14 °F) 130 °C (266 °F)
PTFE Stainless steel -25 °C (-13 °F) 130 °C (266 °F)
PFA Steel -10 °C (14 °F) 180 °C (356 °F)
PFA Stainless steel -25 °C (-13 °F) 180 °C (356 °F)
Thick PTFE Steel -10 °C (14 °F) 180 °C (356 °F)
Thick PTFE Stainless steel -25 °C (-13 °F) 180 °C (356 °F)
ETFE Steel -10 °C (14 °F) 130 °C (266 °F)
ETFE Stainless steel -25 °C (-13 °F) 130 °C (266 °F)
1) Only China production site
25
Table 2: Measuring medium temperature for model FEP315

Ambient temperature
Temperature class
Nominal diameter
(- 40 °C)1) - 20 °C ... + 40 °C (- 40 °C)1) - 20 °C ... + 50 °C (- 40 °C)1) - 20 °C ... + 60 °C

Design
Not thermally Thermally Not thermally Thermally Not thermally Thermally

insulated insulated insulated insulated insulated insulated
Gas & Gas & Gas & Gas & Gas & Gas &
Gas Gas Gas Gas Gas Gas
dust dust dust dust dust dust
NT 130 °C 90 °C 30 °C 80 °C 40 °C
T1
HT 180 °C 120 °C 20 °C 120 °C 20 °C
NT 130 °C 90 °C 30 °C 80 °C 40 °C
T2
HT 180 °C 120 °C 20 °C 120 °C 20 °C
DN 3 ... DN 100
NT 130 °C 90 °C 30 °C 80 °C 40 °C
T3
HT 180 °C 120 °C 20 °C 120 °C 20 °C
NT 120 °C 90 °C 30 °C 80 °C 40 °C
T4
HT 120 °C 120 °C 20 °C 120 °C 20 °C
NT 85 °C 70 °C 30 °C 80 °C 40 °C
T5
HT 85 °C 85 °C 20 °C 85 °C 20 °C
NT 70 °C 70 °C 30 °C 70 °C 40 °C
T6
HT 70 °C 70 °C 20 °C 70 °C 20 °C
NT 130 °C 90 °C 30 °C 80 °C 40 °C
T1
HT 180 °C 120 °C 20 °C 120 °C 20 °C
NT 130 °C 90 °C 30 °C 80 °C 40 °C
DN 125 ... DN 2000
T2
HT 180 °C 120 °C 20 °C 120 °C 20 °C
NT 130 °C 90 °C 30 °C 80 °C 40 °C
T3
HT 180 °C 120 °C 20 °C 120 °C 20 °C
NT 125 °C 90 °C 30 °C 80 °C 40 °C
T4
HT 125 °C 120 °C 20 °C 120 °C 20 °C
NT 90 °C 90 °C 30 °C 80 °C 40 °C
T5
HT 90 °C 90 °C 20 °C 90 °C 20 °C
NT 75 °C 75 °C 30 °C 75 °C 40 °C
T6
HT 75 °C 75 °C 20 °C 75 °C 20 °C
1) Low-temperature version (option)
NT: standard sensor design, Tmedium maximum 130 °C (266 °F),

HT: high-temperature sensor design, Tmedium maximum 180 °C (356 °F)
Not thermally insulated: The flowmeter sensor is not surrounded by pipe insulation material.
Thermally insulated: The flowmeter sensor is surrounded by pipe insulation material.
Note
The standard version includes explosion protection for gases and dust. Explosion protection for dust is only available for devices
featuring a transmitter in a dual-compartment housing.
• If the installation location for the device is classified as a potentially explosive area for gases and dust, the temperature data
in the "Gas & dust" columns in the table must be taken into consideration.
• If the installation location for the device is classified as a potentially explosive area for gases only, the temperature data in
the "Gas" column in the table must be taken into consideration.
26

Ambient temperature
Temperature class
Nominal diameter
(- 40 °C)1) - 20 °C ... + 40 °C (- 40 °C)1) - 20 °C ... + 50 °C (- 40 °C)1) - 20 °C ... + 60 °C

Design

NT 130 °C 110 °C 110 °C 110 °C 110 °C
T1
HT 180 °C 160 °C 150 °C 160 °C 150 °C
NT 130 °C 110 °C 110 °C 110 °C 110 °C
T2
HT 180 °C 160 °C 150 °C 160 °C 150 °C
DN 3 ... DN 100
NT 130 °C 110 °C 110 °C 110 °C 110 °C

T3
HT 180 °C 160 °C 150 °C 160 °C 150 °C
NT 120 °C 110 °C 110 °C 110 °C 110 °C
T4
HT 120 °C 120 °C 120 °C 120 °C 120 °C
NT 85 °C 85 °C 85 °C 85 °C 85 °C
T5
HT 85 °C 85 °C 85 °C 85 °C 85 °C
NT 70 °C 70 °C 70 °C 70 °C 70 °C
T6
HT 70 °C 70 °C 70 °C 70 °C 70 °C
NT 130 °C 110 °C 110 °C 110 °C 110 °C
T1
HT 180 °C 160 °C 150 °C 160 °C 150 °C
NT 130 °C 110 °C 110 °C 110 °C 110 °C
DN 125 ... DN 2000
T2
HT 180 °C 160 °C 150 °C 160 °C 150 °C
NT 130 °C 110 °C 110 °C 110 °C 110 °C
T3
HT 180 °C 160 °C 150 °C 160 °C 150 °C
NT 125 °C 110 °C 110 °C 110 °C 110 °C
T4
HT 125 °C 125 °C 125 °C 125 °C 125 °C
NT 90 °C 90 °C 90 °C 90 °C 90 °C
T5
HT 90 °C 90 °C 90 °C 90 °C 90 °C
NT 75 °C 75 °C 75 °C 75 °C 75 °C
T6
HT 75 °C 75 °C 75 °C 75 °C 75 °C
NT: standard sensor design, Tmedium maximum 130 °C (266 °F).

HT: high-temperature sensor design, Tmedium maximum 180 °C (356 °F).
Note
The standard version includes explosion protection for gases and dust.
the "Gas" columns in the table must be taken into consideration.
27
Electrical connection for operation in zone 2, 21, 22 / Div. 2

Sensor and transmitter in Zone 2 / Division 2, or transmitter outside the potentially explosive atmosphere
Transmitter FET321
Sensor FEP315, FET325 and transmitter FET325
outside the potentially explosive
Zone 2, Div 2
atmosphere
6
PA
PA
FEP315 FEP325 FET325 FET321
A HART
24 V
+ - + - + - + -
31 32 51 52 81 82 41 42 M1 M2 D1 D2 3 2S E2 E1 1S
PA /
FF+ FF-
1+ 2-
PA+ PA- + -
L N
97 98 41 42
PE
B M1 M2 D1 D2 3 2S E2 E1 1S
PA
G01329
A = transmitter, B = sensor
Fig. 26: HART, PROFIBUS PA and FOUNDATION Fieldbus protocols

mode.
N Neutral
Fieldbus (FF+ / FF-) in acc. with IEC 61158-2.
DC power supply 51 / 52 Digital output DO1 active / passive
Sensor cable terminal connections 41 / 42 Digital output DO2 passive
M1 Magnet coil Brown PA Potential Equalization (PA)
M2 Magnet coil Red Functional ground
D1 Data line Orange (only for transmitter outside the hazardous area)
D2 Data line Yellow
/ SE Shield - Note
connected to the potential equalization PA. The operator must
1S Schield for E1 -
ensure that when connecting the protective conductor (PE) no
E2 Signal line Blue
potential differences can occur between protective conductor
2S Schield for E2 - and potential equalization (PA).
28
Electrical data for operation in zones 2, 21, 22 / Div. 2

Devices with HART protocol
transmitter. For the correct current output design (active/passive), see the marking contained in the device's terminal box.

Operating values Type of protection Ex n/NI
Signal inputs and outputs Ui [V] Ii [mA] Ui [V] Ii [mA]
Current / HARToutput, active/passive (terminals 31/32)
30 30 30 30
Load: 250 Ω ≤ R ≤ 650 Ω
Digital output DO1, active/passive (terminals 51/52) 30 220 30 220
Digital output DO2, passive (terminals 41/42) 30 220 30 220
Digital input DI (terminals 81/82) 30 10 30 10
All inputs and outputs are electrically isolated from each other and from the supply power.
Devices with PROFIBUS PA or FOUNDATION Fieldbus

transmitter. For the correct design (PROFIBUS PA or FOUNDATION Fieldbus), see the marking contained in the device's
terminal box.
For devices in Zone 2 / Div. 2 the bus termination must conform to the FNICO model or the explosion protection regulations,
respectively.

Operating values Type of protection Ex n, NI and FNICO
[V] [mA] [V] [mA] [mW] [nF] [nF] [µH]
Digital output DO2, passive (terminals 41/42) 30 220 - - - - - -
Fieldbus (terminals 97/98) 32 30 32 500 1) 7000 1) 1 1 5
1) Single-channel or multi-channel barriers (supply isolators) with resistance characteristic must be used.
29
Temperature data
Table 1: Measuring medium temperature as a function of lining and flange material for models FEP315 and FEP325
Materials Measuring medium temperature (operating values)
Lining Flange Minimum Maximum
-10 °C (14 °F) 90 °C (194 °F)
Hard rubber Steel
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
-15 °C (5 °F) 90 °C (194 °F)
Hard rubber Stainless steel
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
Soft rubber Steel -10 °C (14 °F) 60 °C (140 °F)
Soft rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F)
PTFE Steel -10 °C (14 °F) 130 °C (266 °F)
PTFE Stainless steel -25 °C (-13 °F) 130 °C (266 °F)
PFA Steel -10 °C (14 °F) 180 °C (356 °F)
PFA Stainless steel -25 °C (-13 °F) 180 °C (356 °F)
Thick PTFE Steel -10 °C (14 °F) 180 °C (356 °F)
Thick PTFE Stainless steel -25 °C (-13 °F) 180 °C (356 °F)
Elastomer 2) Steel -10 °C (14 °F) 130 °C (266 °F)
Elastomer 2) Stainless steel -20 °C (-4 °F) 130 °C (266 °F)
ETFE Steel -10 °C (14 °F) 130 °C (266 °F)
ETFE Stainless steel -25 °C (-13 °F) 130 °C (266 °F)
1) Only China production site

2) USA production site, only (only for FM / cFM Div 2)
30

Ambient temperature
Temperature class
Nominal diameter
- 20 °C ... + 40 °C - 20 °C ... + 50 °C - 20 °C ... + 60 °C

- 40 °C ... + 40 °C 1) - 40 °C ... + 50 °C 1) - 40 °C ... + 60 °C 1)
Design

100 °C 2)
NT 130 °C 130 °C --- --- 130 °C --- --- 80 °C 40 °C --- ---
ProcessMaster DN 3 ... DN 2000
HygienicMaster DN 3 ... DN 100
T1 110 °C 3)
HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 40 °C 180 °C 40 °C
100 °C 2)
NT 130 °C 130 °C --- --- 130 °C --- --- 80 °C 40 °C --- ---
T2 110 °C 3)
HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 40 °C 180 °C 40 °C
100 °C 2)
NT 130 °C 130 °C --- --- 130 °C --- --- 80 °C 40 °C --- ---
T3 110 °C 3)
HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 40 °C 180 °C 40 °C
100 °C 2)
NT 130 °C 130 °C --- --- 130 °C --- --- 80 °C 40 °C --- ---
T4 110 °C 3)
HT 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 40 °C 130 °C 40 °C

2) Temperature values for ProcessMaster
3) Temperature values for HygienicMaster
NT: standard sensor design, Tmedium maximum 130 °C (266 °F)

Note
The standard version includes explosion protection for gases and dust. Explosion protection for dust is only available for devices
featuring a transmitter in a dual-compartment housing.
the "Gas" column in the table must be taken into consideration.
31

Ambient temperature
Nominal diameter
- 20 °C ... + 40 °C - 20 °C ... + 50 °C - 20 °C ... + 60 °C

Temperature - 40 °C ... + 40 °C 1) - 40 °C ... + 50 °C 1) - 40 °C ... + 60 °C 1)
Design
class Not thermally Thermally Not thermally Thermally Not thermally Thermally
110 °C 2)
NT 130 °C 130 °C --- --- 130 °C 130 °C --- --- 110 °C --- ---
T1 120 °C 3)
HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C
ProcessMaster DN 3 ... DN 2000
HygienicMaster DN 3 ... DN 100
110 °C 2)
NT 130 °C 130 °C --- --- 130 °C 130 °C --- --- 110 °C --- ---
T2 120 °C 3)
HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C
110 °C 2)
NT 130 °C 130 °C --- --- 130 °C 130 °C --- --- 110 °C --- ---
T3 120 °C 3)
HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C
110 °C 2)
NT 130 °C 130 °C --- --- 130 °C 130 °C --- --- 110 °C --- ---
T4 120 °C 3)
HT 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C
NT 95 °C 95 °C --- --- 95 °C 95 °C --- --- 95 °C 95 °C --- ---
T5
HT 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C
NT 80 °C 80 °C --- --- 80 °C 80 °C --- --- 80 °C 80 °C --- ---
T6
HT 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C

2) Temperature values for ProcessMaster
3) Temperature values for HygienicMaster
NT: standard sensor design, Tmedium maximum 130 °C (266 °F)

Note
The standard version includes explosion protection for gases and dust.
the "Gas" columns in the table must be taken into consideration.
32
Specifications for operation in areas with combustible dust

The device with dual-compartment transmitter housing is approved for use in potentially explosive areas
(gas and dust).
The Ex certification is provided on the name plate.
DANGER - Risk of explosion!
The dust explosion protection is also provided by the housing.
Modifications to the housing are not allowed (e.g., removing or omitting parts).
Maximum allowable surface temperature

Model Maximum surface temperature
FEP325 T 85 °C (185 °F) ... Tmedium
FEP315 T 70 °C (158 °F) ... Tmedium
FET325 T 70 °C (158 °F)
The maximum surface temperature is applicable to dust layers of up to 5 mm (0.20 inch) in thickness. The
minimum permissible ignition and smoldering temperatures of the dust atmosphere should be calculated in
accordance with IEC61241ff.
With thicker dust layers, the maximum permissible surface temperature must be reduced. The dust can be
conductive or non-conductive. IEC61241ff must be observed.
Minimum signal cable length

In explosion protection areas, the signal cable cannot be shorter than 5 m (16.4 ft).
33
Installation requirements
Grounding Electrode axis

The flowmeter sensor must be connected to ground potential. Electrode axis (1) should be horizontal if at all possible or no
For technical reasons, this potential should be identical to the more that 45° from horizontal.
potential of the metering fluid.
For plastic or insulated lined pipelines, the fluid is grounded by
installing ground plates. When there are stray potentials max. 45°
present in the pipeline, a ground plate is recommended on
both ends of the meter sensor.
1
G00041
Mounting
Fig. 28
The following points must be observed during installation:
• The meter tube must always be completely full Inlet and outlet pipe sections
• The flow direction must correspond to the marking, if The metering principle is independent of the flow profile as
present long as standing eddies do not extend into the metering
• The maximum torque for all flange screws must be section, such as may occur after double elbows (1), in the
complied with These must be selected depending on the event of tangential inflow, or where half-open gate valves are
temperature, pressure, screw material, gasket material located upstream of the flowmeter sensor.
etc., and in accordance with the currently applicable In such cases, measures must be put in place to normalize
regulations the flow profile.
• The devices must be installed without mechanical tension • Do not install fittings, manifolds, valves, etc., directly in
(torsion, bending) front of the flowmeter sensor (1).
• Flange devices with plane parallel counterflanges may • Butterfly valves must be installed so that the valve plate
only be installed with suitable gaskets does not extend into the flowmeter sensor.
• Only flat gaskets made from a material that is compatible • Valves or other turn-off components should be installed in
with the measuring medium and measuring medium the outlet pipe section (2).
temperature may be used Experience has shown that, in most installations, straight inlet
• Gaskets must not extend into the flow area, since possible sections 3 x DN long and straight outlet sections 2 x DN long
turbulence could influence the accuracy of the device are sufficient (DN = nominal diameter of the sensor Fig. 29 ).
• The piping may not exert any inadmissible forces or For test stands, the reference conditions of 10 x DN straight
torques on the device inlet and 5 x DN straight outlet must be provided, in
• Do not remove the sealing plugs in the cable glands until accordance with EN 29104 / ISO 9104.
you are ready to install the electrical cable
• When using a separate transmitter, this must be installed
at a location that is largely free of vibrations 1 2
• Do not expose the transmitter to direct sunlight and
provide for appropriate sun protection where necessary
3xDN 2xDN G00037
Flow direction
Fig. 29
The device measures the flowrate in both directions. Forward
flow is the factory setting, as shown in Fig. 27. Vertical connections
Vertical installation for measuring abrasive fluids, preferably
with flow in upward direction.
G00657-01
Fig. 27
G00039-01
Fig. 30
34
Horizontal connections Installation of the high temperature design

• Meter tube must always be completely full. The high temperature design allows for complete thermal
• Provide for a slight incline of the connection for degassing. insulation of the sensor. The pipeline and sensor must be
insulated after installing the unit according to the following
illustration.
3°
1
G00038
Fig. 31
Free inlet or outlet

• Do not install the flowmeter at the highest point or in the
draining- off side of the pipeline, flowmeter runs empty, air
bubbles can form (1).
• Provide for a siphon fluid intake for free inlets or outlets so
that the pipeline is always full (2). G00654
Fig. 35
1 Insulation
2
Installation in pipelines with larger nominal diameters
1 Determine the resulting pressure loss when using reduction
pieces (1):
G00040
1. Calculate the diameter ratio d/D.
Fig. 32 2. Determine the flow velocity based on the flow range
nomograph (Fig. 37).
Strongly contaminated measuring media 3. Read the pressure drop on the Y-axis in Fig. 37.
For strongly contaminated measuring media, a bypass
connection according to the figure is recommended so that
operation of the system can continue to run without
interruption the during the mechanical cleaning.
Fig. 36
1 Flange transition piece p pressure loss [mbar]
d Inside diameter of the D Inside diameter of the
flowmeter pipeline
G00042
V flow velocity [m/s]
Fig. 33
Installation near pumps
If sensors are installed near pumps or other installations that cause
vibration, the use of mechanical snubbers is recommended.
G00561
Fig. 34
35
Nomograph for pressure drop calculations

For flange transition piece with /2 = 8°
Fig. 37
36
Dimensions for sensor design level „B“

Flange DN 3 ... 125 (1/10 ... 5"), aluminum sensor housing (shell housing)
77,8 (3.06) 105 (4.13) 98 (3.86)
168 (6.61) 102.5 (4.04)
74,2 (2.92)
100 (3.94)
187 (7.36)
201 (7.91)
84.5 (3.33)
35 (1.38)
F
E
G
D
C
A B
L* G00479-02
Fig. 38: Dimensions in mm (inches)

Dimensions mm (inch) Approx. weight in
kg (lb)
DN Process connection D B L 2) 3) 8) F 4) C E 4) G 4) A Integral Remote
3 ... 8 5) EN 1092-1 7) 90 19 200 255 82 188 143 113 7 (15) 5 (11)
(1/8 ... 5/16 6)) PN 10 … 40 1) (3.54) (0.75) (7.84) (10.04) (3.23) (7.4) (5.63) (4.45)
ASME B16.5 CL 150 89 14.2
10 (3.50) (0.56)
(3/8 6) ASME B16.5 CL 300 96 17.3
(3.78) (0.68)
JIS 10K 90 15
(3.54) (0.59)
15 (1/2) EN 1092-1 7) 95 19 200 255 82 188 143 113 7 (15) 5 (11)
PN 10 … 40 1) (3.74) (0.75) (7.84) (10.04) (3.23) (7.4) (5.63) (4.45)
ASME B16.5 CL 150 89 14.2
(3.50) (0.56)
ASME B16.5 CL 300 96 17.3
(2.72) (0.68)
JIS 10K 95 15
(3.74) (0.59)
20 (3/4) EN 1092-1 7) 105 21 200 255 82 188 143 113 8 (18) 6 (13)
PN 10 … 40 1) (4.13) (0.83) (7.84) (10.04) (3.23) (7.4) (5.63) (4.45)
ASME B16.5 CL 150 98 15.7
(3.86) (0.62)
ASME B16.5 CL 300 118 18.7
(4.65) (0.74)
JIS 10K 100 17
(3.94) (0.67)
25 (1) EN 1092-1 7) 115 21 200 255 82 188 143 113 9 (20) 7 (15)
PN 10 … 40 1) (4.53) (0.83) (7.84) (10.04) (3.23) (7.4) (5.63) (4.45)
ASME B16.5 CL 150 108 17.2
(4.25) (0.68)
ASME B16.5 CL 300 124 20.5
(4.88) (0.81)
JIS 10K 125 17
(4.92) (0.67)
32 (1 1/4) EN 1092-1 7) 140 21 200 262 92 195 150 113 10 (22) 8 (18)
PN 10 … 40 1) (5.51) (0.83) (7.87) (10.31) (3.62) (7.68) (5.91) (4.45)
ASME B16.5 CL 150 118 18.7
(4.65) (0.74)
ASME B16.5 CL 300 134 22.1
(5.28) (0.87)
JIS 10K 135 19
(5.31) (0.75)
40 (1 1/2) EN 1092-1 7) 150 21 200 262 92 195 150 113 11 (24) 9 (20)
PN 10 … 40 1) (5.91) (0.83) (7.87) (10.31) (3.62) (7.68) (5.91) (4.45)
ASME B16.5 CL 150 127 20.5
(5.00) (0.81)
ASME B16.5 CL 300 156 23.6
(6.14) (0.93)
JIS 10K 140 19
(5.51) (0.75)
Tolerance for L: +0 / -3 mm (+0 / -0.018 inch)
37
Dimensions mm (inch) Weight in kg (lb)

DN Process connection D B L 2) 3) 8) F 4) C E 4) G 4) A Integral Remote
50 (2) EN 1092-1 7) 165 23 200 268 97 201 156 115 12 (26) 10 (22)
PN 10 … 40 1) (6.50) (0.91) (7.87) (10.55) (3.82) (7.91) (6.14) (4.53)
ASME B16.5 CL 150 153 22.1
(6.02) (0.87)
ASME B16.5 CL 300 165 25.4
(6.50) (1.0)
JIS 10K 155 19
(6.10) (0.75)
AS2129 table D 150
AS2129 table E (5.91)
65 (2 1/2) EN 1092-1 7) PN 16 1) 185 22 200 279 108 212 167 104 15 (33) 13 (29)
(7.28) (0.87) (7.87) (10.98) (4.25) (8.35) (6.57) (4.09)
EN 1092-1 7) PN 40 1) 185 26 15 (33) 13 (29)
(7.28) (1.02)
ASME B16.5 CL 150 178 25.4 13 (29) 11 (24)
(7.01) (1.0)
ASME B16.5 CL 300 191 28.4 15 (33) 13 (29)
(7.52) (1.12)
JIS 10K 175 21 15 (33) 13 (29)
(6.89) (0.83)
AS2129 table D 165 13 (29) 11 (24)
AS2129 table E (6.50)
80 (3) EN 1092-1 7) 200 28 200 279 108 212 167 104 17 (38) 15 (33)
PN 10 … 40 1) (7.87) (1.10) (7.87) (10.98) (4.25) (8.35) (6.57) (4.09)
ASME B16.5 CL 150 191 26.9 17 (38) 15 (33)
(7.52) (1.06)
ASME B16.5 CL 300 210 31.4 19 (42) 17 (38)
(8.27) (1.24)
JIS 10K 185 21 19 (42) 17 (38)
(7.28) (0.83)
AS2129 table D 185 17 (38) 15 (33)
AS2129 table E (7.28)
100 (4) EN 1092-1 7) PN 16 1) 220 24 250 301 122 234 189 125 19 (42) 17 (38)
(8.66) (0.94) (9.84) (11.85) (4.80) (9.21) (7.44) (4.92)
EN 1092-1 7) 235 28 23 (51) 21 (46)
PN 25 … 40 1) (9.25) (1.10)
ASME B16.5 CL 150 229 27.4 21 (46) 19 (42)
(9.02) (1.08)
ASME B16.5 CL 300 254 35.8 30 (66) 28 (62)
(10.0) (1.41)
JIS 10K 210 21 19 (42) 17 (38)
(8.72) (0.83)
AS2129 table D 215 21 (46) 19 (42)
AS2129 table E (8.46)
125 (5) EN 1092-1 7) PN 16 1) 250 25 250 311 130 244 199 125 22 (49) 20 (44)
(9.84) (0.98) (9.84) (12.24) (5.12) (9.61) (7.83) (4.92)
EN 1092-1 7) 270 29 29 (64) 27 (60)
PN 25 … 40 1) (10.63) (1.14)
ASME B16.5 CL 150 254 27.9 22 (49) 20 (44)
(10.0) (1.10)
ASME B16.5 CL 300 280 39.1 35 (77) 33 (73)
(11.02) (1.54)
JIS 10K 250 27 22 (49) 20 (44)
(9.84) (1.06)
AS2129 table D 255 22 (49) 20 (44)
AS2129 table E (10.04)
1) Other pressure ratings on request.
2) If an earthing plate is fitted (attached to one side of the flange), dimension L increases as follows: by 3 mm (0.118 inch) for DN 3 ... 100, and by 5 mm (0.197 inch) for DN 125.
3) If protection plates are fitted (attached to both sides of the flange), dimension L increases as follows: by 6 mm (0.236 inch) for DN 3 ... 100, and by 10 mm (0.394 inch) for DN 125.
4) Depending on the device design, the dimensions change in accordance with the following table:
Device design Dimension E, F Dimension G
Without explosion protection Standard temperature design 0 0
High temperature design +127 mm (+5 inch) +127 mm (+5 inch)
Explosion protection Zone 1, Standard temperature design +74 mm (+2.91 inch) +47 mm (+1.85 inch)
Division 1
High temperature design +127 mm (+5 inch) +174 mm (+6.85 inch)
Explosion protection Zone 2, Standard temperature design 0 0
Division 2
5) Connection flange DN 10.
6) Connection flange 1/2".
7) Connecting dimensions in accordance with EN 1092-1. For DN 65, PN 16 in accordance with EN 1092-1, please order PN 40.
8) For devices with ordering code "Installation length JN" (China production site), the installation length corresponds to the ISO installation length.
38
Flange DN 150 ... 400 (6 ... 16"), aluminum sensor housing (shell housing)
77,8 (3.06) 105 (4.13) 98 (3.86)
74,2 (2.92)
168 (6.61) 100 (3.94) 102.5 (4.04)
POWER SUPPLY
84.5 (3.33)
201 (7.91)
187 (7.36)
35 (1.38)
FIELD TERMINALS
F
E
G
D
C
A
L* B
G00480-02
Dimensions mm (inch) Approx. weight in kg

(lb)
DN Process connection D B L 2) 3) F 4) C E 4) G 4) A Integral Remote
150 (6) EN 1092-1 PN 16 1) 285 25 300 358 146 291 246 166 33 (73) 31 (68)
(11.22) (0.98) (11.81) (14.09) (5.75) (11.46) (9.69) (6.54)
EN 1092-1 300 31 39 (86) 37 (82)
PN 25 … 40 1) (11.81) (1.22)
ASME B16.5 CL 150 280 29.4 33 (73) 31 (68)
(11.02) (1.16)
ASME B16.5 CL 300 318 40.5 47 (104) 45 (99)
(12.52) (1.59)
JIS 10K 280 28 33 (73) 31 (68)
(11.02) (1.10)
AS2129 table D 280 — 33 (73) 31 (68)
AS2129 table E (11.02)
200 (8) EN 1092-1 340 28 350 399 170 331 286 200 41 (90) 39 (86)
PN 10 … 16 1) (13.39) (1.10) (13.78) (15.71) (6.69) (13.03) (11.26) (7.87)
EN 1092-1 PN 25 1) 360 34 43 (95) 41 (90)
(14.17) (1.34)
EN 1092-1 PN 40 1) 375 38 43 (95) 41 (90)
(14.76) (1.50)
ASME B16.5 CL 150 345 33.6 50 (110) 48 (106)
(13.58) (1.32)
ASME B16.5 CL 300 381 46.1 72 (158) 70 (154)
(15) (1.81)
JIS 10K 330 33 43 (95) 41 (90)
(12.99) (1.30)
AS2129 table D 335 — 50 (110) 48 (106)
AS2129 table E (13.19)
250 (10) EN 1092-1 PN 10 1) 395 30 450 413 198 346 301 235 61 (135) 59 (130)
(15.55) (1.18) (17.72) (16.26) (7.80) (13.62) (11.85) (9.25)
EN 1092-1 PN 16 1) 405 30 61 (135) 59 (130)
(15.94) (1.18)
EN 1092-1 PN 25 1) 425 36 65 (143) 63 (139)
(16.73) (1.42)
EN 1092-1 PN 40 1) 450 42 65 (143) 63 (139)
(17.72) (1.65)
ASME B16.5 CL 150 407 35.2 70 (154) 68 (150)
(16.02) (1.39)
ASME B16.5 CL 300 445 52.8 105 (232) 103 (227)
(17.52) (2.08)
JIS 10K 400 37 65 (143) 63 (139)
(15.75) (1.46)
AS2129 table D 405 — 70 (154) 68 (150)
AS2129 table E (15.94)
Tolerance for L: DN 150 ... 200 +0 / -3 mm (+0 / -0.118 inch), DN 250 ... 400 +0 / -5 mm (+0 / -0.197 inch)
39

(lb)
300 (12) EN 1092-1 PN 10 1) 445 31 500 436 228 369 324 272 74 (163) 72 (159)
(17.52) (1.22) (19.68) (17.17) (8.98) (14.53) (12.76) (10.71)
EN 1092-1 PN 16 1) 460 33 74 (163) 72 (159)
(18.11) (1.30)
EN 1092-1 PN 25 1) 485 39 80 (176) 78 (172)
(19.09) (1.54)
EN 1092-1 PN 40 1) 515 47 80 (176) 78 (172)
(20.28) (1.85)
ASME B16.5 CL 150 483 36.8 105 (232) 103 (227)
(19.02) (1.45)
ASME B16.5 CL 300 521 55.8 140 (309) 138 (304)
(20.51) (2.20)
JIS 10K 445 40 80 (176) 78 (172)
(17.52) (1.57)
AS2129 table D 455 — 105 (232) 103 (227)
AS2129 table E (17.19)
350 (14) EN 1092-1 PN 10 1) 505 31 550 451 265 384 339 322 95 (209) 93 (203)
(19.88) (1.22) (21.65) (17.76) (10.43) (15.12) (13.35) (12.68)
EN 1092-1 PN 16 1) 520 35 95 (209) 93 (203)
(20.47) (1.38)
EN 1092-1 PN 25 1) 555 43 110 (243) 108 (238)
(21.85) (1.69)
ASME B16.5 CL 150 533 40.1 130 (278) 128 (282)
(20.98) (1.58)
ASME B16.5 CL 300 584 58.8 150 (331) 148 (326)
(22.99) (2.31)
JIS 10K 490 — 110 (243) 108 (238)
(19.29)
AS2129 table D 525 — 105 (232) 103 (227)
AS2129 table E (20.67)
400 (16) EN 1092-1 PN 10 1) 565 31 600 493 265 426 381 322 103 (227) 101 (223)
(22.24) (1.22) (23.62) (19.41) (10.43) (16.77) (15.00) (12.68)
EN 1092-1 PN 16 1) 580 37 103 (227) 101 (223)
(22.83) (1.46)
EN 1092-1 PN 25 1) 620 45 126 (278) 124 (273)
(24.41) (1.77)
ASME B16.5 CL 150 597 41.6 175 (386) 173 (381)
(23.50) (1.64)
ASME B16.5 CL 300 647 62.2 265 (584) 263 (580)
(25.47) (2.45)
JIS 10K 560 — 126 (278) 124 (273)
(22.05)
AS2129 table D 580 — 175 (386) 173 (381)
AS2129 table E (22.83)
2) If an earthing plate is fitted (attached to one side of the flange), the length L increases by 5 mm (0.197 inch).
3) If protection plates are fitted (attached to both sides of the flange), the length L increases by 10 mm (0.394 inch).
4) Depending on the device design, the dimensions change in accordance with the following table.

Without explosion protection Standard temperature design 0 0
Explosion protection Zone 1, Division Standard temperature design +74 mm (+2.91 inch) +47 mm (+1.85 inch)
1
Explosion protection Zone 2, Division Standard temperature design 0 0
2
40
Flange DN 450 ... 2000 (18 ... 80"), steel sensor housing
77,8 (3.06) 105 (4.13) 98 (3.86)

168 (6.61) 100 (3.94) 101.5 (4.04)
7.42 (2.92)
84.5 (3.33)
35 (1.38)
201 (7.91)
187 (7.36)
F
E
G
D
C
A
B
L*
G00481-03

(lb)
450 (18) ASME B16.5 CL 150 635 44.6 686 501 310 434 389 407 260 (573) 258 (569)
(25.0) (1.76) (27.01) (19.72) (12.20) (17.09) (15.31) (16.02)
AS2129 table D 640 —
AS2129 table E (25.20)
500 (20) EN 1092-1 PN 10 1) 670 33 650 501 310 434 389 407 190 (419) 188 (415)
(26.38) (1.30) (25.59) (19.72) (12.20) (17.09) (15.31) (16.02)
EN 1092-1 PN 16 1) 715 39 240 (529) 238 (525)
(28.15) (1.54)
ASME B16.5 CL 150 699 47.9 762 300 (661) 298 (657)
(27.52) (1.89) (30.0)
AS2129 table D 705 — 650

AS2129 table E (27.76) (25.59)
600 (24) EN 1092-1 PN 10 1) 780 33 780 552 361 485 440 469 246 (542) 244 (537)
(30.71) (1.30) (30.71) (21.73) (14.21) (19.09) (17.32) (18.46)
EN 1092-1 PN 16 1) 840 41 318 (701) 316 (697)
(33.07) (1.61)
ASME B16.5 CL 150 813 52.8 914 425 (937) 423 (933)
(32.01) (2.08) (35.98)
AS2129 table D 825 — 780
AS2129 table E (32.48) (30.71)
700 (28) EN 1092-1 PN 10 1) 895 35 910 596 405 529 484 537 320 (706) 318 (701)
(35.24) (1.38) (35.83) (23.46) (15.94) (20.83) (19.06) (21.14)
EN 1092-1 PN 16 1) 910 41 440 (970) 438 (966)
(35.83) (1.61)
ASME 16.47 series B 837 49.6 350 (772) 348 (767)
CL 150 (32.95) (1.95)
760 (30) ASME B16.5 CL 150 888 44.5 990 606 435 539 494 - 230 (507) 228 (503)
(34.96) (1.75) (38.96) (23.86) (17.13) (21.22) (19.45)
800 (32) EN 1092-1 PN 10 1) 1015 37 1040 646 455 579 534 605 420 (926) 418 (922)
(39.96) (1.46) (40.94) (25.43) (17.91) (22.8) (21.02) (23.82)
EN 1092-1 PN 16 1) 1025 43 490 (1080) 488 (1076)
(40.35) (1.69)
ASME 16.47 series B 942 51 502 (1107) 500 (1102)
CL 150 (37.09) (2.01)
41

(lb)
900 (36) EN 1092-1 PN 10 1) 1115 39 1170 696 505 629 584 671 505 503
(43.90) (1.54) (46.06) (27.40) (19.88) (24.76) (22.99) (26.42) (1113) (1109)
EN 1092-1 PN 16 1) 1125 45 590 588
(44.29) (1.77) (1301) (1296)
ASME 16.47 series B 1157 57.3 680 678
CL 150 (45.55) (22.56) (1499) (1495)
1000 (40) EN 1092-1 PN 10 1) 1230 39 1300 746 555 679 634 739 690 688
(48.43) (1.54) (51.18) (29.37) (21.85) (26.73) (24.96) (29.09) (1521) (1516)
EN 1092-1 PN 16 1) 1255 47 850 848
(49.41) (1.85) (1873) (1869)
ASME 16.47 series B 1175 60.6 880 878
CL 150 (46.26) (2.39) (1940) (1936)
1050 (42) ASME 16.47 series B 1067 58.7 1365 771 580 704 659 739 932 930
CL 150 (42.01) (2.31) (53.74) (30.35) (22.83) (72.72) (25.94) (29.09) (2055) (2050)
1100 (44) ASME 16.47 series B 1118 60.5 1430 — — — — 739 962 960
CL 150 (44.02) (2.38) (56.30) (29.09) (2121) (2116)
1200 (48) EN 1092-1 PN 10 1) 1455 43 1560 856 660 789 742 800 700 698
(57.28) (1.69) (61.42) (33.7) (25.98) (31.06) (29.21) (31.5) (1543) (1538)
EN 1092-1 PN 16 1) 1485 53 930 928
(58.46) (2.09) (2050) (2046)
1400 (56) EN 1092-1 PN 10 1) 1675 47 1820 950 755 884 838 900 810 808
(65.94) (1.85) (71.65) (37.4) (29.72) (34.8) (32.99) (35.43) (1786) (1781)
EN 1092-1 PN 16 1) 1685 57 1210 1208
(66.34) (2.24) (2668) (2663)
1500 (60) ASME 16.47 series B 1676 76.2 1950 996 805 929 884 900 1952 1950
CL 150 (65.98) (3.00) (76.77) (39.21) (31.69) (36.57) (34.80) (35.43) (4303) (4299)
1600 (64) EN 1092-1 PN 10 1) 1915 51 2080 1060 865 994 948 990 1180 1178
(75.39) (2.01) (81.89) (41.73) (34.06) (39.13) (37.32) (38.98) (2602) (2597)
EN 1092-1 PN 16 1) 1930 () 63 1630 1628
(2.48) (3593) (3589)
1800 (72) EN 1092-1 PN 10 1) 2115 55 2340 1176 980 1109 1062 1080 1490 1488
(83.27) (2.17) (92.13) (46.3) (38.58) (43.66) (41.81) (42.52) (3285) (3280)
EN 1092-1 PN 16 1) 2130 67 2230 2228
(83.86) (2.64) (4916) (4912)
2000 (80) EN 1092-1 PN 10 1) 2325 59 2600 1286 1090 1219 1172 1170 1880 1878
(91.54) (2.32) (102.36) (50.63) (42.91) (47.99) (46.14) (46.06) (4145) (4140)
EN 1092-1 PN 16 1) 2345 71 2650 2648
(92.32) (2.80) (5842) (5838)

2) If an earthing plate is fitted (attached to one side of the flange), dimension L increases as follows: by 5 mm (0.197 inch) for DN 400 ... 600.
3) If protection plates are fitted (attached to both sides of the flange), dimension L increases as follows: by 10 mm (0.394 inch) for DN 400 ... 600.

Without explosion Standard temperature design 0 0
protection
Explosion protection Zone Standard temperature design +74 mm (+2.91 inch) +47 mm (+1.85 inch)
1, Division 1
Explosion protection Zone Standard temperature design 0 0
2, Division 2
42
Dimensions for sensor design level „C“

Flange DN 25 … 600 (18 … 24"), steel sensor housing
205 (8.07)
98,3 (3.87)
77,8 (3.06) 106 (4.17)
167,9 (6.61) 102 (4.02)
35 (1.38) 84.5 (3.33)
F + 14 (0.55)
F
ØD
B
L
G01339-01
Dimensions mm (inch) Approx. weight in kg (lb)

DN Process connection D B L 2) 3) F 4) E 4) G 4) Integral Remote
25 (1") EN 1092-1 PN 10 ... 40 1) 115 23 200 244 177 131 9 (20) 7 (15)
(4.53) (0.91) (7.84) (9.61) (6.97) (5.16)
ASME B16.5 CL 150 115 23
(4.53) (0.91)
ASME B16.5 CL 300 125 22
(4.92) (0.87)
JIS 10K 115 23
(4.53) (0.91)
AS2129 table D 115 23
AS2129 table E (4.53) (0.91)
32 (1 1/4") EN 1092-1 PN 10 ... 40 1) 150 25 200 249 182 136 10 (22) 8 (18)
(5.91) (0.98) (7.84) (9.80) (7.17) (5.35)
ASME B16.5 CL 150 150 25
(5.91) (0.98)
ASME B16.5 CL 300 135 23
(5.31) (0.91)
JIS 10K 150 25
(5.91) (0.98)
AS2129 table D 150 25
AS2129 table E (5.91) (0.98)
40 (1 1/2") EN 1092-1 PN 10 ... 40 1) 150 23 200 254 187 141 11 (24) 9 (20)
(5.91) (0.91) (7.84) (10.0) (7.36) (5.55)
ASME B16.5 CL 150 150 23
(5.91) (0.91)
ASME B16.5 CL 300 155 25
(6.10) (0.98)
JIS 10K 140 21
(5.51) (0.83)
AS2129 table D 150 23
(5.91) (0.91)
AS2129 table E 135 23
(5.31) (0.91)
50 (2") EN 1092-1 PN 10 ... 40 1) 165 27 200 257 190 144 12 (26) 10 (22)
(6.50) (1.06) (7.84) (10.12) (7.48) (5.67)
ASME B16.5 CL 150 165 27
(6.50) (1.06)
ASME B16.5 CL 300 165 27
(6.50) (1.06)
JIS 10K 165 27
(6.50) (1.06)
AS2129 table D 150 18
AS2129 table E (5.91) (0.71)
43

65 (2 1/2") EN 1092-1 PN 10 ... 40 1) 185 30 200 271 204 158 15 (33) 13 (29)
(7.28) (1.18) (7.87) (10.67) (8.03) (6.22)
ASME B16.5 CL 150 180 30 13 (29) 11 (24)
(7.09) (1.18)
ASME B16.5 CL 300 190 29 15 (33) 13 (29)
(7.48) (1.14)
JIS 10K 185 30 15 (33) 13 (29)
(7.28) (1.18)
AS2129 table D 165 18 13 (29) 11 (24)
AS2129 table E (6.50) (0.71)
80 (3") EN 1092-1 PN 10 ... 40 1) 205 30 200 275 208 162 17 (38) 15 (33)
(8.07) (1.18) (7.87) (10.83) (8.19) (6.38)
ASME B16.5 CL 150 205 30 17 (38) 15 (33)
(8.07) (1.18)
ASME B16.5 CL 300 210 33 19 (42) 17 (38)
(8.27) (1.30)
JIS 10K 205 30 19 (42) 17 (38)
(8.07) (1.18)
AS2129 table D 205 30 17 (38) 15 (33)
AS2129 table E (8.07) (1.18)
100 (4") EN 1092-1 PN 10 ... 16 1) 235 29 250 306 239 193 24 (53) 22 (48)
(9.25) (1.14) (9.84) (12.05) (9.41) (7.60)
EN 1092-1 PN 25 … 40 1) 235 28 24 (53) 22 (48)
(9.25) (1.10)
ASME B16.5 CL 150 235 29 24 (53) 22 (48)
(9.25) (1.14)
ASME B16.5 CL 300 255 38 30 (66) 28 (62)
(10.04) (1.50)
JIS 10K 235 29 19 (42) 17 (38)
(9.25) (1.14)
AS2129 table D 235 29 21 (46) 19 (42)
AS2129 table E (9.25) (1.14)
125 (5") EN 1092-1 PN 10 ... 16 1) 270 38 250 318 251 205 25 (55) 23 (51)
(10.63) (1.50) (9.84) (12.52) (9.88) (8.07)
EN 1092-1 PN 25 … 40 1) 270 36 25 (55) 23 (51)
(10.63) (1.42)
ASME B16.5 CL 150 270 38 25 (55) 23 (51)
(10.63) (1.50)
ASME B16.5 CL 300 280 42 35 (77) 33 (73)
(11.02) (1.65)
JIS 10K 270 38 22 (49) 20 (44)
(10.63) (1.50)
AS2129 table D 270 38 22 (49) 20 (44)
AS2129 table E (10.63) (1.50)
150 (6") EN 1092-1 PN 10 ... 16 1) 300 31 300 339 272 226 33 (73) 31 (68)
(11.81) (1.22) (11.81) (13.35) (10.71) (8.90)
EN 1092-1 PN 25 … 40 1) 300 38 39 (86) 37 (82)
(11.81) (1.50)
ASME B16.5 CL 150 300 31 33 (73) 31 (68)
(11.81) (1.22)
ASME B16.5 CL 300 320 44 47 (104) 45 (99)
(12.60) (1.73)
JIS 10K 300 31 33 (73) 31 (68)
(11.81) (1.22)
AS2129 table D 300 31 33 (73) 31 (68)
(11.81) (1.22)
AS2129 table E 280 24 33 (73) 31 (68)
(11.02) (0.94)
44

200 (8") EN 1092-1 PN 10 1) 375 35 350 364 297 252 41 (90) 39 (86)
(14.76) (1.38) (13.78) (14.33) (11.69) (9.92)
EN 1092-1 PN 16 1) 375 35 43 (95) 41 (90)
(14.76) (1.38)
ASME B16.5 CL 150 375 35 50 (110) 48 (106)
(14.76) (1.38)
ASME B16.5 CL 300 380 51 72 (158) 70 (154)
(14.96) (2.01)
JIS 10K 330 30 43 (95) 41 (90)
(12.99) (1.18)
AS2129 table D 335 35 50 (110) 48 (106)
(13.19) (1.38)
AS2129 table E 335 35 50 (110) 48 (106)
(13.19) (1.38)
250 (10") EN 1092-1 PN 10 1) 395 37 450 390 323 278 61 (135) 59 (130)
(15.55) (1.46) (17.72) (15.35) (12.72) (10.94)
EN 1092-1 PN 16 1) 405 37 65 (143) 63 (139)
(15.94) (1.46)
ASME B16.5 CL 150 405 37 70 (154) 68 (150)
(15.94) (1.46)
ASME B16.5 CL 300 445 61 105 (232) 103 (227)
(17.52) (2.40)
JIS 10K 405 37 65 (143) 63 (139)
(15.94) (1.46)
AS2129 table D 405 37 70 (154) 68 (150)
(15.94) (1.46)
AS2129 table E 405 25 70 (154) 68 (150)
(15.94) (0.98)
300 (12") EN 1092-1 PN 10 1) 445 38 500 415 348 303 74 (163) 72 (159)
(17.52) (1.50) (19.68) (16.34) (15.12) (11.93)
EN 1092-1 PN 16 1) 445 38 80 (176) 78 (172)
(17.52) (1.50)
ASME B16.5 CL 150 483 38 105 (232) 103 (227)
(19.02) (1.50)
ASME B16.5 CL 300 521 55 150 (331) 148 (326)
(20.51) (2.17)
JIS 10K 445 38 80 (176) 78 (172)
(17.52) (1.50)
AS2129 table D 455 38 105 (232) 103 (227)
(17.19) (1.50)
AS2129 table E 455 29 105 (232) 103 (227)
(17.19) (1.14)
350 (14") EN 1092-1 PN 10 1) 505 35 550 438 371 326 95 (209) 93 (203)
(19.88) (1.38) (21.65) (17.24) (14.61) (12.83)
EN 1092-1 PN 16 1) 520 40 110 (243) 108 (238)
(20.47) (1.57)
ASME B16.5 CL 150 533 54 105 (232) 103 (227)
(20.98) (2.13)
ASME B16.5 CL 300 584 80 140 (309) 138 (304)
(22.99) (3.15)
JIS 10K 490 31 110 (243) 108 (238)
(19.29) (1.22)
AS2129 table D 525 27 105 (232) 103 (227)
(20.67) (1.06)
AS2129 table E 525 38 105 (232) 103 (227)
(20.67) (1.50)
45

400 (16") EN 1092-1 PN 10 1) 565 37 600 462 395 350 103 (227) 101 (223)
(22.24) (1.46) (23.62) (18.19) (15.55) (13.78)
EN 1092-1 PN 16 1) 580 43 126 (278) 124 (273)
(22.83) (1.69)
ASME B16.5 CL 150 597 57 175 (386) 173 (381)
(23.50) (2.24)
ASME B16.5 CL 300 647 88 265 (584) 263 (580)
(25.47) (3.46)
JIS 10K 560 33 126 (278) 124 (273)
(22.05) (1.30)
AS2129 table D 580 31 175 (386) 173 (381)
(22.83) (1.22)
AS2129 table E 580 39 175 (386) 173 (381)
(22.83) (1.54)
450 (18") ASME B16.5 CL 150 635 66 600 487 420 375 260 (573) 258 (569)
(25.00) (2.60) (23.62) (19.17) (16.54) (14.76)
AS2129 table D 640 30
(25.20) (1.18)
AS2129 table E 640 40
(25.20) (1.57)
500 (20") EN 1092-1 PN 10 1) 670 43 600 514 447 402 190 (419) 188 (415)
(26.38) (1.96) (23.62) (20.24) (17.60) (15.83)
EN 1092-1 PN 16 1) 715 51 240 (529) 238 (525)
(28.15) (2.01)
ASME B16.5 CL 150 699 69 300 (661) 298 (657)
(27.52) (2.72)
AS2129 table D 705 34
(27.76) (1.34)
AS2129 table E 705 43
(27.76) (1.69)
600 (24") EN 1092-1 PN 10 1) 780 47 800 569 502 457 246 (542) 244 (537)
(30.71) (1.85) (31.50) (22.40) (19.76) (17.99)
EN 1092-1 PN 16 1) 840 60 318 (701) 316 (697)
(33.07) (2.36)
ASME B16.5 CL 150 813 80 425 (937) 423 (933)
(32.01) (3.15)
AS2129 table D 825 47
(32.48) (1.85)
AS2129 table E 825 53
(32.48) (2.09)
2) If an earthing plate is fitted (attached to one side of the flange), dimension L increases by 5 mm (0.197 inch).
3) If protection plates are fitted (attached to both sides of the flange), dimension L increases by 10 mm (0.394 inch).

Without explosion Standard temperature design 0 0
protection
Explosion protection Zone Standard temperature design +74 mm (+2.91 inch) +47 mm (+1.85 inch)
1, Division 1
Explosion protection Zone Standard temperature design 0 0
2, Division 2
46
Dimensions for high-pressure sensor version

Flange DN 15 ... 400 (1/2 ... 16"), high-pressure version, Sensor housing made of Aluminium (Clamp Shell)
77,8 (3.06) 105 (4.13) 98 (3.86)

168 (6.61) 102.5 (4.04)
74,2 (2.92)
100 (3.94)
187 (7.36)
201 (7.91)
84.5 (3.33)
35 (1.38)
F
E
G
D
C
A
L*
G00479-01
Fig. 42: Dimensions in mm (inch)
Dimensions mm (inch) Approx. weight kg (lb)

)
DN Process connection D L 1) 2 F 4) C E 3) G 3) A Integral Remote
15 DIN 2636 PN 63 105 270 255 82 188 143 113 10 (22) 8 (18)
(1/2“) DIN 2637 PN 100 (4.13) (10.63) (10.04) (3.23) (7.4) (5.63) (4.45)
ASME B16.5, CL 600 95 270 12 (26) 10 (22)
(3.74) (10.63)
25 (1“) DIN 2636 PN 63 140 270 255 82 188 143 113 12 (27) 10 (22)
DIN 2637 PN 100 (5.51) (10.63) (10.04) (3.23) (7.4) (5.63) (4.45)
ASME B16.5, CL 600 124 270 12 (26) 10 (22)
(4.88) (10.63)
ASME B16.5, CL 900 149 300
(5.87) (11.81)
ASME B16.5, CL 1500 149 300
(5.87) (11.81)
ASME B16.5, CL 2500 158 350
(6.22) (13.78)
40 DIN 2636 PN 63 170 280 262 92 195 150 113 13 / 14 11 / 12
(1 1/2“) DIN 2637 PN 100 (6.69) (11.02) (10.31) (3.62) (7.68) (5.91) (4.45) (29 / 31) (24 / 27)
ASME B16.5, CL 600 156 280 13 (29) 11 (24)
(6.14) (11.02)
ASME B16.5, CL 900 177 300
(6.97) (11.81)
ASME B16.5, CL 1500 177 350
(6.97) (13.78)
ASME B16.5, CL 2500 203 400
(7.99) (15.75)
50 (2“) DIN 2636 PN 63 180 280 268 97 (3.82) 201 156 115 15 (33) 13 (29)
(7.09) (11.02) (10.55) (7.91) (6.14) (4.53)
DIN 2637 PN 100 195 280 18 (40) 16 (35)
(7.68) (11.02)
ASME B16.5, CL 600 165 280 15 (33) 13 (29)
(6.50) (11.02)
ASME B16.5, CL 900 216 400
(8.50) (15.75)
ASME B16.5, CL 1500 216 400
(8.50) (15.75)
ASME B16.5, CL 2500 235 450
(9.25) (17.72)
Tolerance L: DN 25 ... 100 +0 / -3 mm (+0 / -0,018 inch), DN 150 … 200 +0 / -3 mm (+0 / -0,118 inch),
DN 250 ... 400 +0 / -5 mm (+0 / -0,197 inch)
47

)
65 DIN 2636 PN 63 205 330 279 108 212 167 104 18 (40) 16 (35)
(2 1/2“) (8.07) (12.99) (10.98) (4.25) (8.35) (6.57) (4.09)
DIN 2637 PN 100 220 330 23 (51) 21 (46)
(8.66) (12.99)
ASME B16.5, CL 600 190 330 20 (44) 18 (40)
(7.48) (12.99)
ASME B16.5, CL 900 244 400
(9.61) (15.75)
ASME B16.5, CL 1500 244 400
(9.61) (15.75)
ASME B16.5, CL 2500 266 450
(10.47) (17.72)
80 (3“) DIN 2636 PN 63 215 340 279 108 212 167 104 22 (49) 20 (44)
(8.46) (13.39) (10.98) (4.25) (8.35) (6.57) (4.09)
DIN 2637 PN 100 230 340 26 (57) 24 (53)
(9.06) (13.39)
ASME B16.5, CL 600 209 340 25 (55) 23 (51)
(8.23) (13.39)
ASME B16.5, CL 900 241 400
(9.49) (15.75)
ASME B16.5, CL 1500 266 400
(10.47) (15.75)
ASME B16.5, CL 2500 305 500
(12.01) (19.68)
100 (4“) DIN 2636 PN 63 250 400 301 122 (4.8) 234 189 125 29 (64) 27 (60)
(9.84) (15.75) (11.85) (9.21) (7.44) (4.92)
DIN 2637 PN 100 265 400 38 (84) 26 (57)
(10.43) (15.75)
ASME B16.5, CL 600 273 400 46 (101) 44 (97)
(10.75) (15.75)
ASME B16.5, CL 900 292 400
(11.50) (15.75)
ASME B16.5, CL 1500 311 420
(12.24) (16.54)
ASME B16.5, CL 2500 355 600
(13.98) (23.62)
125 (5“) DIN 2636 PN 63 295 450 311 130 244 199 125 on request on request
(11.61) (17.72) (12.24) (5.12) (9.61) (7.83) (4.92)
DIN 2637 PN 100 315 450
(12.4) (17.72)
ASME B16.5, CL 600 330 400
(12.99) (15.75)
ASME B16.5, CL 900 349 450
(13.74) (17.72)
ASME B16.5, CL 1500 374 500
(14.72) (19.68)
ASME B16.5, CL 2500 419 700
(16.50) (27.56)
(13.58) (17.72) (14.09) (5.75) (11.46) (9.69) (6.54)
DIN 2637 PN 100 355 450
(13.98) (17.72)
ASME B16.5, CL 600 355 450
(13.98) (17.72)
ASME B16.5, CL 900 381 500
(15.0) (19.68)
ASME B16.5, CL 1500 393 600
(15.47) (23.62)
ASME B16.5, CL 2500 482 800
(18.98) (31.50)
DN 250 ... 400 +0 / -5 mm (+0 / -0,197 inch)
48

)
(16.34) (19.68) (15.71) (6.69) (13.03) (11.26) (7.87)
DIN 2637 PN 100 430 500
(16.93) (19.68)
ASME B16.5, CL 600 419 500
(16.50) (19.68)
ASME B16.5, CL 900 470 600
(18.50) (23.62)
ASME B16.5, CL 1500 482 700
(18.98) (27.56)
ASME B16.5, CL 2500 552 950
(21.73) (37.40)
250 ASME B16.5, CL 600 508 500 413 198 346 301 235 on request on request
(10“) (20.0) (19.68) (16.26) (7.80) (13.62) (11.85) (9.25)
ASME B16.5, CL 900 546 700
(21.5) (27.56)
ASME B16.5, CL 1500 584 850
(22.99) (33.46)
ASME B16.5, CL 2500 673 1200
(26.50) (47.24)
(12“) (22.01) (29.53) (17.17) (8.98) (14.53) (12.76) (10.71)
ASME B16.5, CL 900 609 800
(23.98) (31.50)
ASME B16.5, CL 1500 673 950
(26.50) (37.40)
ASME B16.5, CL 2500 762 1400
(30.00) (55.12)
(14“) (23.74) (29.53) (17.76) (10.43) (15.12) (13.35) (12.68)
ASME B16.5, CL 900 641 850
(25.24) (33.46)
ASME B16.5, CL 1500 749 1050
(29.49) (41.34)
(16“) (27.01) (31.50) (19.41) (10.43) (16.77) (15.00) (12.68)
ASME B16.5, CL 900 705 900
(27.76) (35.43)
ASME B16.5, CL 1500 825 1100
(32.48) (43.31)
DN 250 ... 400 +0 / -5 mm (+0 / -0,197 inch)
1) If a grounding plate is installed (attached to one side of the flange), this increases dimension L as follows: DN 3 ... 100 by 3 mm (0.118 inch; DN 125 by 5 mm (0.197 inch).
2) If protection plates are installed (attached to both sides of the flange), this increases dimension L as follows: DN 3 ... 100 by 6 mm (0.236 inch; DN 125 by 10 mm (0.394 inch).
3) Depending on the device design, the dimensions change according to the following table.

Without explosion protection Standard sensor design 0 0
High-temperature sensor design +127 mm (+5 inch) +127 mm (+5 inch)
Explosion protection Zone 1, Div. 1 Standard sensor design +74 mm (+2.91 inch) +47 mm (+1.85 inch)
High-temperature sensor design +127 mm (+5 inch) +174 mm (+6.85 inch)
Explosion protection Zone 2, Div. 2 Standard sensor design 0 0
49
Flange DN 25... 400 (1 ... 16"), high-pressure version, Sensor housing made of stainless steel
77,8 (3.06) 105 (4.13) 98 (3.86)

168 (6.61) 101,5 (4.04)
201 (7.91)
187 (7.36)
F
E
D
C
L*
G00481-02
Dimensions [mm (inch)] Approx. weight

)
DN Process connection D L 1) 2 F 4) C E 3) A [kg (lb)]
25 (1“) ASME B16.5 CL 600 124 270 283 73 216 105 12 (26)
(4.88) (10.63) (11.14) (2.87) (8.50) (4.13)
ASME B16.5 CL 900 149 300
(5.87) (11.81)
ASME B16.5 CL 1500 149 300
(5.87) (11.81)
ASME B16.5 CL 2500 158 350
(6.22) (13.78)
40 (1 1/2“) ASME B16.5 CL 600 156 280 288 78 221 105 13 (29)
(6.14) (11.02) (11.34) (3.07) (8.70) (4.13)
ASME B16.5 CL 900 177 300
(6.97) (11.81)
ASME B16.5 CL 1500 177 350
(6.97) (13.78)
ASME B16.5 CL 2500 203 400
(7.99) (15.75)
50 (2”) ASME B16.5 CL 600 165 280 305 85 238 105 15
(6.5) (11.02) (12.01) (3.35) (9.37) (4.13) (33)
ASME B16.5 CL 900 216 400
(8.50) (15.75)
ASME B16.5 CL 1500 216 400
(8.50) (15.75)
ASME B16.5 CL 2500 235 450
(9.25) (17.72)
65 (2 1/2“) ASME B16.5 CL 600 190 330 316 91 249 105 20
(7.48) (12.99) (12.44) (3.58) (9.80) (4.13) (44)
ASME B16.5 CL 900 244 400
(9.61) (15.75)
ASME B16.5 CL 1500 244 400
(9.61) (15.75)
ASME B16.5 CL 2500 266 450
(10.47) (17.72)
Tolerance L: DN 25 ... 100 +0 / -3 mm (+0 / -0.018 inch)
50

)
80 (3“) ASME B16.5 CL 600 209 340 316 91 249 105 25
(8.23) (13.39) (12.44) (3.58) (9.80) (4.13) (55)
ASME B16.5 CL 900 241 400
(9.49) (15.75)
ASME B16.5 CL 1500 266 400
(10.47) (15.75)
ASME B16.5 CL 2500 305 500
(12.01) (19.68)
100 (4“) ASME B16.5 CL 600 273 400 331 91 249 109 46
(10.75) (15.75) (13.03) (3.58) (9.80) (4.29) (101)
ASME B16.5 CL 900 292 400
(11.50) (15.75)
ASME B16.5 CL 1500 311 420
(12.24) (16.54)
ASME B16.5 CL 2500 355 600
(13.98) (23.62)
125 (5“) ASME B16.5 CL 600 330 400 344 116 277 109
(12.99) (15.75) (13.54) (4.57) (10.91) (4.29)
ASME B16.5 CL 900 349 450
(13.74) (17.72)
ASME B16.5 CL 1500 374 500
(14.72) (19.68)
ASME B16.5 CL 2500 419 700
(16.50) (27.56)
150 (6“) ASME B16.5 CL 600 355 450 385 136 318 143
(13.98) (17.72) (15.16) (5.35) (12.52) (5.63)
ASME B16.5 CL 900 381 500
(15.00) (19.68)
ASME B16.5 CL 1500 393 600
(15.47) (23.62)
ASME B16.5 CL 2500 482 800
(18.98) (31.50)
200 (8“) ASME B16.5 CL 600 419 500 411 162 344 175
(16.50) (19.69) (16.18) (6.38) (13.54) (6.89)
ASME B16.5 CL 900 470 600
(18.50) (23.62)
ASME B16.5 CL 1500 482 700
(18.98) (27.56)
ASME B16.5 CL 2500 552 950
(21.73) (37.40)
250 (10“) ASME B16.5 CL 600 508 500 440 191 373 208
(20.00) (19.68) (17.32) (7.52) (14.68) (8.19)
ASME B16.5 CL 900 546 700
(21.50) (27.56)
ASME B16.5 CL 1500 584 850
(22.99) (33.46)
ASME B16.5 CL 2500 673 1200
(26.50) (47.25)
300 (12“) ASME B16.5 CL 600 559 750 457 209 390 243
(22.01) (29.53) (17.99) (8.23) (15.35) (9.57)
ASME B16.5 CL 900 609 800
(23.98) (31.50)
ASME B16.5 CL 1500 673 950
(26.50) (37.40)
ASME B16.5 CL 2500 762 1400
(30.00) (55.12)
Tolerance L: DN 25 ... 100 +0 / -3 mm (+0 / -0.018 inch), DN 150 … 200 +0 / -3 mm (+0 / -0.118 inch),
DN 250 … 400 +0 / -5 mm (+0 / -0.197 inch)
51

)
350 (14“) ASME B16.5 CL 600 603 750 501 221 434 271
(23.74) (29.61) (19.72) (8.70) (17.09) (10.67)
ASME B16.5 CL 900 641 850
(25.24) (33.46)
ASME B16.5 CL 1500 749 1050
(29.49) (41.34)
400 (16“) ASME B16.5 CL 600 686 800 501 258 434 291
(27.01) (31.50) (19.72) (10.16) (17.09) (11.46)
ASME B16.5 CL 900 705 900
(27.76) (35.43)
ASME B16.5 CL 1500 825 1100
(32.48) (43.31)
Tolerance L: DN 25 ... 100 +0 / -3 mm (+0 / -0.018 inch), DN 150 … 200 +0 / -3 mm (+0 / -0.118 inch),
DN 250 … 400 +0 / -5 mm (+0 / -0.197 inch)
1) If a grounding plate is installed (attached to one side of the flange), this increases dimension L as follows: DN 3 ... 100 by 3 mm (0.118 inch; DN 125 by 5 mm (0.197 inch).
2) If protection plates are installed (attached to both sides of the flange), this increases dimension L as follows: DN 3 ... 100 by 6 mm (0.236 inch; DN 125 by 10 mm (0.394 inch).
3) Depending on the device design, the dimensions change according to the following table.

Without explosion protection Standard sensor design 0 0
Explosion protection Zone 1, Div. 1 Standard sensor design +74 mm (+2.91 inch) +47 mm (+1.85 inch)
High-temperature sensor design +127 mm (+5 inch) +174 mm (+6.85 inch)
Explosion protection Zone 2, Div. 2 Standard sensor design 0 0
52
Dimensions for transmitter

Model FET321 and FET325 (dual-compartment housing) for Ex zone 2 / Div 2
min. 62 (2.44)
7)
198 (7.79) 139,7 (5.50) 167 (6.57) ( 0.2
10 (0.39)
Ø7
265 (10.43)
249 (9.80)
14,5 (0.57)
min.175
(6.88)
1
3
38 (1.49) 2
66 (2.59)
132 (5.19) 83,5 (3.28)
M20 x 1,5
4
G00073
1 Field-mount housing with window 3 Installation holes for pipe mounting set, for 2" pipe installation
2 Cable gland M20 x 1.5 4 Protection class IP 67
Model FET325 (dual-compartment housing) for Ex zone 1 / Div 1

168 (6.61) 142 (5.59)
Ø 134 (5.28)
(2x1.77 = 3.54)
142,5 (5.61)
2x45 = 90
262 (10.31)
1
71 (2.8)
205 (8.07)
71 (2.8)
G00882
1 2“ Pipe mounting kit included (material: zinc plated carbon steel)
Model FET321 (single-compartment housing)

150 (5.91)
72,5 (2.85)
36,3 (1.43)
200 (7.87)
98,1 (3.86) 36 (1.42) 36 (1.42)

36,5 (1.44) G01085
53
Bestellangaben
Ordering information
uh
Electromagnetic flowmeter ProcessMaster - FEP311 and FEP315 , integral mount design

Add.
Main order number order no.
Version number 1–6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Without explosion protection FEP311 X X X X X X X X X X X X X X X X X X X X X X XX
With explosion protection FEP315 X X X X X X X X X X X X X X X X X X X X X X XX
Nominal diameter
DN 3 (1/10 in.) 0 0 3
DN 4 (5/32 in.) 0 0 4
DN 6 (1/4 in.) 0 0 6
DN 8 (5/16 in.) 0 0 8
DN 10 (3/8 in.) 0 1 0
DN 15 (1/2 in.) 0 1 5
DN 20 (3/4 in.) 0 2 0
DN 25 (1 in.) 0 2 5
DN 32 (1-1/4 in.) 0 3 2
DN 40 (1-1/2 in.) 0 4 0
DN 50 (2 in.) 0 5 0
DN 65 (2-1/2 in.) 0 6 5
DN 80 (3 in.) 0 8 0
DN 100 (4 in.) 1 0 0
DN 125 (5 in.) 1 2 5
DN 150 (6 in.) 1 5 0
DN 200 (8 in.) 2 0 0
DN 250 (10 in.) 2 5 0
DN 300 (12 in.) 3 0 0
DN 350 (14 in.) 3 5 0
DN 400 (16 in.) 4 0 0
DN 450 (18 in.) 4 5 0
DN 500 (20 in.) 5 0 0
DN 550 (22 in.) 1) 5 5 0
DN 600 (24 in.) 6 0 0
DN 650 (26 in.) 1) 6 5 0
DN 700 (28 in.) 7 0 0
DN 760 (30 in.) 7 6 0
DN 800 (32 in.) 8 0 0
DN 900 (36 in.) 9 0 0
DN 1000 (40 in.) 0 0 1
DN 1050 (42 in.) 0 5 1
DN 1100 (44 in.) 1 0 1
DN 1200 (48 in.) 2 0 1
DN 1400 (54 in.) 4 0 1
DN 1500 (60 in.) 5 0 1
DN 1600 (66 in.) 6 0 1
DN 1800 (72 in.) 8 0 1
DN 2000 (80 in.) 0 0 2
Lining material
PTFE A
ETFE E
Thick PTFE F
Hard rubber H
Linatex 2) J
PFA P
Soft rubber S
Electrode design
Standard 1
Standard + full filling electrode (TFE) 3) 2
Pointed head 5
Pointed head + full filling electrode (TFE) 3) 6
Continued on next page

1) Available with JIS-Flanges.
2) For US production only, model FEP315, FEP325 (Certificate: without PED, Process Connection: ASME Cl 150 / 300, Installation length:
ASME CL 150, US-compliant length).
2) TFE electrode for detecting partially filled tubes, available from DN 50 (2 in.) with sensor design level "B". Not available for Zone 1 / Div 1.
54
Continued
Add.
Version number 1–6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Signal electrode material
Stainless steel 1.4539 (904) A
Hastelloy C-4 (2.4610) D
Titanium F
Tantalum G
Hastelloy B-3 (2.4600) H
Platinum-iridium J
Stainless steel 1.4571 (316Ti) S
Grounding accessories
Standard 1
Grounding electrodes
2
(for material, refer to "Signal electrode material")
Grounding plate made of stainless steel, attached to one
4) 3
side of the flange
Protection plate made of stainless steel, attached to both
4) 4
sides of the flange
Process connection
Flange DIN PN 6 5) D 0
Flange DIN PN 10 D 1
Flange, ASME CL 150 7) A 1
Flange, JIS 10K J 1
Flange, JIS 5K J 2
Flange, JIS 20K J 3
Flange, AS2129 table E 8) E 4
Flange, AS2129 table D 8) E 5
Process connection material
Steel B
Stainless steel flange 9) D
Certificates
Meter tube with PED approval 0
Meter tube without PED approval (only China and US production sites. 1
Specify installation length J1, J3 or JN)
Acceptance test certificate (3.1) to EN 10204 2
Pressure test to AD-2000 3
Material certificate 3.1 to EN 10204 and pressure test to AD-2000 4
Calibration
Standard accuracy 10) A
Increased accuracy 12) B
Standard accuracy + ScanMaster function 10) K
Increased accuracy + ScanMaster function 11) L
Witnessed factory calibration 12) M
5-point DKD calibration 13) T

4) Can only be used for sensors ≤ DN 600 (24 in) and PTFE / thick PTFE / ETFE / PFA linings. Material: See data sheet.
5) Available from DN 1000 (40 in.)
6) DN 15 ... DN 200 (1/2 ... 8 in.) Hard rubber.
7) Flange DN 15 … 600 according to ASME B16.5. Flange > DN 600 according to ASME 16.47 Serie B.
8) Upon request
9) Material: See data sheet
10) Standard accuracy (0.4% of rate) assumes 2 calibration points. If more than 2 calibration points are required, you must specify 3 or 5 points
under "Number of test points"
11) Increased accuracy (0.2% of rate) assumes 3 calibration points. If more than 3 calibration points are required, you must specify 5 points
under "Number of test points". Available for DN10 (3/8 in.) ... 800 (32 in.)
12) 3rd party witnessed calibration
13) Available for nominal diameters DN 50 (2 in.) ... 600 (24 in.), DN 800 (32 in.)
55
Continued
Add.
Version number 1–6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Sensor temperature range / Ambient temperature range
Standard sensor design / -20 ... 60 °C (-4 ... 140 °F) 14) 1
High-temperature sensor design / -20 ... 60 °C (-4 ... 140 °F) 15) 3
Name plate
Sticker A
Stainless steel B
Stainless steel, and TAG label stainless steel C
Sticker, chinese language 19) S
Stainless steel, chinese language 19) T
Stainless steel, and TAG label stainless steel, chinese language 19) U
Signal cable length
No cable 0
Explosion protection
None 16) A
ATEX / IEC Zone 1 / 21 L
ATEX / IEC Zone 2 / 21 M
usFMc Div 2 Zone 2 P
usFMc Div 1 17) R
NEPSI Zone1 18) U
NEPSI Zone2 18) V
Protection type for transmitter / sensor
Standard / IP67 (NEMA 4X) 18) 1
Other 9
Cable gland
M20 x 1.5 A
1/2 in. NPT B
PF 1/2 in. 15) C
Power supply
100 ... 230 V AC, 50 Hz 1
24 V AC / DC, 50 Hz 2
100 ... 230 V AC, 60 Hz 3
24 V AC / DC, 60 Hz 4
Signal inputs and outputs
HART + 20 mA passive + pulses + contact input / output 19) B
HART + 20 mA active + pulses + contact input / output 20) C
HART + 20 mA active + pulses + contact output 21) D
PROFIBUS PA + contact output E
FOUNDATION Fieldbus + contact output F
Default settings / Diagnostics
Parameters are at factory settings / Standard 1
Parameters are set according to customer specifications / Standard 3
Design Level
Sensordesign Level B 26) B
Sensordesign Level C 26) C
14) Maximum fluid temperature for standard sensor design: 130 °C with PTFE, PFA, ETFE, thick PTFE,
90 °C (80 °C for China production site) with hard rubber,
60 °C with soft rubber,
70 °C with Linatex,
-40 °C only in conjunction with stainless steel flange.
15) Maximum fluid temperature for high-temperature sensor design: 180 °C with PFA, thick PTFE. 130 °C with ETFE, PTFE. Thick PTFE
available for DN 25 ... DN 300, PFA available for DN 10 ... DN 200. -40 °C only in conjunction with stainless steel flange.
16) Only with model FEP311.
17) Div 1 available up to DN 300 (12 in.).
18) Production site: China.
19) Transmitter degree of protection = IP67 (NEMA 4X) with single-compartment and dual-compartment housing
20) Available with Ex design Zone 2 / Div 2 or Zone 1 / Div1.
21) Available with Ex design Zone 2 / Div 2.
22) Available with Ex design Zone 1 / Div 1.
23) Specified by ABB. Sesordesign Level C with model FEP311 only
56
Continued
Add.
Version number 1–6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Accessories
None AY
Plug connector
M12 x 1 fieldbus 24) U2
Transmitter housing design
Single-compartment housing / Aluminium 25) H1
Dual-compartment housing / Aluminium H2
Lay Length
Flanges, ASME CL 150, ISO-compliant installation length JA
Flanges, ASME CL 300, ISO-compliant installation length JC
Flanges (Chinese installation length) (production site: China. Certificate: Without PED approval) 26) JN
Sensor housing material
Aluminium / Carbon steel SMA
Additional certificates
Russia, metrological and GOST R certificate CG1
Kazakhstan, metrological and GOST K certificate CG2
Ukraine, metrological certificate CG3
Belarus, metrological certificate CG6
Additional Ex certificates and approvals
Russia, GOST-Ex and RTN certificate EG7
Kazakhstan, Ex applications certificate EG3
Ukraine, GOST Ex and Ex application certificate EG5
Belarus, GGTN certificate EG9
Inmetro (Brazil) 27) EB1
Number of test points
3 points T3
5 points T5
Language of documentation
German M1
English M5
Chinese M6
Russian MB
Western Europe / Scandinavia language package (languages: DE, EN, DA, ES, FR, IT, NL, PT, FI, SV) MW
Eastern Europe language package (languages: DE, EL, CS, ET, LV, LT, HU, PL, SK, SL, RO, BG) ME
Shipping Register Certificates
Marine class approval (DNV) CL5
SIL2 - Declaration of Conformity
SIL2 - Declaration of Conformity CS
24) Only for PROFIBUS PA Not for model FEP315

25) Not available with Ex design Zone 1
26) To be coded in case of FM approval only.
27) Inmetro only in conjunction with explosion protection ATEX / IECEx Zone 1 (code "L") or ATEX / IECEx Zone 2/21 (code "M") and
transmitter housing design "dual-compartment housing " (code H2).
57
uh
Electromagnetic flowmeter ProcessMaster - FEP321 and FEP325, remote mount design

Add.
Version number 1–6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Nominal diameter
DN 3 (1/10 in.) 0 0 3
DN 4 (5/32 in.) 0 0 4
DN 6 (1/4 in.) 0 0 6
DN 8 (5/16 in.) 0 0 8
DN 10 (3/8 in.) 0 1 0
DN 15 (1/2 in.) 0 1 5
DN 20 (3/4 in.) 0 2 0
DN 25 (1 in.) 0 2 5
DN 32 (1-1/4 in.) 0 3 2
DN 40 (1-1/2 in.) 0 4 0
DN 50 (2 in.) 0 5 0
DN 65 (2-1/2 in.) 0 6 5
DN 80 (3 in.) 0 8 0
DN 100 (4 in.) 1 0 0
DN 125 (5 in.) 1 2 5
DN 150 (6 in.) 1 5 0
DN 200 (8 in.) 2 0 0
DN 250 (10 in.) 2 5 0
DN 300 (12 in.) 3 0 0
DN 350 (14 in.) 3 5 0
DN 400 (16 in.) 4 0 0
DN 450 (18 in.) 4 5 0
DN 500 (20 in.) 5 0 0
DN 550 (22 in.) 1) 5 5 0
DN 600 (24 in.) 6 0 0
DN 650 (26 in.) 1) 6 5 0
DN 700 (28 in.) 7 0 0
DN 760 (30 in.) 7 6 0
DN 800 (32 in.) 8 0 0
DN 900 (36 in.) 9 0 0
DN 1000 (40 in.) 0 0 1
DN 1050 (42 in.) 0 5 1
DN 1100 (44 in.) 1 0 1
DN 1200 (48 in.) 2 0 1
DN 1400 (54 in.) 4 0 1
DN 1500 (60 in.) 5 0 1
DN 1600 (66 in.) 6 0 1
DN 1800 (72 in.) 8 0 1
DN 2000 (80 in.) 0 0 2
Lining material
PTFE A
ETFE E
Thick PTFE F
Hard rubber H
Linatex 2) J
PFA P
Soft rubber S
Electrode design
Standard 1
Standard + full filling electrode (TFE) 3) 2
Pointed head 5
Pointed head + full filling electrode (TFE) 3) 6

1) Available with JIS flanges.
2) Upon request: Available with model FEP321 DN 50 … 600 (2 … 24 in.)
3) TFE electrode for detecting partially filled tubes, available from DN 50 (2 in.) with sensor design level "B". Not available for Zone 1 / Div 1.
58
Continued
Add.
Version number 1–6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Stainless steel 1.4539 (904) A
Titanium F
Tantalum G
Hastelloy B-3 (2.4600) H
Platinum-iridium J
Tungsten carbide coated T
Standard 1
Grounding electrodes
2
(for material, refer to "Signal electrode material")
Grounding plate made of stainless steel, attached to one
4) 3
side of the flange
Protection plate made of stainless steel, attached to both
4) 4
sides of the flange
Process connection
Flange, JIS 10K J 1
Flange, JIS 5K 8) J 2
Flange, JIS 20K 8) J 3
Flange, AS2129 table E 8) E 4
Flange, AS2129 table D 8) E 5
Steel B
Certificates
Meter tube without PED approval (only China and US production sites. 1
Specify installation length J1, J3 or JN)
Acceptance test certificate (3.1) to EN 10204 2
Pressure test 3
Material certificate 3.1 to EN 10204 and pressure test 4
Calibration
5-point DKD calibration 13) T
4) Can only be used for sensors ≤ DN 600 (24 in) and PTFE / thick PTFE / ETFE / PFA linings. Material: See data sheet. For Hard rubber, Soft
rubber and Linatex please use loose grounding rings.
5) Available from DN 1000 (40 in.)
6) DN 15 ... DN 200 (1/2 ... 8 in.) Hard rubber
7) Flange DN 15 … 600 according to ASME B16.5. Flange > DN 600 according to ASME 16.47 Series B
8) Upon request
13) Available for nominal diameters DN 50 (2 in.) ... 600 (24 in.), DN 800 (32 in.)
59
Continued
Add.
Version number 1–6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Name plate
Sticker A
Stainless steel B
Signal cable length 16)
No cable 0
5 m (approx. 15 ft.) standard cable 1
Explosion protection
None 17) A
ATEX / IEC Zone 1 L
usFMc Div 1 18) R
NEPSI Zone1 19) U
NEPSI Zone2 19) V
Standard / IP 67 (NEMA 4X) 20) 1
Standard / IP 68 (NEMA 6P) 20) 21) 2
Standard / IP 68 (NEMA 6P), signal cable fitted and potted 20) 22) 3
Cable gland
M20 x 1.5 A
1/2 in. NPT B
PF 1/2 in. C
Power supply
None 0
None 17) Y
Parameters are at factory settings / Standard diagnostic functions activated 1
Parameters are set according to customer specifications / Standard diagnostic functions activated 3

14) Maximum fluid temperature for standard sensor design: 130 °C with PTFE, PFA, ETFE, thick PTFE,
90 °C (80 °C for China production site) with hard rubber,
60 °C with soft rubber,
70 °C with Linatex,
15) Maximum fluid temperature for high-temperature sensor design: 180 °C with PFA, thick PTFE. 130 °C with ETFE, PTFE. Thick PTFE
available for DN 25 ... DN 300, PFA available for DN 10 ... DN 200. -40 °C only in conjunction with stainless steel flange.
16) For flowmeter sensor model FEP325 designed for zone 1 / Div 1, signal cable length can be max. 50 m (164 ft) in combination with
transmitter model FET321 or transmitter model FET 325 designed for zone 2 / Div 2. For sensor model FEP325 designed for zone 1 / Div 1,
signal cable length can be max. 10 m (32.8 ft) in combination with transmitter model FET325 designed for zone 1 / Div 1.
17) Model FEP321 only.
20) Transmitter degree of protection = IP67 (NEMA 4X) with single-compartment and dual-compartment housing.
21) Only with external transmitter, sealing compound (optional) D141B038U01.
22) Not available with FET325 transmitter in zone1 / Div1 design.
60
Continued
Add.
Version number 1–6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Design Level
Sensordesign Level C 23) C
Accessories
None AY
With preamplifier, integrated into sensor housing 24) AP
Lay length
Flanges, ASME CL 150, ISO-compliant installation length JA
Flanges, ASME CL 300, ISO-compliant installation length JC
Flanges (Chinese installation length) (production site: China. Certificate: Without PED approval) 25) JN
Connection box material
Aluminum UTA
Aluminium / Carbon steel SMA
Power frequency
50 Hz (When ordering the sensor without a transmitter, specify the mains frequency.) F5
60 Hz (When ordering the sensor without a transmitter, specify the mains frequency.) F6
3 points T3
5 points T5
German M1
English M5
Chinese M6
Russian MB
23) Specified by ABB. Sesordesign Level C with model FEP321 only.
24) Preamplifier required if signal cable length is > 50 m (>160 ft). Preamplifier not available for zone1 / Div1.
25) To be coded in case of FM approval only.
26) Inmetro only in conjunction with explosion protection ATEX / IECEx Zone 1 (code "L") or ATEX / IECEx Zone 2/21 (code "M).
61
uh
Electromagnetic flowmeter ProcessMaster - FEP311 and FEP315, integral mount design, high pressure
version
Add.
Version number 1–6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Nominal diameter
DN 25 (1 in.) 0 2 5
DN 32 (1-1/4 in.) 0 3 2
DN 40 (1-1/2 in.) 0 4 0
DN 50 (2 in.) 0 5 0
DN 65 (2-1/2 in.) 0 6 5
DN 80 (3 in.) 0 8 0
DN 100 (4 in.) 1 0 0
DN 125 (5 in.) 1 2 5
DN 150 (6 in.) 1 5 0
DN 200 (8 in.) 2 0 0
DN 250 (10 in.) 2 5 0
DN 300 (12 in.) 3 0 0
DN 350 (14 in.) 3 5 0
DN 400 (16 in.) 4 0 0
Lining material
ETFE E
Hard rubber H
Electrode design
Standard 1
Pointed head 5
Standard 1
Process connection
Flange ASME CL 600 A 6
Flange ASME CL 2500 1) A 9
Flange ASME CL 600 RTJ H 6
Flange ASME CL 2500 RTJ 1) H 9
Steel B
Certificates
Calibration

1) Available up to DN 300 (12 in.)
62
Continued
Add.
Version number 1–6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Name plate
Sticker A
Stainless steel B
Signal cable length
No cable 0
Explosion protection 7)
None 8) A
ATEX / IEC Zone 1 / 21 L
usFMc Div 1 9) R
Standard / IP67 (NEMA 4X) 10) 1
Other 9
Cable gland
M20 x 1.5 A
1/2 in. NPT B
PF 1/2 in. 8) C
Power supply
100 ... 230 V AC, 50 Hz 1
24 V AC / DC, 50 Hz 2
100 ... 230 V AC, 60 Hz 3
24 V AC / DC, 60 Hz 4
Parameters are at factory settings / Standard 1
Parameters are set according to customer specifications / Standard 3
Design-Level
6) Maximum fluid temperature for standard sensor design:
130 °C with ETFE, 90 °C (194 °F) with hard rubber
7) Explosion protection only possible in conjunction with dual-compartment transmitter housing.
8) Only with model FEP311.
10) Transmitter degree of protection = IP67 (NEMA 4X) with single-compartment and dual-compartment housing
11) Not Available with design Zone 2 / Div 2 or Zone 1 / Div1.
12) Choice with design Zone 2 / Div 2.
14) Specified by ABB.
63
Continued
Add.
Version number 1–6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Accessories
None AY
Steckverbinder
Feldbus M12 x 1 15) U2
Dual-compartment housing / Stainless steel 17) H4
Aluminium / Carbon steel 18) SMA
Stainless steel 19) SMS
3 points T3
5 points T5
Material Sourcing
Material sourcing limitations apply MS1
German M1
English M5
Chinese M6
Russian MB
Material Certifications
Test report 2.2 acc. EN 10204 confirmation of material C1
Material monitoring with inspection certificate 3.1 acc. EN 10204 C2
Declaration of compliance with the order 2.1 acc. EN 10204 C4
Inspection certificate 3.1 acc. EN 10204 for visual, dimensional and functional test C6
Inspection certificate 3.1 acc. EN 10204 for positive material identification PMI (inclusive heat analysis) CA
Certificate of accuracy 2.1 acc. EN 10204 CM
Material monitoring NACE MR 0175 / MR 0103 if applicable, with inspection certificate 3.1 acc. EN 10204 CN
Others CZ
Tests and Reports
Inspection certificate 3.1 acc. EN 10204 for non‐destructive testing of welds (X‐Ray) acc. to ASME NA
Inspection certificate 3.1 acc. EN 10204 for non‐destructive testing of welds (Dye Pen Test) acc. to ASME NB
Pressure test acc. AD2000 acc. to ASME N6
Welder qualification & welding procedure certificate acc. to ASME NF
15) Only for PROFIBUS PA Not for model FEP315.

16) Not available with Ex design Zone 1
17) In conjunction with sensor housing material Stainless steel.
18) In conjunction with Transmitter housing design (Aluminium) only.
19) In conjunction with Transmitter housing design (Stainless steel) only.
64
uh
Electromagnetic flowmeter ProcessMaster - FEP321 and FEP325, remote mount design, high pressure
version
Add.
Version number 1–6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 27
Nominal diameter
DN 25 (1 in.) 0 2 5
DN 32 (1-1/4 in.) 0 3 2
DN 40 (1-1/2 in.) 0 4 0
DN 50 (2 in.) 0 5 0
DN 65 (2-1/2 in.) 0 6 5
DN 80 (3 in.) 0 8 0
DN 100 (4 in.) 1 0 0
DN 125 (5 in.) 1 2 5
DN 150 (6 in.) 1 5 0
DN 200 (8 in.) 2 0 0
DN 250 (10 in.) 2 5 0
DN 300 (12 in.) 3 0 0
DN 350 (14 in.) 3 5 0
DN 400 (16 in.) 4 0 0
Lining material
ETFE E
Hard rubber H
Electrode design
Standard 1
Pointed head 5
Stainless steel 316Ti (1.4571) S
Standard 1
Process connection
Flanges ANSI Class 600 RF A 6
Flanges ANSI Class 2500 RF 1) A 9
Flange ANSI Class 600 RTJ H 6
Flange ANSI Class 2500 RTJ 1) H 9
Steel B
Usage Certifications
Calibration Type

1) Available up to DN 300 (12 in.)
65
Continued
Add.
Version number 1–6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Name plate
Adhesive label A
Stainless steel B
Stainless steel and TAG plate (stainless steel) C
Signal Cable Length and Type 7)
No cable 0
5 m (15 ft) standard cable 1
Other 9
Explosion Protection Certification
None 8) A
ATEX / IEC Zone 1 L
usFMc Div 1 9) R
Protection Class Transmitter / Protection Class Sensor
IP 67 (NEMA 4X) / IP 67 (NEMA 4X) 10) 1
IP 67 (NEMA 4X) / IP 68 (NEMA 6P), cable not fitted and potted 11) 2
IP 67 (NEMA 4X) / IP 68 (NEMA 6P), cable fitted and potted 12) 3
Cable Conduits
M20 x 1.5 A
1/2 in. NPT B
PF 1/2 in. 13) C
Power supply
Without 0
Input and Output Signal Type
Without Y
Configuration Type / Diagnostics Type
Parameters set to factory defaults / Standard diagnostic functions activated 1
Parameters set customer-specific / Standard diagnostic functions activated 3
Design Level
Design Level B 14) B

6) Maximum fluid temperature for standard sensor design:
130 °C with ETFE, 90 °C (194 °F) with hard rubber
7) For flowmeter sensor model FEP325 designed for zone 1 / Div 1, signal cable length can be max. 50 m (164 ft) in combination with
transmitter model FET321 or transmitter model FET 325 designed for zone 2 / Div 2.
For sensor model FEP325 designed for zone 1 / Div 1, signal cable length can be max. 10 m (32.8 ft) in combination with transmitter model
FET325 designed for zone 1 / Div 1.
8) Model FEP321 only.
10) Transmitter degree of protection = IP67.
11) Only available with remote transmitter, sealing compound (optional) D141B038U01.
12) Not available with FET325 transmitter in zone1 / Div1 design.
13) Not available with Zone 2 / Div 2 or Zone 1 / Div1.
14) Specified by ABB.
66
Continued
Add.
Version number 1–6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28
Accessories
None AY
With pre-amplifier installed in sensor terminal box 15) AP
Connectionbox Material
Aluminum UTA
Aluminum < DN 450 / Carbon Steel > DN 400 SMA
Power Frequency
50 Hz (If the Sensor is ordered without a Transmitter, the line frequency has to be specified here) F5
60 Hz (If the Sensor is ordered without a Transmitter, the line frequency has to be specified here) F6
3 points T3
5 points T5
Material Sourcing
Material sourcing limitations apply MS1
German M1
English M5
Chinese M6
Russian MB
Language package Western Europe / Scandinavia (Languages: DE, EN, DA, ES, FR, IT, NL, PT, FI, SV) MW
Language package Eastern Europe (Languages: DE, EL, CS, ET, LV, LT, HU, PL, SK, SL, RO, BG) ME
Material Certifications
Test report 2.2 acc. EN 10204 confirmation of material C1
Declaration of compliance with the order 2.1 acc. EN 10204 C4
Inspection certificate 3.1 acc. EN 10204 for visual, dimensional and functional test C6
Inspection certificate 3.1 acc. EN 10204 for positive material identification PMI (inclusive heat analysis) CA
Certificate of accuracy 2.1 acc. EN 10204 CM
Material monitoring NACE MR 0175 / MR 0103 if applicable, with inspection certificate 3.1 acc. EN 10204 CN
Others CZ
Tests and Reports
Inspection certificate 3.1 acc. EN 10204 for non‐destructive testing of welds (X‐Ray) acc. to ASME NA
Inspection certificate 3.1 acc. EN 10204 for non‐destructive testing of welds (Dye Pen Test) acc. to ASME NB
Pressure test acc. AD2000 acc. to ASME N6
Welder qualification & welding procedure certificate acc. to ASME NF
15) Preamplifier required if signal cable length is > 50 m (>160 ft). Preamplifier not available for zone1 / Div1.
67
Remote transmitter - FET321, FET325

Add. order
Main order number no.
Version number 1–6 7 8 9 10 11 12 13 14 15 XX
Without explosion protection FET321 X X X X X X X X X XX
With explosion protection FET325 X X X X X X X X X XX
Standard sensor design / -20 ... 60 °C (-4 ... 140 °F) 1
Standard sensor design / -40 ... 60 °C (-4 ... 140 °F) 2
High-temperature sensor design / -20 ... 60 °C (-4 ... 140 °F) 3
High-temperature sensor design / -40 ... 60 °C (-4 ... 140 °F) 4
Name plate
Sticker A
Stainless steel B
Signal cable length
No cable 1) 0
Explosion protection 2)
None 2) 10) A
ATEX / IEC Zone 1 2) L
ATEX / IEC Zone 2 / 21 2) M
usFMc Div 2 Zone 2 2) P
usFMc Div 1 2) 10) R
NEPSI Zone1 2) 3) 10) U
NEPSI Zone2 2) 3) V
Standard / IP 67 (NEMA 4X) 1
Cable gland
M20 x 1.5 A
1/2 in. NPT B
PF 1/2 in. 9) C
None Y
Power supply
100 ... 230 V AC, 50 Hz 1
24 V AC / DC, 50 Hz 2
100 ... 230 V AC, 60 Hz 3
24 V AC / DC, 60 Hz 4
Signal inputs / outputs
Without / standard diagnostic functions 8) 0
Parameters are at factory settings / Standard diagnostic functions activated 1
Parameters are set according to customer specifications / Standard diagnostic functions activated 3
1) For model FET325 designed for Ex Zone 1 / Div 1, 10 m (32.81 ft) of cable is connected to the transmitter.
2) Model FET325 only.
4) Protection type for transmitter = IP 67 (NEMA 4X) with single-compartment housing and dual-compartment housing, IP 20 with panel mount
housing.
5) Choice with design Zone 2 / Div 2 or Zone 1 / Div 1 or without explosion protection.
6) Choice with design Zone 2 / Div 2 or without explosion protection.
8) Must be selected if transmitter is being ordered as a spare part or without a sensor.
9 Only for model FET321.
10) Only available with Dual-compartment housing.
68
Continued
Add. order
Main order number no.
Version number 1–6 7 8 9 10 11 12 13 14 15 XX
Without explosion protection FET321 X X X X X X X X X XX

With explosion protection FET325 X X X X X X X X X XX
Plug connector
M12 x 1 fieldbus 11) U2
Additional options
With Gore-Tex membrane 12) KG
Other certificates
PMO approval (only for USA) CR
German M1
English M5
Chinese M6
Russian MB
11) Only for Profibus PA, not for model FET325.
12) Available with Model FET521 and FET525 Zone 2 / Div 2.
13) Inmetro only in conjunction with explosion protection ATEX / IECEx Zone 1 (code "L") or ATEX / IECEx Zone 2/21 (code "M") and
transmitter housing design "dual-compartment housing " (code H2).
69
Transmitter plug-in module - FET301

Additional
Version number 1–6 7 8 9 10 11 12 13 14 15 X
FET301 X X X X X X X X X X
Temperature Range of Installation / Ambient Temperature Range
Standard design / -20 ... 60 °C (-4 ... 140 °F) 1
Name Plate
Adhesive label A
Signal Cable Length and Type
Without signal cable 0
Explosion Protection Certification
Without A
Protection Class Transmitter / Protection Class Sensor
Others 9
Cable Conduits
Others Z
Power Supply
100 ... 230 V AC, 50 Hz 1
24 V AC / DC, 50 Hz 2
100 ... 230 V AC, 60 Hz 3
24 V AC / DC, 60 Hz 4
Input and Output Signal Type
HART + 20 mA passive + Pulse + Contact I/O B
HART + 20 mA active + Pulse + Contact I/O C
FOUNDA FOUNDATION Fieldbus + contact output F
Configuration Type / Diagnostics Type
Without / Standard diagnostic functions 1) 0
Language of Documentation
German M1
English M5
Chinese M6
Russian MB
Language package Western Europe / Scandinavia (Languages: DE, EN, DA, ES, FR, IT, NL, PT, FI, SV) MW
Language package Eastern Europe (Languages: DE, EL, CS, ET, LV, LT, HU, PL, SK, SL, RO, BG) ME
1) To be specified if Transmitter is ordered without Sensor or as a spare part.
Flowmeter sensor simulator - FXC4000

Main order number
Version number 1–5 6 7 8 9 10
55XC4 X X X X X
Flow Signal Setting
Without (adapter only) 0
3-position digitswitch with 1000 steps 1
Power Supply
Without (adapter only) 0
110 ... 240 V AC 50 / 60 Hz // With Schuko plug 1
24 ... 48 V AC / DC // With 4 mm plug 2
110 ... 240 V AC 50 / 60 Hz // With US plug 3
Accessories
Without 0
Adapter for converter type FXE4000-E4, FXM2000-XM2, FXF2000-DF23 1
Adapter board for converter type FSM4000-S4 5
Adapter plate for converter FET321, FET325, FET521, FET525 6
Design level (specified by ABB) *
Name Plate
German 1
English 2
French 3
70
Accessories
Description Order number
Diagnostic and verification software - ScanMaster FZC500 FZC500
ScanMaster allows you to easily check the installed device for proper functioning. The determined test and verification
results are stored in a database and can be printed if required.
ScanMaster is based on DTM technology and can be run on Asset Vision Basic or other frame applications
(as of FDT 1.2).
There are two ways to communicate with the device.
- Via a HART modem (e.g. NHA121Nx (explosion-proof design) or NHA121No (standard design))
- Via FZA100 infrared service port adapter FZA100
Infrared service port adapter FZA100 FZA100
G00788
Installation set for 2" pipe installation in dual-compartment field-mount housing 612B091U07
G00789
Installation set for NPT 1/2" cable gland 3KXF081300L0001

For sealing the cable conduit during outdoor installation.
G01312
Signal cable for nominal diameter ≥ DN 15 (1/2 inch) out of potentially explosive areas and in zone 2 / Div. 2 D173D031U01
Signal cable for all applications (including zone 1, 2 / Div. 1, 2) D173D027U01
Trademarks
® HART is a registered trademark of FieldComm Group, Austin,
Texas, USA.
® PROFIBUS and PROFIBUS PA are registered trademarks of
PROFIBUS & PROFINET International (PI)
® FOUNDATION Fieldbus is a registered trademark of FieldComm
Group, Austin, Texas, USA.
® LINATEX is a registered trademark of Linatex Ltd.
™ Hastelloy C-4 is a Haynes International trademark
™ Hastelloy B-3 is a Haynes International trademark
71
Contact us
DS/FEP300-EN Rev. K 01.2016

ABB Limited Note
We reserve the right to make technical changes or
Process Automation
modify the contents of this document without prior
Howard Road, St. Neots notice.
Cambridgeshire, PE19 8EU With regard to purchase orders, the agreed
UK particulars shall prevail. ABB does not accept any
responsibility whatsoever for potential errors or
Tel: +44 (0)870 600 6122
possible lack of information in this document.
Fax: +44 (0)1480 213 339
Mail: enquiries.mp.uk@gb.abb.com We reserve all rights in this document and in the
subject matter and illustrations contained therein.
Any reproduction, disclosure to third parties or
ABB Inc.
utilization of its contents in whole or in parts – is
Process Automation forbidden without prior written consent of ABB.
125 E. County Line Road
Warminster, PA 18974 Copyright© 2016 ABB
All rights reserved
USA
Tel: +1 215 674 6000 3KXF231300R1001
Fax: +1 215 674 7183
ABB Automation Products GmbH

Process Automation
Dransfelder Str. 2
37079 Goettingen Sales Service
Germany
Tel: +49 551 905-0
Fax: +49 551 905-777
ABB Engineering (Shanghai) Ltd.

Process Automation
No. 4528, Kangxin Highway, Pudong
New District
Shanghai, 201319,
P.R. China
Tel: +86(0) 21 6105 6666
Fax: +86(0) 21 6105 6677
Mail: china.instrumentation@cn.abb.com
www.abb.com/flow
R
CONTROLS
OPERATION AND MAINTENANCE MANUAL
RESILIENT SEATED BUTTERFLY VALVES

20/21, 22/23, 30/31, 3A/3AH, 31H, 31U, 32/33, 35/36, 36H
The
High
Performance
Company
Table Of Contents:
page
Safety Instructions: Definition Of Terms . .......................................................................1
Introduction .........................................................................................................................1
Shipment & Storage . ...........................................................................................................1
Installation Considerations . ..............................................................................................2
Valves With Spring Return Actuators .............................................................................2
Fail Open Assembly ....................................................................................................2
Fail Closed Assembly ................................................................................................2
Valve Location And Orientation In Piping ........................................................................3
Valve Orientation Diagrams .................................................................................4-6
Installation Procedure ....................................................................................................6-9
PTFE Seated Butterfly Valves in Plastic Flanges................................................9
Maintenance & Repair . .......................................................................................................9
Appendix ‘A’ - S20/21 Disassembly/Assembly Instructions ............................................10-11
Appendix ‘B’ - S22/23 Disassembly/Assembly Instructions................................................ 12-13
Appendix ‘C’ - S30/31 Disassembly/Assembly Instructions . ......................................... 14-15
Appendix ‘D’ - S3a/3ah Disassembly/Assembly Instructions ..................................... 16-17
Appendix ‘E’ - S31H Disassembly/Assembly Instructions ............................................. 18-19
Appendix ‘F’ - S31U Disassembly/Assembly Instructions ............................................. 20-21
Appendix ‘G’ - S32/33 Disassembly/Assembly Instructions .......................................... 22-24
Appendix ‘H’ - S35/36 (Taper Pin Disc/Stem Connection)
Disassembly/Assembly Instructions ....................................................... 25-27
Appendix ‘I’ - S35/36 (Internal Spline or Keyed Disc/Stem Connection)
Disassembly/Assembly Instructions ....................................................... 28-33
Appendix ‘J’ - S36H Disassembly/Assembly Instructions .............................................. 34-36
for information on these products and other bray products

please visit us at our web page - www.bray.com
BRAY Resilient Seated BFV
Operation and Maintenance Manual
Safety Instructions - Definition of Terms

READ AND FOLLOW THESE INSTRUCTIONS
SAVE THESE INSTRUCTIONS
indicates a potentially hazardous situation which, if not avoided, could

WARNING
! result in death or serious injury.
indicates a potentially hazardous situation which, if not avoided, may

CAUTION
! result in minor or moderate injury.
used without the safety alert symbol indicates a potential situation which, if
NOTICE not avoided, may result in an undesirable result or state, including
property damage.
Introduction change in this interference due to improper installation

directly affects the pressure rating and seating/unseating
torques.
Historical Experience
Based on over twenty years experience in the butterfly
Finally, unlike many valve types, the resilient seated
industry, Bray can state without question the majority of all
butterfly valve’s disc actually extends beyond the face of the
field problems for resilient seated butterfly valves are directly
valve body at given angles of opening (say, 30° or more)
related to poor installation procedures. For this reason, it is
when installed between flanges.
very important all distributor salespeople educate their cus-
tomers regarding proper installation of resilient seated butter-
fly valves.
! Caution
Butterfly Valve Seat / Disc Function
It is very important before installation to ensure the criti-
Before reviewing the proper installation, maintenance, and re-
cal chord dimension of the disc at the full open position
pair procedures for resilient seated butterfly valves, let’s dis-
is less than the adjacent pipe flange I.D.
cuss the seat-disc function of a butterfly valve. The seat in a
resilient seated butterfly valve has molded o-rings on its flange
face. As a result, no gaskets are required as these o-rings Shipment & Storage
serve the function of a gasket. The flange face and molded o-
A. The seat, disc, stem and bushing of the resilient seated
rings of the seat extend beyond the body face-to-face to ensure butterfly valve should be coated with silicone lubricant
sealing at the flange faces. The seat material, which extends unless specified otherwise as recommended by Bray
past the face is compressed in installation and flows toward Technical Bulletin 1028.
the center of the valve seat I.D.
B. The disc should be positioned at 10° open.
Note: See page 2 for special considerations for valves
In essence, the elastomer seat acts as a liquid, and the with spring return actuators.
displaced elastomer moves toward the point of least resis-
C. Valves should be stored indoors with a preferred tempera-
tance. The seat I.D. of all resilient seated butterfly valves
ture range from 40° F (4°C) to 85° F (29°C).
is smaller than the disc O.D. This difference, the disc-seat
interference, plus the increased interference due to the elas- D. When valves are stored for a long time, open and close
tomer movement toward the seat center after installation, the valves once every 3 months.
has been engineered so as to be the basis for pressure rat- E. Ship and store valves so that no heavy loads are
ing capability and the related seating/unseating torques. Any applied to the bodies.
1
Installation Considerations – Piping and Valve Orientation and Placement
Piping and Flanged Compatibilities are especially important with non-metallic flanges.
In some cases, non-metallic flanges of low quality
Piping will not mate tightly with butterfly valves regardless
These valves have been engineered so that the of the care taken during installation.
critical disc chord dimension at the full open posi-
tion will clear the adjacent inside diameter of most Valves with Spring Return Actuators
types of piping, including Schedule 40, lined pipe,
heavy wall, etc. 1. Fail Closed Assemblies
If the valve is supplied with an actuator, the butterfly
Metal Flanges valve is shipped in the full closed position (as no
Resilient seated butterfly valves have been designed air pressure is present to compress the springs and
to be suitable for all types of flanges (ASME, DIN, open the disc).
JIS and other international flange standards), whether
flat-faced, raised face, slip-on, weld-neck, etc. Proper
alignment of any butterfly valve between flanges is Caution
critical to good performance of the valve. The flange
!
bolts must also be evenly tightened around the cir- Installing the valve with the disc in the full closed
cumference of the valve, providing consistent flange position may create a compression set on the seat
compression of the molded o-ring in the seat face. causing higher than expected torques or premature
seat failure. It is recommended to:
Since Bray does not recommend the use of gaskets • Remove the actuator. Be sure to scribe the valve and
between flanges on resilient seated butterfly valves, actuator to ensure the re-installed actuator is in the
a uniform flange face is critical to proper valve exact same quadrant as originally configured
sealing. Most weld-neck and slip-on flanges con- • Install the valve per the attached installation tag
forming to ASME specifications have an appropri- instructions
ate flange face. Types A and B butt-weld stub-end • Re-install the actuator ensuring it is in the proper
flanges also provide a suitable mating surface for quadrant
the molded o-ring.
2. Fail Open Assemblies
It should be noted that Type C butt-weld stub-end If the valve is supplied with an actuator, the butterfly
flanges have an “as formed” flange face. The vary- valve disc is shipped in the full open position (as
ing surface of this flange face can create sealing no air pressure is present to compress the springs
problems between any resilient-seated butterfly and close the valve disc.) The sealing surface, or
valve and the flange face. For this reason, Type C disc edge, is therefore exposed. Damage to that
flanges are not recommended for use with resilient- surface will cause premature seat failure.
seating butterfly valves.
Non-Metallic Flanges Caution

When non-metallic flanges, such as plastic or PVC, !
are used with resilient seated butterfly valves, care Use caution installing the valve being careful not to
must be taken not to over-tighten the flange bolts. damage the disc edge. It is recommended to:
The inherent flexibility of these non-metallic flange • Remove the actuator. Be sure to scribe the valve and
materials allow them to be over-tightened relatively actuator to ensure the re-installed actuator is in the
easily. Flexing caused by this over-tightening can exact same quadrant as originally configured
actually reduce the compression of the valve be- • Install the valve per the attached installation tag
tween the flanges, causing leaks between the valve instructions
and the flange face. Proper alignment and firm, • Re-install the actuator ensuring it is in the proper
even, but not excessive tightening of flange bolts quadrant
2
3. Valve Location b. For slurries, sludge, mine tailing, pulp

a. Resilient seated butterfly valves should be stock, dry cement, and any media with
installed if possible a minimum of 6 pipe di- sediment or particles, Bray recommends
ameters from other line elements, i.e., elbows, the resilient seated valve be installed with
pumps, valves, etc. of course, 6 pipe diameters the stem in the horizontal position with
are not always practical, but it is important to the lower disc edge opening in the down-
achieve as much distance as possible. stream direction.
b. Where the resilient seated butterfly valve
is connected to a check valve or pump, use
an expansion joint between them to ensure
the disc does not interfere with the adjacent
equipment.
4. Valve Orientation
a. In general, Bray recommends the resilient
seated valve be installed with the stem in the
vertical position and the actuator mounted
vertically directly above the valve; however,
there are those applications as discussed
below where the stem should be horizontal.
NOTE: Bray does not recommend valves
be installed in an upside-down position.
FLOW
Stem (Vertical)
INCORRECT INSTALLATION
Sludge builds up on disc
FLOW
Stem (Horizontal)
CORRECT INSTALLATION
Sludge passes under disc
3
Valve Orientation (Continued)

c. Resilient seated butterfly valve located at the discharge of a pump should be oriented as follows:
INCORRECT INSTALLATION CORRECT INSTALLATION
i.) For
centrifugal
Pump – Pump Pump Shaft Pump Shaft
shaft horizon- (Horizontal) (Horizontal)
tal and stem
vertical FLOW FLOW
Stem (Horizontal) Stem (Vertical)
ii.) Centrifu-
gal Pump – Pump Shaft
Pump Shaft
Pump shaft (Vertical) (Vertical)
vertical &
stem
horizontal FLOW FLOW
Stem Stem
(Vertical) (Horizontal)
Suction Suction
iii.) Axial
Pump – Pump
Pump Shaft Pump Shaft
shaft vertical
(Vertical) (Vertical)
& stem
vertical
FLOW FLOW
Stem Stem
Suction (Horizontal) Suction (Vertical)
4

d. Butterfly valves located downstream of a bend or pipe reducer should be oriented as follows:
i.) Bend
Stem Stem
(Horizontal) (Vertical)
FLOW FLOW
ii.) Tee
Stem Stem
FLOW FLOW
iii.) Pipe
Reducer
Stem Stem
FLOW FLOW
5

e. Butterfly valves in combination for control/isolation applications should be installed as follows:
FLOW FLOW
Combination with all valve stems in the same Combination with the stem of the control
direction accelerates possible noise, vibration, valve at right angle to those of other valves
& erosion problems. tends to cancel the drift of the fluid, and re-
duces noises, vibration, and erosion.
Installation Procedure 4. Check to see that the valve disc has been
positioned to a partially open position, with
A. General Installation the disc edge about 1/2 inch to 3/8 inch
1. Make sure the pipeline and pipe flange faces are inside the face of the seat, (approxi-
clean. Any foreign material such as pipe scale, mately 10° open) (see figure 1 page 6)
metal chips, welding slag, welding rods, etc., can Note: See page 2 for special consideration
obstruct disc movement or damage the disc or for valves with spring return actuators.
seat. 5. Insert the valve between the flanges as shown
2. The Bray elastomer seat has molded o-rings in figure 1 of page 6, taking care not to damage
on the face of the seat. As a result, no the seat faces. Always pick the valve up by the
gaskets are required as these o-rings serve locating holes or by using a nylon sling on the
the function of a gasket. neck of the body.
3. Align the piping and then spread the pipe flang-
WARNING
es a distance apart so as to permit the valve !
body to be easily dropped between the flanges
without contacting the pipe flanges (see figure Never pick up the valve by the actuator or opera-
1 page 6). tor mounted on top of the valve.
6
Figure 1 – Insert Resilient Seated Butterfly Valve Between Flanges

Pipe spread and aligned, disc rotated;
CAUTION
! Results; no undesirable beginning seating/
unseating torque, disc edge protected.
Pipe not spread, disc opened beyond valve
body face; Results; Disc edge damaged when
it hits pipe flange.
6. Place the valve between the flanges, center it, below. Very slowly close the valve disc to ensure
and then span the valve body with all flange bolts, disc edge clearance from the adjacent pipe flange
but do not tighten the bolts. Carefully open the disc I.D. Now open the disc to full open and tighten all
to the full open position, making sure the disc does flange bolts per specification as shown in Figure
not hit the adjacent pipe I.D. Now systematically 2. Finally, repeat a full close to full open rotation
remove jack bolts or other flange spreaders, and of the disc to ensure proper clearances (See figures
hand-tighten the flange bolts as shown in Figure 2 3 & 4 page 7).
Figure 2 – Flange Bolt Tightening Pattern
5 1
3 7
8 4
2 6
7
Figure 3 – Initial Centering & Flanging of Valve
Gasket

Disc in closed position; gaskets used; Results Bolts snugged, not torqued tight, disc edge
– Seat distorted and over-compressed causing within body face-to-face but not fully closed,
high initial unseating torque problems. no flange gaskets; Results: No disc edge
damage, proper sealing allowed.
Figure 4 – Final Aligning & Tightening of Flange Bolts

Piping misaligned; Results Disc O.D. strikes Piping aligned properly when bolts tightened,
pipe I.D. causing disc edge damage, increased disc in full open position; Results – disc clears
torque & leakage. Seat face o-rings will not adjacent pipe I.D., seat face seals properly, no
seal properly with incorrectly aligned piping. excessive initial torque.
8
When resilient seated butterfly valves are to be 2. The plastic flange can be either one piece
installed between ASME welding type flanges, care construction, or two piece construction comprised
should be taken to abide by the following procedure to of a stub end and a backup ring.
ensure no damage will occur to the seat: 3. The plastic flange style can be butt-weld, socket
1. Place the valve between the flanges with the or slip-on, but butt-weld and socket are preferred.
flange bores and valve body aligned properly.
The disc should be in the 10° open position. 4. The plastic flange face must be flat. Concave
and convex flange faces are not acceptable. This
2. Span the body with the bolts. includes flange faces that were originally flat
3. Take this assembly of flange-body-flange and but later distorted into a concave shape by over
align it properly to the pipe. tightening the flange bolts.
4. Tack weld the flanges to the pipe. 5. The plastic flange face surface may have grooves
5. When tack welding is complete, remove the or serrations, provided the grooves do not exceed
bolts and the valve from the pipe flanges .100” (2.54 mm) in width or .020” (.508 mm) in
and complete the welding of the flang- depth. If the grooves are less than .100” (2.54 mm)
es. Be sure to let the pipe and flanges cool in width, the groove depth must not exceed the
before installing the valve. width. However, fine conentric or “phonograph
record” grooves are acceptable regardless of the
groove depth.
! CAUTION 6. Flange gaskets must not be used with PTFE seats,
since they create an uncontrolled over compression
Never complete the welding process (after tacking) that can buckle the PTFE and damage the seat.
with the valve between pipe flanges. This causes If a damaged face, a flange gasket can appear to
severe seat damage due to heat transfer. cure the leak to atmosphere, while simultaneously
damaging the PTFE seat and creating a second leak
across the disc or up the stem hole. Leaks across
Installation of Bray PTFE Seated Butterfly Valves the plastic flange must be cured without the use of
in Plastic Flanges. gaskets, by proper selection and installation of the
flange.
Bray recommends the following guidelines when PTFE
Seated Valves are installed between plastic flanges: 7. The bolts holding plastic flanges should be
installed in strict conformance to the recommended
1. The valve body should be coated with epoxy, not practices of the plastic flange manufacturer. This
nylon. The extra thickness of the nylon coating usually involves aligning the flanges accurately,
slightly reduces the seat compression, and every using lubricated bolts, and tightening the bolts in
advantage to maximize seat compression should the proper sequence and to the specified torque.
be taken with plastic flanges. Uniform stress across the flange prevents leakage.
Maintenance and Repair
The many Bray features minimize wear and maintenance requirements. No routine lubrication is re-
quired. All components – stem, disc, seat, bushing, stem seal, etc., are field replaceable, no
adjustment is required. If components require replacement, the valve may be removed from the line by placing the
disc in the near closed position, then supporting the valve and removing the flange bolts.
No valve maintenance, including removal of manual or power actuators, should be

! WARNING
performed until the piping system is completely depressurized.
9
Appendix A
Disassembly/Assembly Instructions
Series 20/21 Resilient Seated Butterfly Valves
Disassembly
1. Remove handle, gear operator or power actuator from actuator mounting flange.
2. Remove the body bolts and pull the lower body half away from the seat.
3. Pull the seat and disc stem from the upper body half.
4. Remove bushing and seal from the upper body.
5. Push the seat into an oval shape and remove the disc stem by withdrawing the short stem end first.
Assembly
1. Push the long stem end of the disc into the seat.
2. Then push the seat over the disc’s short stem.
3. Place the disc stem and seat into the upper body half.
4. Align the lower body with the upper body and position lower body in the seat.
The body halves have a matching casting node on one side only to ensure
NOTICE
correct assembly of body halves.
5. Replace the body bolts and tighten.

6. Install the stem seal, then the stem bushing.
Note: It is recommended that the stem bushing be coated with a light amount of silicone grease
before installation in the valve body. This coating of silicone grease will assist in keeping the
stem bushing in the valve body until an actuator is mounted on the valve.
7. Replace handle, manual gear operator or power actuator on the actuator mounting flange.
10
Appendix A
11
Appendix B
Disassembly –
1. Remove the handle, gear operator, or power actuator from actuator mounting flange.
2. Remove the “Spirolox”® retaining ring and the two C-ring stem retainers from the stem hole.
3. Then remove the stem, bushing and seal.
4. Remove the disc from the seat, protecting the disc edge at all times.
5. Remove the seat energizer from the stems and seat.
6. Remove the lower and upper stems from the disc or remove the lower stem if the upper stem is con-
nected to the disc
7. Compress the seat just enough to allow the disc to be removed along with the seal capsules.
8. Remove the retainer bushing and upper stem seal.
Assembly –
1. Install the stem bearings in upper and lower body halves.

2. Place the body seal strip on the lower body half, overlapping the body width by approximately 0.19”
on both sides.
3. Press the seat to make the I.D. elliptical, then insert the shaft seals and place the disc into the seat.
Rotate the disc hubs into alignment with the seat.
4. Insert the upper and lower stems.
5. Slip one seat energizer strip onto the lower portion of the upper shaft.
6. Insert the upper shaft with the pre-installed seat energizer strip into the disc/seat sub assembly.
7. Drive the upper shaft into the disc and slip one seat energizer strip onto the lower shaft.
8. Rotate the disc into the open position and insert the disc/seat/stems/energizer sub assembly into the
upper body half.
9. Place the lower body half over the seat, and ensure that both body halves are properly aligned (iden-
tified by cast-on markings.
10. Attach and tighten the body fasteners.
12
SERIES 22/23 12
6
RESILIENT SEATED BUTTERFLY VALVES 7
1. BODY
2. DISC
3. SEAT
14
4. UPPER STEM
5. LOWER STEM
6. BUSHING
7. UPPER STEM SEAL 9 1
8. SEAL CAPSULE
9. BEARING
10. SEAT ENERGIZER
11. CAP SCREW 4
12. RETAINER
13. BODY SEAL
14. ID TAG
10
2
3
8
13
5
13
9
11
11
13
Appendix C
Disassembly –
5. Push the seat into an oval shape, and then remove the seat from the body.
Assembly –

1. Push the valve seat into an oval and push it into the body with seat stem holes aligned to body stem
holes.
When installing the seat the larger hole should be on top and the smaller hole
NOTICE
should be on bottom.
2. Insert stem seal and bushing.

3. Push stem into the stem hole of the body until the bottom of the stem is flush with the inner top edge
of the seat.
4. Install a light coating of silicone or grease on the I.D. of seat. Insert the disc into the seat by
lining up the disc holes with the stem holes of the seat.
Note: The broached double “D” flats in the disc must be toward the bottom of the valve body.
5. With a downward pressure and rotating the stem back and forth, push the stem until the stem touches
the bottom of the body stem hole.
6. Make certain that when pushing the stem through the disc bottom, the broached flats of stem and
disc are aligned.
7. Replace the stem bushing and two stem retainers, then replace the “Spirolox”® retaining ring back
into position.
14
15
Appendix D
Series 3A/3AH Resilient Seated Butterfly Valves
Disassembly –
Note: The seat is bonded to the body and is not easily field replaceable. Please contact your local Bray
representative for seat replacement.
Assembly –

of the seat.
3. Install a light coating of silicone or grease on the I.D. of seat. Insert the disc into the seat by lining up
the disc holes with the stem holes of the seat.
disc are aligned.
into position.
16
SERIES 3A/3AH 9
7
1. BODY 6
2. SEAT
3. DISC 5
4. STEM
5. STEM SEAL
6. STEM BUSHING
7. STEM RETAINER
8. THRUST WASHER
9. RETAINING RING
4
17
Appendix E
Series 31H Resilient Seated Butterfly Valves
Disassembly –
Note: Valve is provided with the seat bonded to the body and therefore is not easily field re-
placeable. Please contact your local Bray representative for seat replacement.
Assembly –

of the seat.
3. Install a light coating of silicone or grease on the I.D. of seat. Insert the disc into the seat by lining up
the disc holes with the stem holes of the seat.
disc are aligned.
into position.
18
SERIES 31H
1. BODY (S30 WAFER STYLE SHOWN)
2. SEAT
3. DISC
4. STEM
5. STEM SEAL
6. STEM BUSHING
7. STEM RETAINER
8. THRUST WASHER
9. RETAINING RING
19
Appendix F
Series 31U Resilient Seated Butterfly Valves
Disassembly –
3. Then remove the top stem bushing and seal, upper stem and retaining rod.
5. The upper and lower stem bearings will remain in the valve behind the seat.
Note: The seat is bonded to the body and is not easily field replaceable.
Please contact your local Bray representative for seat replacement.
Assembly –
1. Install a light coating of silicone or grease on the I.D. of seat.

2. Insert the lower stem inside the disc before inserting the disc into the seat.
3. Insert the disc into the seat by lining up the disc holes with the stem holes of the seat.
4. Line up the disc using a T-Bar (Allan key style)
5. With a downward pressure and rotating the T-Bar back and forth, push the lower stem until the
lower stem touches the bottom of the body stem hole recess.
disc are aligned.
7. Insert the spacer bar and upper stem into the disc and valve.
8. Replace the top stem bushing and seal and two stem retainers.
9. Then replace the two “C” ring stem retainers and the “Spirolox”® retaining ring back into position
in the top stem hole.
Note: It is recommended that a torque and seat test be done to confirm all is in order with the
maintenance of the valve.
10. Replace the handle, manual gear operator or power actuator on the actuator mounting flange.
20
SERIES 31U 11
10
8
1. BODY 9. STEM RETAINER 7
2. DISC C WASHERS
3. UPPER STEM 10. UPPER THRUST
4. LOWER STEM WASHER
5. SEAT 11. RETAINING RING
6. BEARING 12. LOWER THRUST WASHER
7. STEM SEAL 13. SPACER 3
8. STEM BUSHING 14. SEAL PLUG
13
6
5
4
2
12
14
21
Appendix G
Disassembly –
1. Remove the gear operator or power actuator from the actuator mounting flange.
2. Secure the valve in a horizontal position with the taper-pin nuts facing upward.
Prior to removal of the valve stem the valve disc must be secured and sup-
ported to insure it does not drop out of the valve body once the stem is
CAUTION removed. Lay the valve down with two wood blocks located under the disc
! at the 6 o’clock and 12 o’clock positions making sure the blocks are in close
contact with the disc but not supporting the valve.
3. Remove the packing gland by removing the retaining screws and sliding the gland off the top of the
stem.
4. Remove bottom plate and thrust bearing to expose bottom of stem.
5. Remove nuts and washers from ends of taper pins and drive taper pins out of the disc. Avoid damag-
ing the disc coating or surface when removing taper-pins.
6. Once taper-pins are removed, drive the stem, bushing, and packing out of the valve body through the
top.
7. Remove the disc from the seat, protecting disc edge at all times.
22
Appendix G (Cont’d)
Assembly –
1. Replace bottom thrust bearing and plate.

2. Push the seat into an oval and push it into the body with seat stem holes aligned to body stem holes.
3. De-bur taper-pin grooves in the stem.
4. Push stem into stem hole of body until the bottom of the stem is flush with the inner top edge of the
seat.
Note: The end of the stem containing the keyway must be toward the top of the valve body.
5. Install a light coating of silicone or grease on the I.D. of the seat.
6. Insert the disc into the seat by lining up the disc hole with the upper stem hole of the seat.
Note: Make certain that when pushing the stem to the bottom of the body, the taper-pin
grooves in the stem line up with the holes in the disc face.
8. Tap the taper-pins into their holes from the large side of the hole, making sure the pins fit tightly in
the hole and allow no movement of the stem in the disc.
Note: Ensure that the taper-pin o-rings are in place before completing valve assembly.
9. Replace the washers and nuts on the ends of the taper-pins.
10. Replace bushing, packing, and packing gland, and then tighten the retaining screws snugly.
11. Replace manual gear operator or power actuator on the actuator mounting flange.
23
24
Appendix H
(Taper Pin Disc/Stem Connection)
Disassembly –
Prior to removal of the valve stem the valve disc must be secured and sup-
ported to insure it does not drop out of the valve body once the stem is re-
! CAUTION moved. Lay the valve down with two wood blocks located under the disc at
the 6 o’clock and 12 o’clock positions making sure the blocks are in close
stem.
top.
Note: Valves 54” and larger are provided with the seat bonded to the body and therefore is not eas-
ily field replaceable. Please contact your local Bray representative for seat replacement.
25
Appendix H (Cont’d)
Assembly –

2. Push the seat into an oval and push it into the body with seat stem holes aligned to body stem holes.
Note: Valves 54” and larger are provided with the seat bonded to the body and therefore is not
easily field replaceable. Please contact your local Bray representative for seat replacement.
seat.
26
SERIES 35/36
1. BODY 11. THRUST BEARING

2. DISC 12. BOTTOM PLATE
3. STEM 13. BOTTOM PLATE GASKET
4. SEAT 14. BOLT-HEX HEAD
5. STEM PACKING 15. KEY
6. STEM BEARING 16. STEM RETAINER
7. TAPER PIN 17. CAP SCREW
8. WASHER 18. PACKING GLAND
9. NUT 19. BOLT-HEX HEAD
10. O-RING 20. ID TAG
21. POP RIVET
27
Appendix I
(Internal Spline or Keyed Disc/Stem Connection)
Disassembly –
2. Secure the valve in a horizontal position.
Prior to removal of the valve stems the valve disc must be secured and sup-
ported to insure it does not drop out of the valve body once the stems are
! CAUTION removed. Lay the valve down with two wood blocks located under the disc
at the 6 o’clock and 12 o’clock positions making sure the blocks are in close
3. Removal of the lower valve stem:

a. Remove the bottom plate screws, bottom plate, bottom plate gasket and thrust bearing.
b. Remove the locking nut from the tie bolt.
c. Remove the stem retainer.
d. Secure a hoist to the lower stem (end is imperial threaded).
e. Then use the hoist to remove the lower stem from the valve body.
f. Remove the stem bearing.
4. Removal of the upper valve stem:
a. Remove the packing gland by removing the retaining screws and sliding the gland off the top
of the stem.
b. Secure a hoist to the upper stem (end is imperial threaded).
c. Then use the hoist to remove the upper stem including the tie bolt from the valve body.
5. Removal of the valve disc:
a. Remove the wood blocks noted above from below the disc.
b. Using a rubber hammer, pound one area of the disc (ex. 12 o’clock position) repeatedly until
the disc clears the face of the valve body.
28
Appendix I (Cont’d)
Disassembly –
6. Removal of packing and bearings:

a. Remove the stem packing.
b. Use a slotted screwdriver to carefully remove the upper and lower stem bearings.
7. Removal of the valve seat:
a. Set the valve body in an upright position and secure it in a floor vice ca-
! WARNING
pable of handling the weight of the valve body and seat.
Note: Be sure to not clamp the seat in the vice.

b. Insert a slotted screwdriver into the space between the body and the seat on the face of the
valve at the 12 o’clock position.
c. Carefully leverage the seat away from the body.
d. Push the seat into an oval shape and remove the seat from the body.
Assembly –
1. Installation of the valve seat:

a. Set the valve body in an upright position and secure it in a floor vice ca-
! WARNING
pable of handling the weight of the valve body and seat.
Note: Be sure to not clamp the seat in the vice.

b. Check to assure the interior surface of the valve body is clean.
c. Install a light coating of silicone lubricant on the interior surface of the valve body.
d. Push the seat into an oval and push it into the body with seat stem holes aligned to the body
stem holes.
29
Assembly –
2. Installation of the valve disc:

Note: Before installing the disc, check to assure the upper and lower stems are matched to the
upper and lower stem holes in the disc.
a. With the valve still in the vice in a vertical position, hoist the upper stem with the splined end
or the double keyed end pointing upward.
b. Push the upper stem into the stem hole of the upper body until the bottom of the stem
exceeds the upper stem hole of the seat by 20-50 mm.
c. Apply a light coating of silicone or grease on the I.D. of the seat.
d. Insert the disc into the seat with the splined end or the double keyed end up.
e. Push the disc into the seat while inserting the upper stem into the upper stem hole in the disc.
f. Adjust the disc to assure the lower stem hole of the disc is properly aligned with the lower
body stem hole.
3. Installation of the lower stem:
a. Close the valve so that the disc is inside the edge of the seat.
b. Carefully place the valve in a horizontal position assuring that there is no damage to the body
and disc coatings and disc edge.
c. Insert the stem bearing into the bottom stem hole of the body.
d. Insert the lower stem into the body and disc.
Note: The cone-shaped end of the lower stem should be toward the center of the disc.
30
Assembly –
4. Installation of the upper stem:
a. Hoist the valve to an angle and secure it (be careful not to go to high so
! CAUTION
the lower stem does not drop out).
b. Remove the upper stem from the valve.

c. Screw the tie bolt with lock nut to the splined or the double keyed end of the upper stem,
tighten the lock nut and insert the upper stem into the valve with the tie bolt end first.
Note: The tie bolt will go through the disc and reach to the bottom of the valve
Note: During this step, the keyway of the upper stem should be vertical to the front face
of the valve.
5. Installation of packing and bearings (upper valve stem):
a. Insert the stem bearing into the top hole of the body followed by the stem packing and pack-
ing gland follower.
b. Use two hexagon bolts to fasten the packing gland.
6. Installation of packing and bearings (lower valve stem):
a. Insert the stem retainer into the bottom hole of the body using a nut to fasten it.
b. Install the locking nut on the tie bolt.
c. Install the thrust bearing, bottom plate gasket and bottom plate follower.
d. Use four hexagon bolts to fasten the bottom plate tightly.
31
SERIES 35/36 5

3
(Internal Spline Valve)
1. BODY 11. BOLT-HEX HD
2. DISC 12. LOWER STEM
3. UPPER STEM 13. STEM RETAINER 6
4. SEAT 14. HEX NUT
5. KEY 15. THRUST BEARING 11
6. TIE BOLT 16. BOTTOM PLATE GASKET 10
9
7. STEM BEARING 17. BOTTOM PLATE
8. STEM PACKING 18. BOLT-HEX HD 8
9. PACKING GLAND 19. ID TAG 7
FOLLOWER 20. POP RIVET 1
10. PACKING GLAND
19
4
20
12
13
14
15
16
17
18
32
SERIES 35/36 5

3
(Internal Keyed Valve)
1. BODY 11. BOLT-HEX HEAD
2. DISC 12. LOWER STEM 5
3. UPPER STEM 13. STEM RETAINER 6
4. SEAT 14. HEX NUT
5. KEY 15. THRUST BEARING 11
6. TIE BOLT 16. BOTTOM PLATE GASKET 10
9
7. STEM BEARING 17. BOTTOM PLATE
8. STEM PACKING 18. BOLT-HEX HEAD 8
9. PACKING GLAND 19. ID TAG 7
FOLLOWER 20. POP RIVET 1
10. PACKING GLAND
19
4
20
5 12
13
14
15
16
17
18
33
Appendix J
Disassembly –
Prior to removal of the valve stem the valve disc must be secured and
supported to insure it does not drop out of the valve body once the stem is
CAUTION removed. Lay the valve down with two wood blocks located under the disc
! at the 6 o’clock and 12 o’clock positions making sure the blocks are in close
stem.
top.
Note: Valve is provided with the seat bonded to the body and therefore is not easily field re-
placeable. Please contact your local Bray representative for seat replacement.
34
Appendix J (Cont’d)
Assembly –

seat.
35
SERIES 36H
1. BODY 11. THRUST BEARING
2. DISC 12. BOTTOM PLATE
3. STEM 13. BOTTOM PLATE GASKET
4. SEAT 14. BOLT-HEX HEAD
5. STEM PACKING 15. KEY
6. STEM BEARING 16. STEM RETAINER
7. TAPER PIN 17. CAP SCREW
8. WASHER 18. PACKING GLAND
9. NUT 19. BOLT-HEX HEAD
10. O-RING 20. ID TAG
21. POP RIVET
36
CONTROLS Bray® is a registered trademark of
R
A Division of BRAY INTERNATIONAL, Inc. Bray International, Inc.
13333 Westland East Blvd. Houston, Texas 77041 © 2012 Bray International. All rights reserved.
281/894-5454 FAX 281/894-9499 www.bray.com OM-RSBFV-001 08-2012
SERIES 6A
ELECTRO-pneumatic positioneR
OPERATION AND MAINTENANCE MANUAL
Series 6A Operation & Maintenance – Table Of Contents
Contents
Safety Information - Definition of terms . . . . . . . . 3
Introduction . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 5
Field Connections . . . . . . . . . . . . . . . . . . . . . 6
Calibration and Commissioning . . . . . . . . . . . . .11
Factory or Field Installable Options . . . . . . . . . . .20
Troubleshooting . . . . . . . . . . . . . . . . . . . . . 26
Service and Maintenance . . . . . . . . . . . . . . . . 29
Technical Data . . . . . . . . . . . . . . . . . . . . . . 30
Dimensional Drawings . . . . . . . . . . . . . . . . . .40
All information herein is proprietary and confidential and may not be copied or reproduced without the expressed written consent of BRAY INTERNATIONAL, Inc.
6A O & M : 2 The technical data herein is for general information only. Product suitability should be based solely upon customer’s detailed knowledge and experience with their application.
Series 6A Operation & Maintenance – Safety
Safety Information - Definition of terms

indicates a potentially hazardous situation which, if not avoided, could result in
Q WARNING death or serious injury.
indicates a potentially hazardous situation which, if not avoided, may result in

Q Caution minor or moderate injury.
used without the safety alert symbol indicates a potential situation which, if not
Notice
avoided, may result in an undesirable result or state, including property damage.
Hazard-free use Qualified Personel

This device left the factory in proper condition to be safely installed A qualified person in terms of this document is one who is familiar
and operated in a hazard-free manner. The notes and warnings in this with the installation, commissioning and operation of the device and
document must be observed by the user if this safe condition is to be who has appropriate qualifications, such as:
maintained and hazard-free operation of the device assured.
• Is trained in the operation and maintenance of electric
• Take all necessary precautions to prevent damage due to rough equipment and systems in accordance with established safety
handling, impact, or improper storage. Do not use abrasive practices.
compounds to clean, or scrape its surfaces with any objects.
• Is trained or authorized to energize, de-energize, ground, tag
• Configuration and calibration procedures are described in this and lock electrical circuits and equipment in accordance with
document. Proper configuration and calibration is required established safety practices.
for the safe operation.
• Is trained in the proper use and care of personal protective
• The control system in which the unit is installed must have equipment (PPE) in accordance with established safety
proper safeguards to prevent injury to personnel, or damage to practices.
equipment, should failure of system components occur.
• Is trained in first aid.
• This document does not cover every detail about every version
• In cases where the device is installed in a potentially
of the product described. It cannot take into account every
explosive (hazardous) location – is trained in the operation,
potential occurrence in installation, operation, maintenance
commissioning, operation and maintenance of equipment in
and use.
hazardous locations.
• If situations transpire that are not documented in sufficient
detail, please request the required information from the Bray
Distributor or Representative responsible for your area.
The technical data herein is for general information only. Product suitability should be based solely upon customer’s detailed knowledge and experience with their application. 6A O & M : 3
Series 6A Operation & Maintenance – Introduction
Introduction
The Bray S6A is a microcontroller based positioner for pneumatic Electrical Operation
actuators. The S6A converts an analog current signal into a
The standard S6A requires 4 to 20mA loop power for all of the
valve position pressure signal and offers positioner, valve and
internal electronics. It can be installed in a two wire, three wire,
actuator diagnostics using a variety of communication protocols.
or four wire architecture. There is no need to run separate power
Optional modules can be added for full range valve position
and signal wiring. The S6A positioners with communication
feedback, valve open/close verification, preset alarm warnings
modules get their power directly from the network. All of the
and electromagnetic compatibility.
wiring diagrams for the different versions of the S6A and any
Principles of Operation optional modules are shown in the “Field Connections” portion
of this manual.
The operation of the S6A can be described in three parts; the user
defined setpoint, the pneumatic actuator air supply, and the S6A Mechanical Operation
internal controller. The user defined setpoint, which is provided
The S6A requires a pneumatic supply in the range of 20 - 102 psi
by the incoming analog signal or the communication protocol,
(1.4 - 7 BAR). Using this pneumatic supply, the S6A will position
tells the positioner where to set the actuator. The pneumatic
the actuator and valve precisely where it needs to be to regulate
actuators air supply provides the power to work the valve, and the
the process. Once in the settled state, the S6A has one of the lowest
S6A internal microcontroller monitors the actuator position and
air bleed rates in the market. The S6A requires a pneumatic sup-
provides diagnostics to the end user.
ply rated at Class 2 in accordance with ISO 8573‑1. An optional
When the microcontroller sees a deviation between the actual filter can be installed upstream of the S6A to clean incoming air.
position of the actuator and the provided setpoint it will pulse the Diagrams are provided showing how to make the pneumatic con-
internal piezo electric valve in order to let air fill the corresponding nections in the “Field Connections”portion of this manual.
actuator chambers and drive the actuator from the pneumatic
supply lines. Once this deviation is within a desired tolerance or
“dead band” the microcontroller will stop the pulsing. Using this
process, the S6A only consumes air when it is needed, meaning it
will pay for itself within a short period of time.
Series 6A Operation & Maintenance – Installation
Installation
Mounting to an Actuator The positioner should be mounted to
the actuator as follows:
All Bray S6A positioners are suitable for mounting on Bray pneu-
matic actuators with the use of a standard mounting bracket. With 1. Turn the positioner upside down and align the provided mount-
proper mounting hardware, the S6A positioner can be installed ing bracket over the positioners output shaft. The bracket
onto other linear or quarter turn pneumatic actuators. The stan- should align with the four threaded holes around the output
dard mounting position is to orient the unit directly over the shaft.
pneumatic actuator using the NAMUR mounting arrangement in
2. Using the 5mm allen key affix the mounting bracket to the
such a way that the LCD and pushbuttons are easily accessible.
positioner using the four lockwashers and mounting bolts [A].
If the positioner is to be mounted on a vertical pipe, it is recom-
mended that the unit be positioned with the conduit entries on the 3. Turn the positioner right side up and position the output shaft
bottom to prevent condensation from entering the positioner by so that the flatted side is facing you.
way of conduit. In all cases, the conduit should be positioned to
prevent drainage into the positioner. 4. Insert the coupler over the output shaft, ensuring that the
couplers set screw is in alignment with the flat of the shaft.
Tools Needed: Tighten the couplers set screw.
5. Place the yellow indicator on the base of the coupler.
• 5mm Allen Key
6. Mount the positioner on top of the actuator and tighten it using
the 5/16" wrench and the four mounting bolts [B].
• 5/16" Wrench
Refer to the S6A Quick Start Guide for details.
Parts Needed:
Item Qty.
Mounting Bolts [A] (4)
Lockwashers (4)
Mounting Bolts [B] (4)
Mounting Bracket (1)
Series 6A Operation & Maintenance – Field Connections
Field WIRING
Each S6A is provided with two conduit entries for power/incom- I. General Area
ing analog signal of the main unit and any optional modules. 1. Two Wire
Please refer to the wiring diagrams referenced in this docu- 4 ... 20 mA
+
+
6
ment when connecting the positioner and any optional modules. J 4 ... 20 mA
4 ... 20 mA
+
–
+
6
7
6
6
8
7
It is essential to install the optional modules before connect- J 4 ... 20 mA – 7
J – 7
9
8
J –
8
ing the positioner electrically. Refer to the following “Technical 8 BE1 = Binary Input
9
10
9 BE1 = Binary Input
9
Description” portion of this manual for relevant power distribu-
2. Two Wire Connection When Using a 2/3/4 Wire Device
10
tion sizing information when installing a S6A positioner and its
optional modules. +
2
3
2
4 ... 20 mA + 2
+ 2
4
3
Safety Notes: J
4 ... 20 mA + 3
3
5
4
J 4 ... 20 mA 4
J 4 ... 20 mA 4
• Local regulations regarding hazardous environments must be J 5
5
5
6
followed when installing this device in a hazardous location. –
7
6
6
6
8
7
• The conduit connections must be properly sealed to maintain
– 7 BE1 = Binary Input
– 7
9
8
– 8
the weatherproof integrity of the actuator enclosure.
10
9
9
10
10
• Never connect the current input (terminals 6 and 7 as shown 3. Three/Four Wire
on the diagrams to the right) to a power source; the positioner
+
2
18 ... 30 V 3 +
will probably be destroyed in that case. Always use a current
2 +
2 +
–
18 ... 30 V 2
4
3
source with a maximum output current of I = 20 mA.
18 ... 30 V 3 –
18 ... 30 V 3
5
4 –
1)
4 –
4
5
1)
5
• To maintain auxiliary power, the input current must be a min-
1) + 5
1) 6
+
imum of 3.6 mA. + 7
0/4 ... 20 mA 6
J +
– 6
0/4 ... 20 mA 6
8
7
J 0/4 ... 20 mA – 78 BE1 = Binary Input
J
0/4 ... 20 mA – 79
J – 8
9 BE1 =
8
10 = Binary Input
Note: The plastic enclosure is metallized from inside to 9 BE1 Binary Input
10
1) Jumper between 5 and 7 only for three-wire
10system
increase the electromagnetic compatibility (EMC) with 10
1) Jumper between 5 and 7 only for three-wire system
respect to high-frequency radiation. The shield is connected
to the threaded bush shown in Figure 1 such that it is elec- 4. HART R 3 250 W if req. 1) 2
trically conductive. This protection is effective only if you
lH+
+ R 33 250 W if req. 1) lH+ 2
3
R 3 250 W if req. 1) 2
connect at least one of the bushes to the grounded control
+
– R 250 W iflyreq.= 41)... 20 mA lH+ 2
4
I + lH+ 3
+
– ly = 4 ... 20 mA 3
3
5
valves through electrically conductive (bare) attachments.
4
I –
– ly = 4 ... 20 mA
ly = 4 ... 20 mA 4
I 4
5
I 5
5
6
lW-
2. 7
6
6
1. lW-
lW-
6
7
8
7
3. lW- 7
8
8
8
HART PC/Laptop
modem
HART PC/Laptop
HART PC/Laptop
modem
HART PC/Laptop
modem
1) modem
Only required with current sources not conforming to HART
1) Only required with current sources not conforming to HART
5. Profibus DA/DP, Foundation Fieldbus

+ ≤ 30 V
81 1)
+
– ≤ 30 V
+ ≤ 30 V 81
82 1)
+
– ≤ 30 V 81 1)
– 81
82 1)
– 82
82
+ ≤ 24 V
Figure 1. ≤ 24 V 6
+ ≤ 24 V
+ ≤ 24 V 6
7
+
– 6
6
7
– 7
– 7
9
– BE1 = Binary Input
9
10
9
Tools Needed: 1) coding BE1
Input for safety shutdown (activated using 10
10
= Binary Input
jumper)
1) Input for safety shutdown (activated using coding jumper)
• Instrument Screwdriver 1)
1)
Input for safety shutdown (activated using coding jumper)
Input for safety shutdown (activated using coding jumper)
Non-Hazardous Hazardous area, Zone 1

All information herein is proprietary and confidential and may not be copied or reproduced without the expressed
Non-Hazardous written
Hazardous consent
area, Zoneof1 BRAY INTERNATIONAL, Inc.
6A O & M : 6 Non-Hazardous
The technical data herein is for general information only. Product suitability should
Non-Hazardous
Hazardous area, Zone 1
be based solely upon customer’s
Hazardous detailed knowledge
area, Zone 811 and experience with their application.
–
81
82
– 81
– 81
82
Power Supply – 82
82
Power Supply
10
2
+
3
4 ... 20 mA
J
4
5
6
II. Hazardous Area (Intrinsically Safe)
7 Multiple Positioners Field Wiring
–
A. Two Wire 8
9 BE1 = Binary Input Split Range
Non-hazardous area Hazardous area, Zone 1 10
Auxiliary power
Intrinsically safe power sources

L+ + 18 to 30 V
4 to 20 mA EEx 2
EEx 6 Positioner
3
7 + M
2 V 4
8
18 ... 30 V9 3 5
– 4 Binary input 1
Intrinsically safe 10 #
power source
1)
5 EEx
Iy + 0/4 to 20 mA
6
Positioning range 1
7
+
6
B. and C. Two Wire Connection When Using a 2/3/4 Wire
I M 8
0/4 ... 20 mA 7
DeviceJ and HART
9
– 8 BE1
Entire positioning 10 #
9 BE1 = Binary Input range Iy
Non-Hazardous Hazardous area, Zone 1 10
area
2 Positioner 2
+ 4 to 20 mA
3 3
EEx
4
5 4
I 5
R 3 250 W if req. 1) lH+ 2
E
+ 6
Intrinsically safe 3A
power source– 7 6
ly = 4 ... 20 mA 4 Positioning range 1
I 8 7
9 5
Binary input 1 8
10 #
9
6 # BE1
10
lW- 7
8
HART Communicator
6A-6DR52**-*E*** only Non-hazardous area Hazardous area, Zone 1
HART PC/Laptop
Series connection of 2 positioners, e.g. split range (auxiliary power wired separately), EEx i
D. Three/Four Wire
modem
1) Only required
Non-hazardous area with current
Hazardous area,sources
Zone 1 not conforming to HART
+ 18 to 30 V
EEx 2 Positioner
3
4
I 5
+ ≤ 30 V
81 1)
– mA
EEx
+ 4 to 20
6
82E
*) A
*) 7
8
I 9
+ ≤ 24 V Binary input 1
Intrinsically safe 10 6 #
power source
7
–
9
BE1 = Binary Input
HART Communicator 10
6A-6DR52**-*E*** only *) Three-wire connection only
E. Profibus DA/DP, Foundation Fieldbus

Non-Hazardous Hazardous area, Zone 1
81
–
82
Power Supply
+ ≤ 24 V
6
7
–
9
BE1 = Binary Input
10
Connecting Pneumatic Supply Lines 1. If required, connect the pressure gauge block for supply air
and actuating pressure.
Refer to the Technical Data portion of this manual for specifica-
tions regarding air quality. 2. Connect supply air to PZ.
The S6A is equipped with three pneumatic connections, Y1, Y2
and PZ. PZ is for the pneumatic supply and Y1 and Y2 are used Connection using female thread G1/4 DIN 45141
to supply the pneumatic actuator. The S6A can also be equipped or 1/4" NPT:
with a pressure gauge block for monitoring supply and actuating • PZ supply air 20psi to 102psi (1.4 to 7 bar)
pressure and a filter to ensure that the S6A is receiving clean air.
• Y1: actuating pressure for single and double-acting
Proceed as follows to make the pneumatic connections: actuators
Refer to Figure 2. • Y2: actuating pressure for double-acting actuators
• E: exhaust air outlet; remove the attenuator if required.
Y1 For double-acting actuators, connect actuating pressures

Y1 or Y2 depending on the desired safety position. The
PZ three pneumatic connections will go to the following
safety position in case of electrical auxiliary power sup-
ply failure:
Y2
• Y1: single-acting, depressurized
E • Y1: double-acting, max. actuating pressure/supply air

pressure.
Figure 2. - Pneumatic connection on the standard controller
• Y2: double-acting, depressurized
Note: Besides continuous air consumption, the positioner may

try to compensate the position deviation due to leakage. This
will lead to premature wear in the entire control unit. To prevent
this ensure that all pneumatic connections are properly sealed
and perform regular maintenance on their fittings.
Restrictors Purging
The S6A is equipped with air restrictors to reduce the air output to The S6A is equipped with a purge air switch that allows the
achieve actuating times of T > 1.5 s for small actuators. Restrictors actuator to purge air either inside of the unit or directly outside.
1 and 2 are used for this purpose. When the enclosure is open, the purge air switch above the
pneumatic terminal strip on the pneumatic block can be accessed.
Tools Needed:
Tools Needed:
• Hexagon socket 2.5 mm
• Instrument Screwdriver
Refer to Figure 3.
Refer to Figure 4.
When turned clockwise, they reduce the air output and finally shut
In the IN position, the enclosure is flushed from inside with a
it off.
small volume of clean and dry instrument air.
In order to set the restrictors, it is recommended to close them and
In the OUT position, the purge air is directed towards outside of
then open them slowly.
the unit.
In case of double-acting actuators, ensure that both restrictors
have approximately the same setting.
Figure 4. - Purge Air Switch

Figure 3. - Air Restrictor 1 2
➀ Purge Air Switch
➀ Restrictor for Y1
➁ Pneumatic Block
➁ Restrictor for Y2, only in the version for double-acting
actuators
➂ Hexagon socket-head screw 2.5 mm
Natural Gas as an Actuator Medium Optional Accessories

The S6A can also be operated with natural gas as an actuator 1. Pressure Gauges – used to measure and indicate supply and
medium. When operating the positioner with natural gas, you actuating pressures
must follow and adhere to the following safety notes:
1. Only the “EEx ia” version of the positioner and optional
modules with the “EEx ia” type of protection may be operated
with natural gas. Positioners with other types of protection,
i.e. flameproof enclosures for zones 1 and 2 are not permitted.
2. Do not operate the positioner with natural gas in closed spaces.
3. Natural gas is continuously blown off in the servo-drive
depending on the model. Special care must therefore be taken
during maintenance activities near the positioner. Always
2. Filter – used to clean the supply medium
ensure that the immediate surroundings of the positioner are
adequately ventilated. 3. Non Contacting/External Position Detection System – used
4. The mechanical limit switch module may not be used when for harsh environments
operating the positioner with natural gas. 4. SIMATIC PDM Operation Software – used for online
5. Depressurize the devices operated with natural gas adequately diagnostics of the S6A
during maintenance activities. Open the cover in an explosion-
free atmosphere and depressurize the device for at least two Contact your Bray representative for specific requirements for
minutes. your intended application.
Normally you operate the positioner with compressed air. Natural
gas has been approved as an actuator medium for intrinsically
safe positioners with the “EEx ia” type of protection. Only use
natural gas which is clean, dry and free from additives.
The positioner releases the used natural gas through the exhaust
air outlet E (see Figure 2). The exhaust air outlet E is equipped
with an attenuator. As an alternative to this standard configuration,
the exhaust air outlet can be replaced with a G¼ screwed fitting.
You have to dismantle the attenuator for this purpose. Natural gas
escapes parallel to the exhaust air outlet E, from the enclosure
vent at the bottom side of the device, and from the control air
outlet near the pneumatic connections. This escaping natural gas
cannot be collected and carried off. When using natural gas as an
actuator medium refer to Figure 5 for maximum bleed off values.
Figure 5. Maximim bleed off values
Bleeding process Operating 6A-6DR5*1*- 6A-6DR5*2*-

mode *E*** *E***
Single-acting Double-acting
[Nl/min] [Nl/min]
Bleed the enclosure volume through the bottom Operation, 0.14 0.14
side of the device. Purge air switch is at "IN": typical
Operation, 0.60 0.60
max.
Error case, 60.0 60,0
max.
Bleed through the control air outlet near the Operation, 1.0 2.0
pneumatic connections: typical
Operation, 8.9 9.9
max.
Error case, 66.2 91.0
max.
Bleed through the exhaust air outlet E Operation, 358.21) 3391),
max.
Error case,
max.
Volume Max. [l] 1.26 1.23
Series 6A Operation & Maintenance – Calibration & Commissioning
Calibration and Commissioning

Installing a New Unit 10. If the displayed actual position value differs from the noted
Please refer to the S6A Quick Start Guide for the Standard Unit. value, correct the deviation by moving the friction clutch.
Replacing a Unit 11. The replacement positioner is ready for operation when the
displayed and the noted values match.
The S6A can be replaced in a running system where a S6A was
already in use without interrupting the process. By copying and Operation
transferring the device and initialization data, it is possible to Reading the LCD screen
commission a replacement positioner without needing to initial-
ize it. The S6A uses the communication interface to transfer data. The S6A digital display has two lines, one on the bottom and one
When this is performed, it is crucial to perform a standard initial- on top. Each element on the top line has seven segments while
ization of the replacement positioner as soon as possible because each element on the bottom line has fourteen. Contents of the dis-
the following properties can be ensured only after initializing: play depend on the selected mode. Figure 6 below provides an
example of what the display will look like when the unit is pow-
• Optimum adjustment of the positioner as per the mechanical ered on.
and dynamic properties of the actuator.
• Unrestricted accuracy and dynamic behavior of the positioner.
• Deviation-free position of the hard-end stops.
• Accuracy of the maintenance data Figure 6.
Example Display
Copy the initialization data and the device parameters as follows:
1. Read in the initialization data and the device parameters of the Note: When operated in temperature ranges below 14°F (-10°C),
positioner to be replaced. Use a suitable parameterization the liquid crystal display of the positioner becomes sluggish and
tool for this purpose. the repetition rate display is reduced considerably.
2. Save the data in the parameterization tool.
Using the pushbuttons
Note: If the positioner to be replaced has already been initialized The S6A is manually operated using three pushbuttons. The cover
or configured using the parameterization tool, you need not read of the positioner has to be removed in order to operate the buttons.
in and save the device data.
Note: The function of the buttons depends on the current
Proceed as follows to replace a positioner in a running system: Operating Mode. As a general rule the following applies:
3. Fix the actuator at its current position mechanically or
pneumatically. The operating mode button is used to select the modes and to
4. Determine the actual position value. forward the parameters.
– Read the actual position value on the digital display of The decrement button is used to select parameter values when
the positioner to be replaced. configuring. You can use this button to move the actuator in
the manual mode.
Take note of the read value.
The increment button is also used to select parameter values
– If the electronic unit of the positioner is defective, mea- when configuring. You can use the increment button to move
sure the actual position value at the actuator or the valve. the actuator in the manual mode.
Take note of the read value.
+ *Parameters are activated in the reverse order by press-
5. Dismantle the positioner. ing the operating mode button and the decrement button at
6. Attach the lever arm of the positioner to be replaced to the the same time
replacement positioner.
7. Install the replacement positioner on the control valve. Note: The IP66/NEMA 4x degree of protection is not ensured
as long as the positioner is open.
8. Set the transmission ratio selector of the replacement positioner
to the same position as that of the positioner to be replaced.
9. Use the parameterization tool to transfer the saved device and
initialization data to the replacement positioner.
Operating Modes Configuration and initialization mode

The S6A has five different operating modes described in detail
below. Refer to Figure 7 to navigate between modes.
Operating Mode Display

P- manual operation
change position with To get to the “Configuration” mode, press the operating mode
button for at least 5 seconds. You can use the “Configuration”
mode to adjust the positioner individually as per your actuator
and start commissioning or initialization. The positioner reports
PRST
Configure >5s
the “Configuration” mode with a configurable fault message. A
select parameter position feedback or display of limits A1 and A2 is not possible.
with or +
>5s
change value with Note: If electrical auxiliary power supply fails when configuring,
Manual Operation >5s >5s the positioner responds as follows until the power supply is
change position with
reestablished:
• The positioner switches to the first parameter.
>2s
• Settings of the values already configured are retained.
1x
Automatic
1x
In order to save the changed parameter values, exit the
“Configuration” mode or switch to another parameter. When
the “Configuration” mode is restarted, the control in the digital
display switches to the last activated parameter.
>2s >2s Manual mode (MAN)

Diagnostics
>2s
Figure 7. Operating Modes Display
P-manual mode (as-delivered condition) You can move the actuator using the decrement and increment
buttons in this mode. The setting selected here is retained
irrespective of the setpoint current and leakages, if any.
Note: To accelerate the actuator movement keep one of the

two direction buttons pressed and simultaneously press the
remaining direction. In the event of a failure of the power
The “P-manual mode” is preset for the positioner in the supply, once the power is reestablished the positioner switches
as-delivered condition. The digital display of the positioner shows to “Automatic” mode.
the current potentiometer position in the upper line. “NOINI”
blinks in the second line of the digital display. You can move the
actuator using the decrement and increment buttons. Switch to
Configuration” and “Initialization mode” to adapt the actuator as
per the positioner.
Alarms or position feedbacks can be triggered only after
initializing the positioner completely.
Automatic (AUT) Using the built in Diagnostics

The S6A has various monitoring functions with which changes on
the actuator and valve can be detected and signaled if applicable
when a selectable limit has been exceeded. This information may
be important for diagnosis of the actuator or valve and will help
to schedule preventative maintenance. The measuring data that is
monitored is listed below:
Automatic is the standard mode. In this mode, the positioner
compares the setpoint position with the actual position. The • Travel integral
positioner moves the actuator until the control deviation reaches • Number of changes in direction
the configurable dead zone. A fault message is displayed if the
dead zone cannot be reached. • Alarm counter
Diagnostics • Self-adjusting dead zone
• Valve end limit position (for detection of valve seat wear or
deposits)
• Operating Hours (also according to temperature and travel
ranges) as well as min./max. temperature
• Operating Cycles of piezoelectric valves
Proceed as follows to call the “Diagnostics” mode from the
“Automatic” or “Manual” modes: • Valve positioning time
Press the three buttons of the positioner at the same time for at • Actuator leakages
least 2 seconds.
The diagnostics display has similar structure to that of the
Current operating data can be called and displayed in this mode, “Configuration” mode:
e.g.:
• The upper line shows the value of the diagnosis variable.
• Stroke number
• The lower line shows the number and the abbreviation of the
• Number of changes in direction displayed variable.
• Number of fault messages Some diagnostics values can be greater than 99999. In such a
case, the display switches over to the exponential view. Example:
Note: The “Automatic” and “Manual” modes remain set when The value “1234567” is shown as “1.23E6”.
switching to the “Diagnostics” mode. The positioner responds In the event of a fault an error code will be shown on the lower
as per the set mode: left hand corner of the display. There is a fault table in the
• The predefined setpoint is used as a control variable in the “Troubleshooting” section of this manual which explains what
automatic mode. each of these codes represents.
• The last reached position is retained in the manual mode. The following table provides an overview of values that can be
displayed. The last column contains “X” if the value can be set
to zero.
Overview
Overview of diagnostics
of Diagnostics Valuesvalues
No. Abbreviation Meaning Values that can Unit Reset

be displayed possible
1 STRKS Stroke number (Strokes) 0 ... 4.29E9 - X

2 CHDIR Changes of direction (Changes of Direction) 0 ... 4.29E9 - X
3 CNT Number of fault messages ( Counter) 0 ... 4.29E9 - X
4 A1CNT Number of alarms 1 (Alarm 1 Counter) 0 ... 4.29E9 - X
5 A2CNT Number of alarms 2 (Alarm 2 Counter) 0 ... 4.29E9 - X
6 HOURS Operating hours (Hours) 0 ... 4.29E9 Hours -
7 WAY Determined actuator travel (Way) 0 ... 130 mm or ° -
8 TUP Actuating time up (Travel Time Up) 0 ... 1000 s -
9 TDOWN Actuating time down (Travel Time Down) 0 ... 1000 s -
10 LEAK Leakage (Leakage) P 0.0 ... 100.0 % -
11 PST Monitoring of the partial stroke test OFF / ###.#, fdini, s for ###.# -
notSt, SdtSt,
fdtSt, notd, Strt
12 PRPST Time since the last Partial-Stroke-Test ###, notSt, Sdtst, Days -
fdtSt
13 NXPST Time until the next Partial-Stroke-Test ###, notSt, SdtSt, Days -
fdtSt
14 DEVI General control valve fault OFF, 0.0 ... 100.0 % -
15 ONLK Pneumatic leakage OFF, 0.0 ... 100.0 - -
16 STIC Static friction/Slipstick effect OFF, 0.0 ... 100.0 % -
17 ZERO Zero point displacement OFF, 0.0 .. 100.0 % -
18 OPEN Displacement of upper end stop OFF, 0.0 ... 100.0 % -
19 PAVG Position average 0.0 ... 100.0 % -
20 P0 Potentiometer value of lower end stop (0%) 0.0 ... 100.0 % -
21 P100 Potentiometer value of upper end stop (100%) 0.0 ... 100.0 % -
22 IMPUP lmpulse length up (Impuls Length Up) 2 ... 160 ms -
23 IMPDN Impulse length down (Impuls Length Down) 2 ... 160 ms -
24 DBUP Dead zone up (Dead Band Up) 0.1 ... 10.0 % -
25 DBDN Dead zone down (Dead Band Down) 0.1 ... 10.0 % -
26 SSUP Slow step zone up (Short Step Zone Up) 0.1 ... 100.0 % -
27 SSDN Slow step zone down (Short Step Zone Down) 0.1 ... 100.0 % -
28 TEMP Current temperature -40 ... 85 °C -
29 TMIN Minimum temperature ("min/max pointer") -40 ... 85 °C -
30 TMAX Maximum temperature ("min/max pointer") -40 ... 85 °C -
31 T1 Number of operating hours in temperature range 1 0 ... 4.29E9 Hours -
Series 6A with and without HART communications

Operation and Maintenance Manual, 09/2008, A5E00756809-03
40 VENT1 Number of switching cycles of pilot valve 1 0 ... 4.29E9 - -
41 VENT2 Number of switching cycles of pilot valve 2 0 ... 4.29E9 - -
42 STORE
Series 6A Operation & Maintenance – Calibration
Save the current value as "last maintenance" (press
- -
& Commissioning
-
the increment button for 5 s) (Store)
43 of Diagnostics
Overview PRUP Prediction
Values up
(cont.) 1 ... 40 - -
44 PRDN Prediction down 1 ... 40 - -
No.
45 Abbreviation
WT00 Meaning
Number of operating hours in the actuating range Values that can
0 ... 4.29E9 Unit
Hours Reset
X
WT00 be displayed possible
46 WT05 Number of operating hours in the actuating range 0 ... 4.29E9 Hours X
37 T7 Number of operating hours in temperature range 7
WT05 0 ... 4.29E9 Hours -
38
47 T8
WT10 Number
Number of
of operating
operating hours
hours in
in temperature
the actuatingrange
range8 0
0 ...
... 4.29E9
4.29E9 Hours
Hours -
X
39 T9 Number of operating hours in temperature range 9
WT10 0 ... 4.29E9 Hours -
40
48 VENT1
WT30 switching cycles
Number of operating hours inofthe
pilotactuating
valve 1 range 0 ... 4.29E9 -
Hours -
X
41 VENT2 WT30
Number of switching cycles of pilot valve 2 0 ... 4.29E9 - -
49
42 WT50
STORE Number
Save theofcurrent
operating hours
value in the
as "last actuating range
maintenance" (press 0
- ... 4.29E9 Hours
- X
-
WT50
the increment button for 5 s) (Store)
50
43 WT70
PRUP Number of up
Prediction operating hours in the actuating range 0 ...
1 ... 4.29E9
40 Hours
- X
-
WT70
44 PRDN Prediction down 1 ... 40 - -
WT90
WT00
WT95
WT05
WT10
Diagnostic value 53WT30
No. Abbreviation Meaning
WT50 Values that can Unit Reset
WT70
53 mA Setpoint current 0.0 to 20.0 mA --
WT90
WT95
Diagnostic value 53
No. Abbreviation Meaning Values that can Unit Reset

53 mA Setpoint current 0.0 to 20.0 mA --


Parameter Function Parameter Values Description

1) YFCT Type of position actuator Turn Automatically sets 2) YAGL to 90◦
WAY Used for linear actuators
LWAY Used for linear actuators
ncSt Used for a non-contacting position sensor on a part
turn actuator
-ncSt Used for a non-contacting position sensor on a part
turn actuator with a reverse direction of action
ncSL Used for linear actuators
ncSLL Used for linear actuators
2) YAGL Angle of rotation 33◦ Used for linear actuators
90◦
3) YWAY Range of Stroke Used for linear actuators
4) INITA Initialization (automatic) NOINI | no/ ###.# | Strt Starts the automatic initialization process
5) INITM Initialization (manual) NOINI | no/ ###.# | Strt Starts the manual initialization process
6) SCUR Current range of setpoint 0 MA 0 MA only available for 3 to 4 wire connections.
4 MA Factory setting.
7) SDIR Setpoint Setup riSE Used to reverse the direction of the action of the
FALL setpoint. Factory setting is “rise”
8) SPRA Setpoint split range start 0.0 … 100.0 Used to limit the setpoint. Factory setting is “0”
9) SPRE Setpoint split range end 0.0 … 100.0 Factory setting is “100”
10) TSUP Setpoint ramp OPEN Auto / 0 … 400 Limits the speed of change of the effective setpoint.
11) TSDO Setpoint ramp CLOSED 0 … 400 Factory setting is “0”
12) SFCT Setpoint Function 1 – 25 Equal Percentage. Linearizes valve characteristics.
1 – 33 Factory setting is “Lin”
1 – 50
n1 – 25 Inverse equal percentage
n1 – 33
n1 – 50
FrEE Freely Adjustable
13) SLO Setpoint Turning Point 0.0 … 100.0 Assigns a flow metric to each setpoint interpolation
…33) SL20 in units of 5%.
34) DEBA Dead Zone of Closed- Auto / .1 … 10.0 Adjust the dead zone to the requirements of the
Loop Controller control loop. Factory setting is “Auto”
35) YA Start of the manipulated 0.0 … 100.0 Used to limit the mechanical actuator travel from
variable limit stop to stop to the configured values. “YE” must
36) YE End of the manipulated 0.0 … 100.0 always be larger than “YA”. Factory setting is “100”
variable limit
37) YNRM Manipulated variable MPOS Mechanical position from 0 to 100% between hard
scaling stops.
FLOW Scaling from 0 to 100% over the range between
“YA” and “YE”
38) YDIR Direction of Manipulated riSE Used to set the direction of action of the display and
Variable FALL the position feedback Iy. Factory setting is “riSE”
39) YCLS Manipulated variable tight No Used to move the valve into its seat with the
closing uP maximum force of the actuator. Factory setting is
Do “No”
uP do
40) YCDO Lower value for tight 0.0 … 0.5 … 100% Factory setting is “0.5”
closing
41) YCUP Upper value for tight 0.0 … 99.5 … 100% Used to set the value for tight “Tight closing below”
closing and “Tight closing above”. Factory setting is “99.5”
42) BIN1 2) Function of BE1 Normally Normally Functions while in binary input mode.
Open Closed
OFF Factory setting.
on -on Binary message from peripherals
bloc1 Used to lock the configuration operation
bloc2
uP -uP Actuator regulating to the valve specified by
doWn -doWn parameters “YA” and “YE”
StoP -StoP Piezo valves are blocked. Actuator remains at last
position.
PST -PST Used to trigger a partial stroke test
43) BIN2 2) Function of BE2 Normally Normally Functions while in binary input mode.
Open Closed
OFF Factory setting.
on -on Binary message from peripherals
uP -uP Actuator regulating to the valve specified by
doWn -doWn parameters “YA” and “YE”
StoP -StoP Piezo valves are blocked. Actuator remains at last
position.
PST -PST Used to trigger a partial stroke test
44) AFCT 3) Alarm Function Normal Inverted Used to determine the value at which going above or
Off below a given offset or angle will result in a
message.
45) A1 Trigger threshold, alarm 1 0.0 … 10.0 … 100 % Used to specify when an alarm should be displayed.
46) A2 Trigger threshold, alarm 2 0.0 … 90.0 …100%
47) FCT 3) Function for fault Normal Inverted Cannot be switched off. Can be suppressed by
message output switching to “No Automatic Mode”
48) TIM Monitoring time for Auto / 0 … 100 Used to set the time in seconds that the positioner
setting of fault message must have reached the regulated condition.
49) LIM Response threshold for Auto / 0 … 100 Used to set a value for the permissible size of the
fault message regulation device to trigger a fault message.
50) PRST Preset (factory setting) no Used to restore factory settings and reset
Strt initialization. Press increment button for 5 seconds.
oCAY
51) XDIAG Activation of extended OFF Used to activate extended diagnostics.
diagnostics On1
On2
On3
52) FSTY Safety Seating FSVL Actuator controlled using the parameterization safety
point. Effective after a power failure.
FSSP Actuator controlled using the last effective set point
FSAC Valves move to location based on spring force.
(Factory Defined)
53) FSTI Monitoring Period for 0 … 100 (s). Once this set value expires the positioner
setting the safety seating switches to its safety position. (Factory defined at 0)
54) FSVL Safety Setpoint 0.0 … 100.0 (%). Default value of the safety position. (Factory
setting is 0%)
55) STNR Station Number 0 … 126 Independent value for each station. (Default position
is 126)
56) IDENT Device operating mode 0 Profile Compliant. Can be replaced with other
(ID No.) positioners complying with Profibus PA profile 3.0
1 Compliant with Extensions (Factory Defined).
Parameter Function Parameter Values Description

A. PST Partial Stroke Test Used to activate the partial stroke test for cyclic or
manual test of up/down and servo solenoid valves.
A1.STPOS Starting position 0.0 … 100.0 Start position in %. Factory setting is “100.0”
A2.STTOL Starting tolerance 0.1 … 2.0 … 10.0 Start position tolerance in %. Factory setting is
“2.0”
A3.STEP Step height 0.1 ..10.0 ..100.0 Step height of partial stroke test in %
A4.STEPD Step Direction uP / do / uP do Step direction of partial stroke test. Factory setting
is “do”
A5.INTRV Test Interval OFF / 1 … 365 Interval time for cyclic partial stroke in days. “Off”
A6.PSTIN Partial Stroke ref. step time NOINI / (C) ###.# / Reference step time for partial stroke in s. “NOINI”
Fdini / rEAL
A7.FACT1 Factor 1 0.1 … 1.5 … 100.0 Factor for the formation of limit threshold 1. “1.5”
b. DEVI General Control Valve Fault Test for dynamic monitoring of control valve
response.
b1.TIM Time constant Auto / 1 … 400 Defines the attenuation effect of the low-pass filter.
“Auto”
b2.LIMIT Limit 0.1 … 1.0 … 100.0 Sets a base limit in %. “1.0”
b3.FACT1 Factor 1 0.1 … 5.0 … 100.0 Factor for the formation of limit threshold 1. “5.0”
b4.FACT2 Factor 2 0.1 ..10.0..100.0 Factor for the formation of limit threshold 2. “10.0”
b5.FACT3 Factor 3 0.1..15.0..100.0 Factor for the formation of limit threshold 3. “15.0”
C. LEAK Pneumatic leakage Activates the pneumatic leakage test
C1.LIMIT Limit 0.1 .. 30.0 .. 100.0 Sets the limit of the leakage indicator in %. “30.0”
C2.FACT1 Factor 1 0.1 … 1.0 … 100.0 Factor for the formation of limit threshold 1. “1.0”
d. STIC Friction (slip-stick effect) Monitors the current static friction of the final
controlling element
d1.LIMIT Limit 0.1 … 1.0 … 100.0 Sets the base limit for the slipstick detection in %.
“1.0”
d2.FACT1 Factor 1 0.1 … 2.0 … 100.0 Factor for the formation of limit threshold 1. “2.0”
d3.FACT2 Factor 2 0.1 … 5.0 … 100.0 Factor for the formation of limit threshold 2. “5.0”
d4.FACT3 Factor 3 0.1 ..10.0..100.0 Factor for the formation of limit threshold 3. “10.0”
E. DEBA Dead zone monitoring Used to measure the automatic adjustment of the
dead zones
e1.LEVEL3 Threshold 0.1 … 2.0 … 10.0 Sets the factor limit threshold to monitor the dead
zone adjustment
F. ZERO Zero point monitoring Activates the zero point displacement test
F1.LEVEL1 Threshold 1 0.1 … 1.0 … 100.0 Sets a threshold in % of the lower hard stop. “1.0”
F2.LEVEL2 Threshold 2 0.1 … 2.0 … 100.0 Sets a threshold in % of the lower hard stop “2.0”
F3.LEVEL3 Threshold 3 0.1 … 4.0 … 100.0 Sets a threshold in % of the lower hard stop “4.0”
G. OPEN Displacement of the upper Activates the test to monitor the displacement of the
stop upper end stop.
G1.LEVEL1 Threshold 1 0.1 … 1.0 … 100.0 Sets a threshold in % of the upper hard stop. “1.0”
H. TMIN Monitoring of the lower limit Activates the test to continuously monitor the lower
temperature limit temperature
H1.TUNIT Temperature Unit Sets the temp. parameter from “C” to “F”. “C”
H2.LEVEL1 Threshold 1 -40 … 194 Sets a threshold in degrees “C” or “F”. “-25 C”
J. TMAX Monitoring of the upper limit Activates the test to continuously monitor the upper
temperature limit temperature
J1.TUNIT Temperature Unit Sets the temp. parameter from “C” to “F”. “C”
J2.LEVEL1 Threshold 1 -40 … 194 Sets a threshold in degrees “C” or “F”. “75 C”
L. STRK Monitoring the path integral Monitors the entire path covered by the final
controlling element.
L1.LIMIT Limit for the number of 1 … 1E6 … 1E8 Sets the base limit for the number of strokes. “1.00
changes of direction E6”
L2.FACT1 Factor 1 0.1 … 1.0 … 40.0 Factor for the formation of limit threshold 1. “1.0”
O. DCHG Monitoring the changes in Continuously monitors the number of changes of
direction direction of the actuator caused in the dead zone.
O1.LIMIT Limit for the number of 1 … 1E6 … 1E8 Sets the base limit for the number of changes of
changes of direction direction. “1.00 E6”
O2.FACT1 Factor 1 0.1 … 1.0 … 40.0 Factor for the formation of limit threshold 1. “1.0”
P. PAVG Position mean value Activates the test to calculate and monitor the
calculation position average
P1.TBASE Time base of the mean value .5h / 8h / 5d / 60d / 2.5y Sets the time interval to calculate the position
generation average
P2.STATE State of the position mean IdLE/ rEF / ###.# / Strt Starting time for the calculation of position average.
value calculation “IdLE”
P3.LEVEL1 Threshold 1 0.1 … 2.0 … 100.0 Sets a threshold for the maximum deviation of the
current position average from the reference avg.
“2.0”
P4.LEVEL2 Threshold 2 0.1 … 5.0 … 100.0 Sets a threshold for the maximum deviation of the
“5.0”
P5.LEVEL3 Threshold 3 0.1 ..10.0..100.0 Sets a threshold for the maximum deviation of the
“10.0”
Series 6A Operation & Maintenance – Installable Options
Factory or Field Installable Options

The S6A comes standard with guides beneath the motherboard so Device features
that optional modules can be added.
The Iy module is:
Tools Needed:
• Single channel
• T2O Torx • Potentially isolated from the standard controller.
• Phillips Screwdriver Note: The current actuator position is indicated only after a suc-
Step A cessful initialization of the positioner. [Refer to the “Calibration
and Commissioning” section]
To install any of the optional modules proceed as follows:
Proceed as follows to install the optional Iy module:
1. Disconnect electrical power from the supply to the positioner
1. Perform Step A to remove the module cover
2. Remove pressure from the pneumatic supply lines to the
positioner. 2. Slide the Iy module up to the end stop in the lower stack of the
module rack.
3. Remove the positioner cover by loosening the 4 screws using
the Phillips screwdriver. 3. Connect the module to the motherboard. For this purpose, use
the 6-pole flat ribbon cable provided.
4. Remove the module cover by loosening the 2 screws using the
T20 torx drive. 4. Refer to Figure 8 and Figure 9 to connect the Iy module in
standard and intrinsically safe applications.
Note: Step A must be performed before installing any of the
modules. +
61 E
≤ 35 V
UH 62 I
Installing the Feedback Module (Iy Module)
+
Iy module
Current Meter
6DR4004-8J
(Ammeter)
Figure
y
8.- Iy module 6DR4004-8J, not Ex
I module 6DR4004-8J, not Ex
Non-hazardous area Hazardous area, Zone 1 or zone 2
Intrinsically safe
power source EEx
+ +
E
UH
U I
≤ 30 V
I
Iy module
+ 6DR4004-6J
Feedback Module (ly Module) Ammeter
Function
The optional Iy module indicates the current actuator position as a Figure 9. - Iy module 6DR4004-6J, EEx i
dual line signal with Iy = 4 to 20 mA. The Iy module is potentially
isolated from the standard controller. Due to the dynamic control,
this module can report the arising operational faults automatically.
Installing the Mechanical Limit Switch Module

Notice
A pin in the actuating disc bearing is pressed. Align this pin

before it touches the special screw. You must rotate the actuating
disc bearing and the special screw simultaneously so that the pin
is inserted into the special screw.
An insulating cover is provided over the mechanical limit switch

module. Place the insulating cover to one side under the mother-
board seat on the container wall. The recesses of the insulating
cover must fit in the corresponding webs of the container wall.
6. Place the insulating cover on the mechanical limit switch
module by bending the container walls carefully.
7. Engage the motherboard into the four brackets.
Mechanical Limit Switch Module
8. Connect the motherboard and the optional modules to the
Function ribbon cables provided.
This module is used to report two limits. These two limit switches 9. Connect the motherboard and the potentiometer to the
are voltage free and rated for 4A at 24V DC or AC 250V. potentiometer cable.
Device features 10. Using both the screws, fasten the module cover provided.
The mechanical limit switch module consists of: Do not use the standard module cover.
• One binary output to display a collective fault message. 11. Refer to Figures 10 and 11 to connect the Mechanical Limit
Compare with the device features of the alarm unit. switch module in standard and intrinsically safe applications.
• Two switches to report two mechanically adjustable limits. Mechanical limit switch
module 6DR4004-8K
Both of these switches are electrically independent from the + 1K21

remaining electronic unit. <35 V
31
10K Fault message
32
Note: Only qualified personnel should be allowed to install and + max. AC 250V
connect the Mechanical Limit switch module

41
24 V DC Limit value A1
42
4A AC/DC
Proceed as follows to install the mechanical limit switch module: + max. AC 250V
51
Limit value A2
24 V DC 52
4A AC/DC
2. Disengage the motherboard by carefully bending the four

brackets. Figure 10. - Mechanical limit switch module 6DR4004-8K, not Ex
3. Insert the mechanical limit switch module from the top up to

the upper printed circuit board guide of the module rack.
4. Slide the mechanical limit switch module unit into the printed
circuit board of the module rack approximately 1/8" towards
the right.
5. Screw in the special screw through the mechanical limit
switch module into the positioner shaft. Tighten the special
screw with a torque of 17.7 in-lbs.
Non Hazardous Area Hazardous Area, Zone 1

Installing the Alarm Module
Intrinsically safe
Mechanical limit switch
switching amplifier module 6DR4004-6K
to DIN EN 60947-5-6
2K1
+
31
max. DC 8,2 V 10K Fault message
32
EEx
+
41 Limit value A1
Umax. DC 30 V
42
= Imax 100 mA
+
51
Umax. DC 30 V Limit value A2
52
= Imax 100 mA
Figure 11. - Mechanical limit switch module 6DR4004-6K, EEx i

Alarm Unit
Function
Connect the mechanical limit switch module as follows:
The alarm unit triggers fault messages and alarms using binary
1. Loosen the screw on the transparent cover outputs. The message function is based on the change in the sig-
2. Pull the transparent cover up to the front end stop. nal status:
3. Tighten every cable in the corresponding terminal. If the signal status is “HIGH”, there is no alarm message and the
binary inputs are conductive.
Notice If the signal status is “LOW”, the module reports an alarm by

shutting down binary outputs using a high-resistance.
Verify the electrical specifications for these terminals based on Due to the dynamic control, this module can report the arising
the wiring diagram. Do not use the non Ex board in a hazard- operational faults automatically. Set parameters 44 to 51 to acti-
ous environment. vate and parameterize the output of alarms and fault messages.
Apart from binary outputs, the alarm unit has a double-acting
4. Slide the transparent cover up to the end stop of the binary input BE2. Depending on the selected parameters, it is used
motherboard. to block or to move the actuator it to its end position. Configure
5. Tighten the screw on the transparent cover the suitable settings on parameter 43.
6. Connect the cables of each switch to the lug of the printed cir- Device features
cuit board in pairs. Use the provided cable tie for this purpose. The alarm unit has the following features:
Available in two versions.
• Explosion-proof version for connecting to a switching
amplifier in conformity with EN 60947-5-6.
• Non-explosion-proof version for connecting to power sources
having a maximum of 35 V.
Three binary outputs. Binary inputs are potentially isolated from
the standard controller and from each other. The binary input has
dual functionality. Both inputs are implemented as logical OR
combination.
• Isolated for voltage level
• Not isolated for dry contacts
Proceed as follows to install the alarm unit: Installing the Slotted Initiator Alarm Unit
2. Slide the alarm unit below the motherboard in the module
rack. Ensure that you slide it up to the end stop.
3. Connect the module to the motherboard. For this purpose, use
the 8-pole flat ribbon cable provided.
4. Refer to Figures 12 and 13 to connect the Alarm unit in stan-
dard and intrinsically safe applications
Alarm module
6DR4004-8A
+
11 #
≤ 30 V
12 ≥1 Digital input 2
21 +3V
22
# + 1K
Slotted Initiator Alarm Unit

31
35 V Fault message
32
Function
# + 1K
41
35 V
42
Limit value A1
If the standard controller requires electrically independent limit
value messages, the slotted initiator alarm unit is used instead of
# the standard alarm unit.
+ 1K
51
35 V Limit value A2
52
A binary output is used to display a collective fault message.
Figure 12. - Alarm unit 6DR4004-8A, not Ex
Compare with the function of the alarm unit. The floating binary
output is implemented as an automatic fault indicating semicon-
ductor output.
Non-hazardous area Hazardous area, zone 1 or zone 2
The other two binary outputs are used for the message of two
Alarm module limits L1 and L2 which can be adjusted mechanically using slotted
initiators. Both these binary outputs are electrically independent
6DR4004-6A
+
11 #
from the remaining electronic unit.
≤ 25,2 V
EEx 12 ≥1 Digital
input 2 Device features
+ 3V
The slotted initiator alarm unit, abbreviated as SIA unit consists
21
22
of three binary outputs.

Intrinsically safe # +
31
2K1
Fault message
Proceed as follows to install the SIA unit:
switching 8,2 V 10K
amplifier to DIN 32
EEx
EN 60947-5-6
# +
41
2K1
8,2 V 10K Limit value A1
42
2. Unscrew both the screws on the motherboard.

EEx
# +
8,2 V
51
2K1
10K Limit value A2 3. Disengage the motherboard by carefully bending the four
brackets.
52
EEx
4. Insert the SIA unit from the top up to the upper printed circuit
Figure 13. - Alarm unit 6DR4004-6A, EEx i board guide of the module rack.
5. Slide the SIA unit in the printed circuit board of the module
rack approximately 1/8" to the right.
6. Screw in the special screw through the SIA unit into the posi-
tioner shaft. Tighten the special screw with a torque of 17.7
in-lbs.
Setting The Limits Of The Slotted Initiator Alarm Unit

Notice
You will require a suitable display device to determine the switch
A pin in the actuating disc bearing is pressed. Align this pin status. For example, use the initiator tester type 2 / Ex by Pepperl
before it touches the special screw. You must rotate the actuat- + Fuchs.
ing disc bearing and the special screw simultaneously so that the
pin is inserted into the special screw. 1. Connect the display device to the following terminals of the
SIA unit:
7. An insulating cover is provided over the SIA unit. Place the
• 41 and 42
insulating cover to one side under the motherboard seat on
the container wall. The recesses of the insulating cover must • 51 and 52
fit in the corresponding webs of the container wall.
2. Read the switch status of slotted initiators
8. Place the insulating cover on the SIA unit by bending the
container walls carefully. Proceed as follows to set the limits:
9. Engage the motherboard into the four brackets. 1. Move the actuator to the first desired mechanical position.
10. Tighten the motherboard using the two screws. 2. Adjust the upper actuating disc manually until the output
11. Reestablish all electrical connections between the mother- signal at terminals 41 and 42 changes. Set a high-low or a
board and the optional modules. Connect the motherboard low-high switch over as follows:
and the optional modules to the ribbon cables provided. • Rotate the actuating disc beyond the switching point
Connect the motherboard and the potentiometer to the poten- until you reach the next switching point.
tiometer cable.
3. Move the actuator to the second desired mechanical position.
12. Using both the screws, fasten the module cover provided. Do
not use the standard module cover. 4. Adjust the lower actuating disc manually until the output
13. Refer to Figures 14 and 15 to connect the SIA module in stan- signal at terminals 51 and 52 changes. Set a high-low or a
dard and intrinsically safe applications low-high switch over as follows:
SIA module • Rotate the actuating disc beyond the switching point
Switching amplifier according to EN 60947-5-6
until you reach the next switching point.

6DR4004-8G
2K1
# +
31
Note: The actuating discs are relatively difficult to move. This

< 35 V 10K Fault message
32
design prevents their unintentional movement during operation.

# +
8,2 V
41
Limit value A1
You can achieve an easier and finer adjustment by reducing
friction temporarily. Move the actuator to and fro while
42
simultaneously holding the actuating discs.

# +
8,2 V
51
Limit value A2
52
Figure 14. - SIA unit 6DR4004-8G, not Ex

Non-hazardous area Hazardous area, zone 1 or zone 2
SIA module
6DR4004-6G
Intrinsically safe
switching # +
8,2 V
31
2K1
10K Fault message

amplifier to DIN 32
EN 60947-5-6 EEx
# +
8,2 V
41
Limit value A1
42
EEx
# +
8,2 V
51
Limit value A2
52
EEx
Figure 15. - SIA unit 6DR4004-6G, EEx i
Installing the EMC Filter Module Proceed as follows to install the EMC filter module:
2. Remove the module cover.
3. Dismantle all existing optional modules.
4. Unscrew the screws of the module rack that are opposite to
the blanking plugs.
5. The EMC filter module has a fastening hole. Tighten the
module on the module rack using the screws provided
6. Lay the ribbon cable of the EMC filter module towards left
through the opening of the module rack.
7. Unplug the connector of the internal potentiometer from the
motherboard.
EMC Module
8. Connect the ribbon cable of the EMC module to the
motherboard.
Function
9. Connect the external position sensor to the terminals of the
You will require the EMC filter module if you use an external EMC module.
position sensor on the positioner, e.g. a potentiometer or a non-
contacting position sensor. The EMC filter module forms the 10. Reinstall the other optional modules in the reverse order.
interface between external position sensors and the motherboard 11. Refer to Figures 14 and 15 to reconnect the SIA module in
of the positioner. This module protects the positioner from elec- standard and intrinsically safe applications
tromagnetic effects.
12. Install the module cover.
Device features include:
• EMC protection
• Connection to motherboard
• Connecting terminals for an external potentiometer
Series 6A Operation & Maintenance – Troubleshooting
Troubleshooting
During operation of the positioner, a few important values and parameters are continually monitored. In configuration mode, you can
configure that monitoring so that the fault message output will be activated if, for instance, a limit is exceeded. Information about what
events can activate the fault message output can be found in Figure 16
Fault See Table #:

In which mode does a fault occur?
Initialization 1
Manual and automatic modes 2, 3, 4, 5
In which environment and under which boundary conditions does a fault occur?
Wet environment (e.g. strong rain or constant condensation) 2
Vibrating (oscillating) control valves 2, 5
Impact or shock loads (e.g. vapor shocks or breakaway valves) 5
Moist (wet) compressed air 2
Dirty (contaminated with solid particles) compressed air 2, 3
When does a fault occur?
Regularly (reproducible) 1, 2, 3, 4
Sporadically (not reproducible) 5
Mostly after a specific operation time 2, 3, 5
Figure 16. - Fault Messages
In automatic and manual mode, when the fault message output triggers the digital display shows what fault triggered the message.
The two digits on the lower left show the corresponding error code. If multiple triggers occur at the same time, they are displayed one
after the other cyclically. The device status, including all fault messages, can be called up using command “#48” over HART. For other
protocols please refer to their specific guide on www.bray.com.
You can use the advance diagnostics parameters to display fault messages in one, two or three stages. The three stage method uses
“traffic light signaling” symbolizing the type of fault occurring. The user will see either a green, yellow, or red wrench on their HMI in
relation to the S6A. Green indicates a need for maintenance, yellow an urgent need for maintenance and red indicates imminent danger
of unit failure or general failure. In addition to the fault message output, alarm outputs 1 and 2 are then used. For this purpose, set the
“XDIAG” parameter as described in Figure 17.
Settings of XDIAG Message due to

OFF Advanced diagnostics not activated
On 1 Fault message output for threshold 3 fault
Figure 17. XDIAG Parameters messages (one-stage)
messages and alarm output 2 for threshold
2 fault messages (two-stage)
messages and alarm output 2 for threshold
2 fault messages and alarm output 1 for
threshold 1 fault messages (three-stage)
When a fault occurs an error code will show up on the lower left hand corner of the screen. Remedial Measures Tables 1-5 respectively,
show possible causes of the fault messages, events which activate the fault message output or alarm outputs, settings of parameters
needed for event monitoring, and remedial measures to cancel a fault message.
Remedial Measures Table 1

Fault profile (symptoms) Possible cause(s) Remedial measures
Positioner remains in “RUN 1”. Initialization started from the end position A waiting time of up to 1 minute is essential
The response time of a maximum of 1 minute was Do not start initialization from the end position
not observed Provide the network pressure
Network pressure not connected or it is too low
Positioner remains in “RUN 2”. Transmission ratio selector and parameter 2 do Check settings: see leaflet: “Device view (7)” picture as well
not match the actuator type. as parameters 2 and 3
Incorrectly set stroke on the lever Check the stroke setting on the lever. See table 2
Piezo valve does not activate
Positioner remains in “RUN 3”. Actuator actuating time is too high Open the restrictor completely and/or set the pressure PZ (1)
to the highest permissible value
Use a booster if required
Positioner remains “RUN 5”, “Gap” (play) in the positioner - actuator - control Part-turn actuator: check for the firmness of the grub screw
does not go up to “FINISH” valve system of the coupling wheel
(waiting time > 5 min) Linear actuator: check for the firmness of the lever on the
positioning shaft
Remove any play between the actuator and the control valve.

“CPU test” blinks on the digital Water in the pneumatic block (due to wet com-
display approximately every two pressed air)
seconds. At an early stage, this fault can be rectified with a subsequent
Piezo valve does not activate. operations using dry air, if required, in a temperature cabinet
at 50 to 70°C
In the manual and automatic Moisture in the pneumatic block
modes, the actuator cannot be Otherwise: repair 1)
moved or can be moved only in
one direction
Piezo valve does not activate (a The screw between the shrouding cover and the Tighten the screw firmly; if required realign cover.
gentle click sound is not audible pneumatic block has not been tightened firmly or
when the “+” or “-” buttons are the cover got stuck
pressed in the manual mode.)
Dirt (swarf, particles) in the pneumatic block Repair or a new device; clean and/or replace the built-
in fine screens
Deposits on the contacts between the electronic Clean all contact surfaces with spirit; if required, bend
printed circuit board and the pneumatic block the pneumatic block contact springs
may develop due to abrasion owing to continuous
loads resulting from strong vibrations

Actuator does not move. Compress air < 1.4 bar Set the supply air pressure to >20 psi
Piezo valve does not activate (a Restrictor valve turned off (screw at the right end Open the restrictor screw by turning it counter clockwise, see
gentle click sound is however stop) leaflet, “Device view (6)”
audible when the “+” or “-” but-
Dirt in the pneumatic block Repair1) or a new device: clean and/or replace the built-in
tons are pressed in the manual
mode.) fine screens
A piezo valve activates Pneumatic leakage in the positioner - actua- Rectify leakage in the actuator and/or feed line.
constantly in the stationary auto- tor system; start the leakage test in “RUN3” In case of an intact actuator and tight feed line; repair1) or a
matic mode (constant setpoint) (initialization). new device
and the manual mode.
Dirt in the pneumatic block, see above

Sticking friction of the packing gland from the Reduce friction or increase dead zone of positioner (param-
control valve or actuator too large eter ”dEbA”) until the oscillation stops
In stationary automatic mode
(constant setpoint) and in manual Looseness (play) in the positioner/actuator/con- Part-turn actuator: Check for firm seating of set screw on cou-
mode, both piezo valves contin- trol valve system pling wheel
ually switch alternately, and the
actuator oscillates around a mean Actuator is too fast Linear actuator: Check for firm seating of lever on positioner
value. shaft
Correct any other play between the actuator and the control
valve
Positioner doesn’t move control Supply pressure too low. Load on the feeding Increase supply pressure, insert ballast converter
valve to the stop (at 20 mA) controller or system output is too low Select 3/4-wire mode

Impact or shock loads result in accelerations Rectify the causes for shock loads
Zero point displaces sporadi-
so high that the friction clutch moves, e.g.
cally (> 3%). Re-initialize the positioner
due to ”vapor shocks” in vapor lines
Electrical auxiliary power supply is not
Check the electrical auxiliary power supply
adequate
In case of very high continuous loads due to
The device function has com- vibrations (oscillations):
pletely failed: no view even Tighten the screws firmly x
on the digital display. Screws of the electrical connecting terminals
Repair 1)
may be loose
For prevention: install the positioner on the damping pads
Electrical connecting terminals and/or elec-
tronic components may be knocked out
Series 6A Operation & Maintenance – Service and Maintenance
Service and Maintenance

The S6A is maintenance-free to a large extent. Screens are Installation of the Screens
installed in the pneumatic connections of the positioners to pro-
tect them from debris. If there are dirt particles in the pneumatic
auxiliary power supply, they damage the screens and hamper the
function of the positioner.
Q Caution
Perform the following steps when needing to clean the screens: Damage to the enclosure. The enclosure is damaged due to
Cleaning the Screens screwing in the self-tapping screws improperly. Ensure that the
available thread pitches are used. Turn the screws counterclock-
wise until they engage noticeably in the thread pitch. Tighten
Q Caution the self-tapping screws only after they have engaged.
1. Insert the screens into the recesses of the plastic enclosure.
Danger Positioner in the plastic enclosure:
2. Place the O-rings on the screens.
Risk of explosion due to electrostatic charge. Electrostatic
3. Fit the pneumatic terminal strip on both studs so that it fits
charges develop when cleaning the positioner in the plastic
flushly.
enclosure with a dry cloth. It is imperative you avoid electro-
static charges in the hazardous environment. 4. Screw-on the three self-tapping screws.
1. Disconnect the pneumatic power supply. 5. Place the cover and tighten it.
2. Remove the lines. 6. Reconnect the pipelines and feed the pneumatic power
supply
3. Unscrew the cover.
4. Unscrew the three self-tapping screws on the pneumatic
terminal strip.
5. Remove the screens and O-rings behind the terminal strip.
6. Clean the screens, e.g. using compressed air.
Series 6A Operation & Maintenance – Technical Data
Technical Data
1. Basic Units
Technical specifications
SIPART PS2 Basic device Basic device Basic device Basic device
without Ex protection with Ex d protection with Ex ia/ib protection with Ex n/
(flameproof enclosure) dust protection
3-/4-wire device (terminals 2/4 and
6/8) (6DR52.. and 6DR53..)
• Power supply UH 18 ... 35 V DC 18 ... 30 V DC
• Current consumption IH (UH - 7.5 V)/2,4 kΩ [mA]
• Internal capacitance Ci – 22 nF 22 nF (at "nL")
• Internal inductance Li – 0.12 mH 0.12 mH (at "nL")
• For connection to circuits with the – intrinsically safe at "nA" and "tD":
following peak values Ui = 30 V DC Un = 30 V DC
Ii = 100 mA In = 100 mA
Pi = 1 W at "nL":
Ui = 30 V DC
Ii = 100 mA
Current input IW
Rated signal range 0/4 ... 20 mA
Load voltage at 20 mA ≤ 0.2 V (corresponds to 10 Ω) ≤ 1 V (corresponds to 50 Ω)
Internal capacitance Ci – 22 nF 22 nF (at "nL")
Internal inductance Li – 0.12 mH 0.12 mH (at "nL")
For connection to circuits with the – intrinsically safe at "nA" and "tD":
following peak values Ui = 30 V DC Un = 30 V DC
Ii = 100 mA In = 100 mA
Pi = 1 W at "nL":
Ui = 30 V DC
Ii = 100 mA
Electrical isolation between UH and IW between UH and IW between UH and IW
(2 intrinsically safe cir-
cuits)
Test voltage 840 V DC, (1 s)
Connections
• Electrical Screw terminals 2.5 Screw terminals 2.5 Screw terminals 2.5 AWG28-12
AWG28-12 AWG28-12 Cable gland M20x1.5 or ½-14 NPT
Cable gland M20x1.5 or Ex d certified cable gland
½-14 NPT M20x1.5, ½-14 NPT or
M25x1.5
• Pneumatic Female thread G1/4 EN ISO 228-1 or
¼ -18 NPT
External position sensor (potentiome-
ter or NCS; as option) with the follow-
ing peak values
• Uo – 5V
• Io (static) – 75 mA
• Is (short-time) – 160 mA –
• Po – 120 mW
Maximum permissible external – 1 μF
capacitance Co
Maximum permissible external – 1 mH
inductance Lo
SIPART PS2 PA Basic device Basic device Basic device Basic device
Explosion protection as per ATEX Without Ex d Ex ia/ib Ex n
II 2 G Ex d II C T4/T5/T6 II 2 G Ex ia/ib II C T6 II 3 G Ex nA nL[nL] IIC T6
Dust
II 3 D Ex tD A22 IP66
T100°C
Mounting location Zone 1 Zone 2/22
Permissible ambient temperature for -30 ... +80 °C T4: -30 ... +80 °C T4: -20 ... +75 °C
operation (-22 ... +176 °F) (-22 ... +176 °F) (-4 ... +167 °F)
At ≤ -10 °C (+14 °F) the display refresh T5: -30 ... +65 °C T5: -20 ... +65 °C
rate of the digital display is limited. (-22 ... +149 °F) (-4 ... +149 °F)
(for basic devices with Ex protection T6: -30 ... +50 °C T6: -20 ... +50 °C
the following applies: Only T4 is per- (-22 ... +122 °F) (-4 ... +122 °F)
missible when using Iy module.)
Electrical specifications
Input
Power supply (terminals 6/7) Bus-supplied
Bus voltage 9 ... 32 V 9 ... 24 V 9 ... 32 V
• Bus connection with supply unit – Intrinsically safe FISCO at "nA" and "tD":
Un = 32 V DC
at "nL":
FNICO
- Max. supply voltage Uo – 17.5 V
- Max. short-circuit current Io – 380 mA 570 mA
- Max. power Po – 5.32 W –
• Bus connection with barrier intrinsically safe at "nL"
- Max. supply voltage (Uo) – 24 V 32 V
- Max. short-circuit current (Io) – 250 mA –
Current consumption 11.5 mA ± 10 %
Additional error signal 0 mA
Effective internal inductance Li – 8 μH 8 μH (at "nL")
Effective Internal capacitance Ci – Negligible
Safety shutdown can be activated
with coding bridge (terminals 81/82;
electrically isolated from the basic
device)
• Input resistance > 20 kΩ
• Signal status "0" (shutdown active) 0 ... 4.5 V or unused
• Signal status "1" 13 ... 30 V
(shutdown not active)
• Effective Internal capacitance Ci – Negligible
• Effective internal inductance Li – Negligible
• For connection to power supply with – intrinsically safe At "nA", "nL" and "tD"
- Max. supply voltage Ui – 30 V 30 V
- Max. short-circuit current Ii – 100 mA 100 mA
- Maximum power Pi – 1W –
Electrical isolation Between basic device and the input for safety shut- The basic device and the Between basic device
down, as well as the outputs of the option modules input to the safety shut- and the input for safety
down, as well as the out- shutdown, as well as the
puts of the option outputs of the option
modules, are separate, modules
intrinsically safe circuits
Test voltage 840 V DC, 1 s
SIPART PS2 PA Basic device Basic device Basic device Basic device
Communication Layers 1 and +2 according to PROFIBUS PA, transmission technology according to IEC 1158-2;
slave function; layer 7 (protocol layer) according to PROFIBUS DP,
EN 50170 standard with the extended PROFIBUS functions
(all data acyclic, manipulated variable, feedbacks and status also cyclic)
C2 connections Four connections to master class 2 are supported,
automatic connection setup 60 s after break in communication
Device profile PROFIBUS PA profile B, version 3.0, more than 150 objects
Response time to master message Typically 10 ms
Device address 126 (when delivered)
PC parameterizing software SIMATIC PDM, supports all device objects. The software is not included in the scope of delivery
Connections
½-14 NPT M20x1.5, ½-14 NPT or
M25x1.5
• Pneumatic Female thread G¼
EN ISO 228-1
(¼ -18 NPT)
External position sensor (potentiome-
ter or NCS; as option) with the follow-
ing peak values
• Uo – 5V
• Po – 120 mW
• Maximum permissible external – 1 μF
capacitance Co
• Maximum permissible external – 1 mH
inductance Lo
SIPART PS2 FF Basic device Basic device Basic device Basic device
Explosion protection as per ATEX Without Ex d Ex ia/ib Ex n
II 2 G Ex d II C T4/T5/T6 II 2 G Ex ia/ib II C T6 II 3 G Ex nA nL[nL] IIC T6
Dust
T100°C
Mounting location Zone 1 Zone 2/22
Permissible ambient temperature for -30 ... +80 °C T4: -30 ... +80 °C T4: -20 ... +75 °C
operation (-22 ... +176 °F) (-22 ... +176 °F) (-4 ... +167 °F)
At ≤ 10 °C (+14 °F) the display refresh T5: -30 ... +65 °C
rate of the indicator is limited (-22 ... +149 °F)
(for basic devices with Ex protection T6: -30 ... +50 °C
the following applies: Only T4 is per- (-22 ... +122 °F)
missible when using Iy module.)
Input
Power supply (terminals 6/7) Bus-supplied
Bus voltage 9 ... 32 V 9 ... 24 V 9 ... 32 V
• Bus connection with supply unit – Intrinsically safe FISCO at "nA" and "tD":
Un = 32 V DC
at "nL":
FNICO
- Max. supply voltage Uo – 17.5 V
- Max. short-circuit current Io – 380 mA 570 mA
• Bus connection with barrier intrinsically safe at "nL"
- Max. supply voltage (Uo) – 24 V 32 V
- Max. short-circuit current (Io) – 250 mA –
Electrical specifications
Current consumption 10.5 mA ± 10 %
Additional error signal 0 mA
Effective internal inductance Li – 8 μH 8 μH (at "nL")
Effective Internal capacitance Ci – Negligible
Safety shutdown can be activated
with coding bridge (terminals 81/82;
electrically isolated from the basic
device)
• Input resistance > 20 kΩ
• Signal status "0" (shutdown active) 0 ... 4.5 V or unused
• Signal status "1" 13 ... 30 V
(shutdown not active)
• Effective Internal capacitance Ci – Negligible
• Effective internal inductance Li – Negligible
• For connection to power supply with – intrinsically safe At "nA", "nL" and "tD"
- Max. supply voltage Ui – 30 V
- Max. short-circuit current Ii – 100 mA
- Maximum power Pi – 1W –
Electrical isolation Between basic device and the input for safety shut- The basic device and the Between basic device
down, as well as the outputs of the option modules input to the safety shut- and the input for safety
down, as well as the out- shutdown, as well as the
puts of the option outputs of the option
modules, are separate, modules
intrinsically safe circuits
SIPART PS2 FF Basic device Basic device Basic device Basic device
Communication
Communications group and class According to technical specification of the Fieldbus Foundation for H1 communication
Function blocks Group 3, Class 31PS (publisher, subscriber)
1 resource block (RB2)
1 analog output function block (AO)
1 PID function block (PID)
1 transducer block (standard advanced positioner valve)
Execution times of the blocks AO: 60 ms
PID: 80 ms
Physical layer profile 123, 511
FF registration Tested with ITK 5.0
Device address 22 (when delivered)
Connections
½-14 NPT M20x1.5, ½-14 NPT or
M25x1.5
• Pneumatic Female thread G¼ EN ISO 228-1 (¼ -18 NPT)
External position sensor
(potentiometer or NCS; as option)
with the following peak values
• Uo – 5V
• Po – 120 mW
• Maximum permissible external – 1 μF
capacitance Co
• Maximum permissible external – 1 mH
inductance Lo
SIPART PS2 (all versions) Weight, basic device
General data • Glass-fiber-reinforced Makrolon Approx. 0.9 kg (1.98 lb)
enclosure
Range of stroke (linear actuators) 3 ... 130 mm (0.12 ... 5.12 inch)
(angle of positioner shaft 16 ... 90°) • Aluminum enclosure Approx. 1,3 kg (2.86 lb)
Angle of rotation (part-turn actuators) 30 ... 100° • Stainless steel enclosure Approx. 3.9 kg (8.58 lb)
• Pressure-proof alum. enclosure Approx. 5.2 kg (11.46 lb)
Assembly
Dimensions See Dimensional drawings
• On linear actuators Using mounting kit 6DR4004-8V and
where necessary with an additional Climatic class According to DIN EN 60721-3-4
lever arm 6DR4004-8L on actuators
according to IEC 534-6 (NAMUR) • Storage 1) 1K5, but -40 ... +80 °C
with ribs, bars or flat face (-40 ... +176 °F)
• On part-turn actuators Using mounting kit 6DR4004-8D • Transport 1) 2K4, but -40 ... +80 °C
on actuators with mounting plane (-40 ... +176 °F)
according to VDI/VDE 3845 and
DIN 3337: The required mounting • Operation 2) 4K3, but -30 ... +80 °C 3)
console has to be provided on the (-22 ... +176 °F)
actuator side; shaft with groove and Certificates and approvals
female thread M6
Classification according to pres- For gases of fluid group 1, complies
Controller unit sure equipment directive with requirements of article 3, par. 3
• Five-point switch Self-adjusting (PED 97/23/EC) (sound engineering practice SEP)
• Deadband CE marking You can find the appropriate guidelines

and standards applied, including the
- dEbA = Auto Self-adjusting or can be set as fixed relevant versions, in the EC Declaration
value of Conformity on the Internet
- dEbA = 0.1 ... 10 % Self-adjusting or can be set as fixed Pneumatic data
value
Auxiliary power (air supply) Compressed air, nitrogen or cleaned
A/D converter natural gas
• Scan time 10 ms • Pressure 1.4 ... 7 bar (20.3 ... 101.5 psi):
Sufficiently greater than max. drive
• Resolution ≤ 0.05 % pressure (actuating pressure)
• Transmission error ≤ 0.2 % Air quality to ISO 8573-1
• Temperature influence effect ≤ 0.1 %/10 K (≤ 0.1 %/18 °F) • Solid particulate size and density Class 2
Cycle time • Pressure dew point Class 2 (min. 20 K (36 °F) below
ambient temperature)
• 20 mA/HART device 20 ms
• Oil content Class 2
• PA device 60 ms
Unrestricted flow (DIN 1945)
• FF device 60 ms (min. loop time)
• Inlet air valve (ventilate actuator) 4)
Binary input BE1 (terminals 9/10; Suitable only for floating contact;
electrically conn. to basic device) max. contact load < 5 µA with 3 V - 2 bar (29 psi) 4.1 Nm³/h (18.1 USgpm)
Degree of protection IP66 to EN 60 529/NEMA 4X - 4 bar (58 psi) 7.1 Nm³/h (31.3 USgpm)
EMC requirements EN 61326/A1 Appendix A.1 and - 6 bar (87 psi) 9.8 Nm³/h (43.1 USgpm)
NAMUR NE21 August 98 • Outlet air valve (vent actuator) 4)
Material - 2 bar (29 psi) 8.2 Nm³/h (36.1 USgpm)
• Enclosure - 4 bar (58 psi) 13.7 Nm³/h (60.3 USgpm)
- 6DR5..0-... (plastic) Glass-fiber-reinforced Macrolon - 6 bar (87 psi) 19.2 Nm³/h (84.5 USgpm)
- 6DR5..1-... (aluminum) GD AISi12 Valve leakage < 6⋅10-4 Nm³/h (0.0026 USgpm)
- 6DR5..2-... (stainless steel) Austenitic stainl. steel mat. No. 1.4581 Throttle ratio Adjustable up to ∞ : 1
- 6DR5..5-... (alum., press.-proof) GK AISi12 Auxiliary power consumption in < 3,6⋅10-2 Nm³/h (0.158 USgpm)
the controlled state
• Pressure gauge block Aluminium AIMgSi, anodized
Device versions
Vibration resistance
• In Makrolon enclosure Single-acting and double-acting
• Harmonic oscillations 3.5 mm (0.14 inch),
(sine-wave) according to 2 ... 27 Hz 3 cycles/axis • In aluminum enclosure Single-acting
EN 60068-2-6/05.96 • In pressure-proof aluminum encl. Single-acting and double-acting
98.1 m/s² (321.84 ft/s²),
27 ... 300 Hz, 3 cycles/axis • In stainless steel enclosure Single-acting and double-acting
• Bumping (half-sine) 150 m/s² (492 ft/s²), 6 ms, 1)
to EN 60068-2-29/03.95 1000 shocks/axis During commissioning at ≤ 0 °C (≤ 32 °F) make sure that the valves are
flushed long enough with the dry medium.
• Noise (digitally controlled) 10 ... 200 Hz; 2)
At ≤ -10 °C (≤ 14 °F) the display refresh rate of the indicator is limited. Only
to EN 60068-2-64/08.95 1 (m/s²)²/Hz (3.28 (ft/s²)²/Hz) T4 is permissible when using Iy module.
3)
200 ... 500 Hz; -20 ... +80 °C (-4 ... + 176 °F) for 6DR55..-0G..., 6DR56..-0G...,
0.3 (m/s²)²/Hz (0.98 (ft/s²)²/Hz) 6DR55..-0D... and 6DR56..-0D...
4)
With the Ex d version (6DR5..5-...) the values are reduced by approx. 20 %
4 hours/axis
Gauge made of Plastic Steel Stainl. Steel 316
• Recommended continuous duty ≤ 30 m/s² (≤ 98.4 ft/s²) without reso-
range of the complete fitting nance sharpness Degree of protection IP31 IP44 IP54
Vibration resistance acc. to DIN EN 837-1
SIPART PS2 Basic device Basic device Basic device Basic device
Explosion protection ATEX - Ex d Ex ia/ib Ex n
II 2 G Ex d II C T6 II 2 G Ex ia/ib II C T6 II 3 G Ex nA nL[nL] IIC T6
Dust
T100°C
Mounting location - Zone 1 Zone 2/22
Permissible ambient temperature for -30 ... +80 °C T4: -30 ... +80 °C (-22 ... +176 °F)
operation (-22 ... +176 °F)
At ≤ -10 °C (+14 °F) the display refresh T5: -30 ... +65 °C (-22 ... +149 °F)
rate of the indicator is limited.
T6: -30 ... +50 °C (-22 ... +122 °F)
(for basic devices with EX ia/ib and Ex n
protection the following applies: Only T4
is permissible when using Iy module)
Input
2-wire connection (terminals 6/8)
Rated signal range 4 ... 20 mA
Current to maintain the auxiliary power ≥ 3.6 mA
supply
Required load voltage
UB (corresponds to Ω at 20 mA)
• Without HART (6DR50..)
- Typical 6.36 V 7.8 V
(corresponds to 318 Ω) (corresponds to 390 Ω)
- max. 6.48 V 8.3 V
(corresponds to 324 Ω) (corresponds to 415 Ω)
• Without HART (6DR53..)
- Typical 7.9 V –
(corresponds to 395 Ω)
- max. 8.4 V –
• With HART (6DR51..)
- Typical 6.6 V –
- max. –
• With HART (6DR52..)
- Typical – 8.4 V
- max. – 8.8 V
• Static destruction limit ± 40 mA –
Internal capacitance Ci
• Without HART – 22 nF 22 nF (at "nL")
• With HART – 7 nF 7 nF (at "nL")
Internal inductance Li
• Without HART – 0.12 mH 0.12 mH (at "nL")
• With HART – 0.24 mH 0.24 mH (at "nL")
For connection to circuits with the fol- – intrinsically safe at "nA" and "tD":
lowing peak values Ui = 30 V DC Un = 30 V DC
Ii = 100 mA In = 100 mA
Pi = 1 W at "nL":
Ui = 30 V DC
Ii = 100 mA
2. Optional Models
Add-on modules Without Ex protection/ With Ex ia/ib protection With Ex n/dust protection
with Ex d protection
Ex protection acc. to ATEX – II 2G Ex ia/ib II C T4/T5/T61) Ex n
II 3 G Ex nA nL[nL] IIC T6
Dust
II 3 D Ex tD A22 IP66 T100°C
Mounting location – Zone 1 Zone 2/22
Permissible ambient temperature for opera- -30 ... +80 °C (-22 ... +176 °F) T4: -30 ... +80 °C (T4: -22 ... +176 °F)
tion
T5: -30 ... +65 °C (-22 ... +149 °F)
(For devices with Ex protection: Only in con-
junction with the basic device 6DR5... -.E.... T6: -30 ... +50 °C (-22 ... +122 °F)
Only T4 permissible when using Iy module.)
Alarm unit 6DR4004-8A
Binary alarm outputs A1, A2 and alarm output
• Signal status High (not responded) Conductive, R = 1 kΩ, +3/1 %* ≥ 2.1 mA
Signal status Low* (responded) Disabled, IR < 60 µA ≤ 1.2 mA
(* Low is also the status when the basic
device is faulty or has no electric power (* When used in the flameproof (Switching threshold with supply to EN 60947-5-6: UH = 8.2 V,
supply) enclosure the current consump- Ri = 1 kΩ)
tion must be limited to 10 mA
per output.)
• Internal capacitance Ci – 5.2 nF 5.2 nF (at "nL")
• Internal inductance Li – Negligible
• Power supply UH ≤ 35 V –
• Connecting to circuits with the following – Intrinsically safe switching at "nA" and "tD":
peak values amplifier to EN 60947-5-6 Un = 15.5 V DC
Ui = 15.5 V DC at "nL":
Ii = 25 mA Ui = 15.5 V DC
Pi = 64 mW Ii = 25 mA
Binary input BE2
• Electrically connected to the basic device
- Signal status 0 Floating contact, open
- Signal status 1 Floating contact, closed
- Contact load 3 V, 5 mA
≤ 4.5 V or open
• Electrically isolated from the basic device
≥ 13 V
- Signal status 0
≥ 25 kΩ
- Signal status 1
- Natural resistance
• Static destruction limit ± 35 V –
• Internal inductance and capacitance – Negligible
• Connecting to circuits with the following – Intrinsically safe Ui = 25.2 V at "nA" and "tD":
peak values Un = 25.2 V DC
at "nL":
Ui = 25.2 V DC
Electrical isolation The 3 outputs, the input BE2 and the basic device are electrically isolated from each other
1)
Only in conjunction with the basic device 6DR5...-.E.... Only T4 permissible when using with Iy module.
Add-on modules Without Ex protection/ With Ex ia/ib protection With Ex n/dust protection
SIA module 6DR4004-8G 6DR4004-6G
Limit transmitter with slot-type initiators (not for Ex d version)
and alarm output
Limit transmitter A1, A2 2-wire connection
Ex protection Without II 2 G Ex ia/ib IIC T6 II 3 G Ex nA nL [nL] IIC T6
Connection 2-wire system to EN 60947-5-6 (NAMUR), for switching amplifier to be connected on load side
2 slot-type initiators Type SJ2-SN
Function NC (normally closed)
Connecting to circuits with the following rated voltage 8 V Intrinsically safe switching ampli- at "nA" and "tD":
peak values Current consumption: fier EN 60947-5-6 Un = 15.5 V DC
≥ 3 mA (limit value not Ui = 15.5 V DC Pn = 64 mW
responded) Ii = 25 mA at "nL":
≤ 1 mA (limit value Pi = 64 mW Ui = 15.5 V DC
responded) Ii = 25 mA
Internal inductance Li – 100 μH 100 μH (at "nL")
Electrical isolation The 3 outputs are electrically isolated from the basic device
Alarm output
Connection To switching amplifier according to EN 60947-5-6 (NAMUR), UH = 8.2 V, Ri = 1 kΩ
Signal state High (not activated) R = 1.1 kΩ ≥ 2.1 mA
Signal state Low (activated) Ri = 10 kΩ ≤ 1.2 mA
Internal capacitance Ci – 5.2 nF 5.2 nF (at "nL")
Internal inductance Li – Negligible
Power supply UH UH ≤ 35 V DC –
I ≤ 20 mA
Connecting to circuits with the following – Intrinsically safe switching ampli- at "nA" and "tD":
peak values fier acc. to EN 60947-5-6 Un = 15.5 V DC
Ui = 15.5 V DC at "nL":
Ii = 25 mA Ui = 15.5 V DC
Pi = 64 mW Ii = 25 mA
Limit value contact module 6DR4004-8K 6DR4004-6K
Limit transmitter with mechanical ground (not for Ex d version)
contact and alarm output
Limit transmitter A1, A2
Ex protection Without II 2 G Ex ia/ib IIC T6 II 3 G Ex nL [nL] IIC T6
Max. switching current AC/DC 4A Connection to intrinsically safe Connection to circuits with maxi-
circuit with maximum values: mum values:
Ui = 30 V, at "nL":
Ii = 100 mA, Ui = 30 V
Pi = 750 mW Ii = 100 mA,
Max. switching voltage AC/DC 250 V/24 V 30 V DC 30 V DC
Internal capacitance – Negligible Negligible
Internal inductance – Negligible Negligible
Electrical isolation The 3 outputs are electrically isolated from the basic device
Alarm output
Connection To switching amplifier according to EN 60947-5-6 (NAMUR), UH = 8.2 V, Ri = 1 kΩ
Signal state High (not activated) R = 1.1 kΩ ≥ 2.1 mA
Signal state Low (activated) Ri = 10 kΩ ≤ 1.2 mA
Internal capacitance Ci – 5.2 nF 5.2 nF (at "nL")
Power supply UH UH ≤ 35 V DC –
I ≤ 20 mA
Connecting to circuits with the following – Intrinsically safe switching ampli- at "nL":
peak values fier acc. to EN 60947-5-6 Ui = 15.5 V DC
Ui = 15.5 V DC Ii = 25 mA
Ii = 25 mA
Pi = 64 mW
Add-on modules Without Ex protection/ With Ex ia/ib protection With Ex n protection
Iy module 6DR4004-8J 6DR4004-6J
DC output for position feedback 2-wire connection
Rated signal range 4 ... 20 mA, short-circuit-proof
Total operating range 3.6 ... 20.5 mA
Power supply UH +12 ... +35 V +12 ... +30 V

External loads RB [kΩ] ≤ (UH [V] - 12 V) /i [mA]
Transmission error ≤ 0,3 %
Temperature influence effect ≤ 0.1 %/10 K (≤ 0.1 %/18 °F)
≤ 0,1 %
Resolution
≤1%
Residual ripple
For connection to circuits with the follow- Intrinsically safe: at "nA" and "tD":
ing peak values Ui = 30 V DC Un = 30 V DC
Ii = 100 mA In = 100 mA
Pi = 1 W (only T4) Pn = 1 W (only T4)
at "nL":
Ui = 30 V DC
Ii = 100 mA
Electrical isolation Electrically isolated from the basic device
NCS sensor (not for Ex d version)
Position range
• Linear actuator 3 ... 130 mm (0.12 ... 5.12 3 ... 130 mm (0.12 ... 5.12 -
inch), to 200 mm (7.87 inch) on inch), to 200 mm (7.87 inch) on
request request
• Part-turn actuator 30° ... 100° (not for Ex d version) 30° ... 100° -
Linearity (after correction by SIPART PS2)
• Linear actuator ±1% ±1% -
• Part-turn actuator ±1% ±1% -
Hysteresis ± 0.2 % ± 0.2 % -
Continuous working temperature -40 °C ... +85 °C -40 °C ... +85 °C -
(-40 °F ... +185 °F), (-40 °F ... +185 °F),
extended temperature range on extended temperature range on
request request
Vibration resistance Harmonic oscillations 7 mm (0.28 inch), 5 ... 54 Hz
(sine-wave) according to EN 60062-2- 500 m/s2 (1640 ft/s2), 80 ... 200 Hz
6/05.96
For connection to circuits with the follow- Intrinsically safe at "nL":
ing peak values Ui = 5 V DC Ui = 5 V DC
Internal inductance Li – 240 μH 240 μH (at "nL")
Degree of protection of enclosure IP68/NEMA 4X -
Series 6A Operation & Maintenance – Dimensional Drawings
Dimensional Drawings
Dimensional drawings
50 x 4 (1.97 x 0.16) x M6
95 (3.74)2)
(1.16) (1.16)
29.5 29.5
72 (2.83)1)
All air connections
185 (7.28) 4) 11.2 (0.44)
G 1/4 or 1/4 NPT
(1.16)
29.5
50 x 4 (1.97 x 0.16) x M6
84 (3.31)
59 (2.32)
All air connections
185 (7.28) 4) 11.2 (0.44)
G 1/4 or 1/4 NPT
Stainless steel version, values:

96.6 (3.80)3)
M20 x 1.5 1) 74 (2.91)

2) 99 (3.89)
3) 98 (3.86)
4) Dimension at electrical
connection ½-14 NPT (with
adapter) 203 mm
Makrolon and stainless steel enclosure double acting (top), aluminum enclosure single acting (center),
Makrolon and aluminum enclosure (bottom), dimensions in mm (inch)
Note: Drawings are shown in first angle
23 (0.91) all a
G1/
M8, 14 (0.55) deep (4x)
7.75 (0.3)
All information herein is proprietaryAlland

information
confidential
herein
and may
is proprietary
not be copied
and confidential
or reproduced
andwithout
may notthebeexpressed
copied orwritten
reproduced
consent
without
of BRAY
the expressed
INTERNATIONAL,
written consent
Inc. of BRAY INTERNATIONAL, Inc.
(1.69)
6Atechnical
The O&M 40 is for general
data: herein The information
technical data
only.
herein
Product
is forsuitability
general information
should be based
only. Product
solely upon
suitability
customer’s
should
detailed
be based
knowledge
solely upon
andcustomer’s
experiencedetailed
with their
knowledge
application. 6AwithOtheir
and experience &M : 40
application.
(0.2)
.65)
Y1
5
G 1/4 or 1/4 NPT
Stainless steel version, values:
96.6 (3.80)3)
M20 x 1.5 1) 74 (2.91)
2) 99 (3.89)
3) 98 (3.86)
4) Dimension at electrical
connection ½-14 NPT (with
Series 6A Operation & Maintenance – Dimensional Drawings
adapter) 203 mm
Makrolon and stainless steel enclosure double acting (top), aluminum enclosure single acting (center),
Makrolon and aluminum enclosure (bottom), dimensions in mm (inch)
23 (0.91) all air connections

G1/4 or 1/4-NPT
M8, 14 (0.55) deep (4x)
10.25 (0.4)
(0.98)
7.75 (0.3)
25
E
7 (0.28)
43 (1.69)
(1.32) (1.32)
33.5 33.5
(0.2)
65 (2.65)
Y1 12 (0.47)
5
(1.34)
34
4.5 (1.8)
19.25 (0.36)
7)
M6, 11 (0.43) deep (4x)
.9 1)
(1
50
M6, 8 (0.31) deep (2x) 87.2 (3.43)

Ø
60 (2.36)
M20x1,5, M25x1,5 or 7.5 25.7 14.3
1/2-NPT (2x) (0.3) (1.01) (0.56)
129.5 (5.1)
3.5 (0.14)
Ø136.5 (5.37)
158.5 (6.24)
82.5 (3.25)
1) Connection Y2 only for double-action version

Ø8 (7)h9
235.3 (9.26)
Flameproof enclosure dimensions in mm (inch)
Note: Drawings are shown in first angle
CONTROLS
R
A Division of BRAY INTERNATIONAL, Inc.
13333 Westland East Blvd. Houston, Texas 77041
281/894-5454 FAX 281/894-9499 www.bray.com
Bray® is a registered trademark of Bray International, Inc.
© 2011 Bray International. All rights reserved. OM-6A-001 12_2011
Series 92/93
Pneumatic Actuator
Series 92/93 Pneumatic Actuator
Operations and Maintenance Manual
TABLE OF CONTENTS
Safety Information - Definition of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Hazard-free use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operating Medium . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Operating Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fail Open Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Fail Open Method 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fail Open Method 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fail Open Method 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Fail Closed Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mounting the Actuator to the Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Setting the Travel Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Final Assembly and Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adding Spring Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Removing Spring Cartridges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Pneumatic System Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Dimensional Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Series 92/93 Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
For information on this product and other Bray products please visit us at our web page - www.bray.com
1
Read and Follow These Instructions

Save These Instructions
SAFETY INFORMATION - DEFINITION OF TERMS
indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury.
used without the safety alert symbol indicates a potential situation which, if not avoided, may
NOTICE result in an undesirable result or state, including property damage.
HAZARD-FREE USE • Is trained in the proper use and care of personal

protective equipment (PPE) in accordance with
This device left the factory in proper condition to be safely established safety practices
installed and operated in a hazard-free manner. The notes
and warnings in this document must be observed by the • Is trained in first aid
user if this safe condition is to be maintained and hazard- • In cases where the device is installed in a potentially
free operation of the device assured. explosive (hazardous) location – is trained in the
Take all necessary precautions to prevent damage to the operation, commissioning, operation and maintenance
actuator due to rough handling, impact, or improper of equipment in hazardous locations
storage. Do not use abrasive compounds to clean the
actuator, or scrape metal surfaces with any objects.
The control systems in which the actuator is installed must
have proper safeguards to prevent injury to personnel,
or damage to equipment, should failure of system The actuator must only be installed, commissioned,
components occur. operated and repaired by qualified personnel.
The device generates large mechanical force when
QUALIFIED PERSONNEL
pressurized with air, and/or powered by springs.
A qualified person in terms of this document is one who is
The actuator stores a large amount of energy when
familiar with the installation, commissioning and operation
pressurized with air, and/or when the springs are
of the device and who has appropriate qualifications, such
compressed.
as:
To prevent injury, installation, commissioning, operation
• Is trained in the operation and maintenance of
and maintenance must be carried out under strict
pneumatic equipment and systems in accordance with
observation of the safety regulations.
established safety practices
Reference is specifically made here to observe the
• Is trained or authorized to energize, de-energize,
applicable safety regulations for actuators installed in
ground, tag and lock electrical and pneumatic circuits
potentially explosive (hazardous) locations.
and equipment in accordance with established safety
practices
Correct and safe operation of this actuator is dependent
upon proper transport, storage and installation in addition
to proper operation and maintenance.
2
DESCRIPTION OF OPERATION INSTALLATION

The Bray Series 92/93 Pneumatic Actuators feature a Bray Series 92/93 Actuators are designed to mount directly
double piston, rack and pinion mechanism designed to on the top plate of Bray Valves. Before the actuator is
automate quarter-turn valves. In the Series 92 Double- mounted on a valve, it is a good practice to lubricate the
Acting Actuator, pressure introduced through Port A (the output bore of the actuator with thick grease. The grease
left port when facing the ports) forces the pistons away will make it easier to remove the actuator from the valve
from each other and causes the pinion to rotate in a stem, even after years of service.
counter-clockwise direction. Pressure introduced through
Normally, the actuator is mounted with its long side parallel
Port B (the right port when facing the ports) is directed
to the pipeline. A double acting actuator will normally
through an internal passage to the opposite side of the
rotate the valve stem clockwise to close, and counter-
pistons, which forces the pistons together and rotates the
clockwise to open. Spring return actuators will normally
pinion in a clockwise direction. Normally, the clockwise
rotate the valve stem clockwise to close with the spring
rotation (pistons moving together) closes the attached
stroke, and counter-clockwise to open with the air stroke.
valve, and the counter-clockwise rotation (pistons moving
The normal operation of the spring cartridges is therefore
apart) opens the attached valve.
fail closed.
In the Series 93 Spring-Return Actuators, spring cartridges
Direction of operation may be changed to fail open by any
have been added to push the pistons together by spring
one of several different methods. Refer to the Assembly
force in the event the compressed air pressure being
Instructions and Exploded View on page 12 for more
lost. This spring force normally closes the attached valve.
details.
However, in the event that the valve is required to open
under spring force, refer to the fail open portion of the Fail Open Assemblies
Installation section.
If the actuator is attached to a valve, the butterfly valve disc
OPERATING MEDIUM is shipped in the full open position (as no air pressure is
present to compress the springs and close the valve disc.)
The sealing surface, or disc edge, is therefore exposed.
NOTICE Damage to that surface will cause premature seat failure.
The recommended operating medium is clean, dry NOTE: Consult a factory representative when a non-
industrial compressed air, 40 - 140 psig (3 - 10 bar.) An air standard actuator configuration is made in the field or is
line lubricator is suggested for fast cycling applications, being changed in the field. Example: Mounting an actuator
i.e. more than 10 cycles per minute. Other media such perpendicular to the pipe due to space restrictions on site.
as hydraulic oil, water, or certain other inert gases may
also be used in some instances, but the factory should be
consulted for specific applications.
OPERATING TEMPERATURE Use caution installing the valve being careful not to
damage the disc edge. It is recommended to:
NOTICE • Remove the actuator. Be sure to scribe the valve and

actuator to ensure the re-installed actuator is in the
The recommended operating temperature range is -20°F exact same quadrant as originally configured
to 200°F (-29°C to 95°C). Below 32°F (0°C) care must
• Install the valve per the attached installation tag
be taken to prevent condensed moisture from freezing
instructions
in the air supply lines. Consider the use of an air dryer
if the device is installed in a cold location. The air dryer • Re-install the actuator ensuring it is in the proper
must be capable of lowering the dew point of the air quadrant
to a temperature 36°F (20 °C) lower than that of the
surrounding environment. The air dryer must be properly
maintained and kept in operation.
3
Fail Open Method 1

Mounting the Actuator Perpendicular to the Pipeline
NOTICE Some actuators may have spring cartridges installed.

Before disassembly, all spring cartridges must be placed
into the relaxed (fully extended) position. All compressed
Fail Open Method 1 – Mounting the Actuator air must be removed from inside the actuator (See previous
Perpendicular to the Pipeline – works only with concentric warning) and the actuator pinion must be allowed to
disc valves such as the Bray Series 20/21, 22/23 and 30/31 rotate so the springs may be relaxed. Care must be taken
or other valves that allow the disc to be swung through to verify that any device connected to the actuator, such
the seat. as a valve mounted underneath, is not preventing the
Turn the actuator so the long side is perpendicular to the movement of the springs to the relaxed position.
pipeline. This will allow the spring cartridges to rotate the Remove the end caps, spring cartridges and pistons from
valve stem clockwise to open, and the air stroke to rotate the actuator. Remove the pinion, rotate it 90°, and reinstall
the valve stem counter-clockwise to close. This is the easiest the pinion in the actuator. This will also allow the spring
method if there is sufficient room to mount the actuator. cartridges to rotate the valve stem clockwise to open, and
Fail Open Method 2 the air stroke to rotate the valve stem counter-clockwise
Rotating the Pinion to close. This is the second easiest method, and allows the
actuator to be mounted with its long side parallel to the
pipeline.
NOTICE
Fail Open Method 3
Fail Open Method 2 – Rotating the Pinion - works only Reversing the Pistons
with concentric disc valves such as the Bray Series 20/21,
22/23 and 30/31 or other valves that allow the disc to be
NOTICE
swung through the seat.
See Assembly (page 7) for detailed instructions on Fail Open Method 3 – Reversing the Pistons – works for
reinstalling the travel stop cam on the pinion. all valves, but must be used with offset disc valves such
as the Bray Series 40/41, 42/43 and 44/45, or other offset
disc valves where the disc may only turn clockwise to
close.
See Assembly (page 7) for detailed instructions on

Before disassembly of the actuator, the pneumatic
reinstalling the travel stop cam on the pinion.
air supply must be completely disconnected from the
actuator, and all compressed air stored within the Remove the end caps, spring cartridges and pistons from
actuator must be released. Auxiliary devices connected the actuator. Rotate the pistons so that the racks turn the
to the actuator, such as tubing, ball valves, solenoid air pinion counter-clockwise as the pistons move toward each
valves, valve positioners, etc. can block the release of air other. (With the air input ports of the actuator body facing
from within the actuator. Do not rely upon the features you, the left hand piston rack should be on the side with
or controls of any auxiliary device to release the air from the air ports.) This is the third easiest method, and allows
inside the actuator to render it safe for disassembly. the actuator to be mounted with its long side parallel to the
pipeline, and clockwise to close rotation to be maintained.
4
Fail Closed Assemblies SETTING THE TRAVEL STOPS

If the actuator is attached to a valve, the butterfly valve The final step in the installation process is to check the
is shipped in the full closed position (as no air pressure is travel stop settings. The travel stops are set for 90° of travel
present to compress the springs and open the disc). at the factory; however, each installation is different so they
should be checked before putting the valve in service. The
actuators are designed with a nominal 5° over or under
travel at each end of rotation. A screwdriver, an open end
or box end wrench and a hex wrench, of the appropriate
Installing the valve with the disc in the full closed position size, are the only tools required to make the necessary
may create a compression set on the seat causing higher adjustments. Refer to Figure 1 below.
than expected torques or premature seat failure. It is
recommended to:
• Remove the actuator. Be sure to scribe the valve and
actuator to ensure the re-installed actuator is in the Before setting the travel stops, the pneumatic air supply
exact same quadrant as originally configured must be completely disconnected from the actuator,
• Install the valve per the attached installation tag and all compressed air stored within the actuator must
instructions be released. Auxiliary devices connected to the actuator,
such as tubing, ball valves, solenoid air valves, valve
• Re-install the actuator ensuring it is in the proper positioners, etc. can block the release of air from within
quadrant the actuator. Do not rely upon the features or controls
MOUNTING THE ACTUATOR TO THE VALVE of any auxiliary device to release the air from inside the
actuator to render it safe for disassembly.
The actuator is attached to the valve by means of the studs
and nuts furnished in the mounting kit. Thread the studs Remove the black Position Indicator Pointer (23) to expose
into the proper holes in the actuator, before installing the the wrench flats on the top of the Pinion (3).
actuator on the valve. The studs should be snug in the
Rotate the valve to the desired position by using a wrench
bottom of the tapped holes; there is no need to torque
on the wrench flats on the top of the Pinion (3).
them. Install the actuator on the valve making sure that
the base of the actuator fits flat against the valve mounting Loosen the Lock Nut (12) on the Travel Stop Screw (13). It
flange. Use the nuts and washers from the kit to complete is not necessary to remove the nut completely. Using the
the installation. Torque the nuts in a diagonal pattern to hex wrench, turn the screw in or out until the desired travel
assure equal loading of the studs. stop position is reached. While holding the screw with the
Figure 1
23
5°
13
12
5°
5
hex wrench, tighten the Lock Nut (12) with the box end
wrench. NOTICE
Replace the Position Indicator Pointer (23) making certain
the pointer is aligned with the position of the valve, open To lengthen service life, it is strongly recommended
or closed. that an adequately sized filter with a 40 micron (or
finer) element be installed adjacent to the inlet of the
Some valves or operating conditions require that the directional control (solenoid air) valve. Air lubricators are
actuator have more than 5° of travel adjustment. For these recommended for rapid cycling applications (10 cycles or
conditions, the Series 92/93 actuator can be fitted with more per minute.)
extended travel stops in the end caps. (See page page 11
for instructions on finding dimensional data) Consult the Routine maintenance of Series 92/93 actuators consists
Bray distributor in your area for this option. primarily of maintaining the air supply system by changing
Spring return actuators may be operated with only one air filter elements before they start by-passing, adding oil to
supply connected to Port A, since the spring cartridges will lubricators before they run dry, and preventing water from
move the pistons when the air pressure in removed. This entering the air lines.
operation, however, will draw the surrounding atmosphere The second most common cause of shortened service life is
into the spring chambers through Port B. misalignment between the valve and the actuator. This can
cause premature failure due to excessive side loads on the
bearings and gear teeth.
NOTICE
To prevent contamination from entering the spring NOTICE
chamber, actuators configured to operate with only one
air supply connected to Port A should be equipped with a To lengthen service life, the mechanical connection
40 micron (or finer) filter element installed in Port B. between the actuator and the valve should be verified to
be properly aligned and free to rotate throughout the full
Even better service may be obtained on spring return range of valve travel.
actuators by installing a four-way solenoid, covering both
Port A and Port B. A four-way solenoid will fill the spring
chambers with compressed air from the plant air supply
with each stroke. The plant air supply is often cleaner than
the surrounding atmosphere, especially in heavy industrial
or chemical areas.
MAINTENANCE
The rugged components and factory lubrication combine
to ensure a long and trouble-free service life for Series
92/93 actuators. Dirt, rust and water are the most common
causes for shortened service life, and they typically enter
the actuator through the air supply line.
Remove any dirt, rust, water or other contaminants from
inside the actuator. Any damaged or corroded components
must be replaced.
6
TROUBLESHOOTING
Table 1 shows several common symptoms and their remedies.
Table 1
Symptom Probable Cause Check Remedy

Loss of Power Low air supply pressure, or Air supply pressure at Boost air supply pressure, repair air
damaged O-rings actuator, leakage across supply line leaks, replace O-rings
O-rings
Binding between valve Misalignment of coupling Alignment Realign coupling
and actuator
Valve “pops” out of Valve torque too high, Valve torque, actuator Repair valve, use proper size
seat and slams open actuator sized too small, or sizing calculations, size actuator, use larger air supply lines
insufficient air supply flow of air supply lines and/or and/or solenoid valve with higher
solenoid valve flow
Air Leakage Loose fasteners or worn, Fasteners and travel stop Tighten fasteners, travel stop lock
damaged seals lock nuts nuts. Replace o-rings.
ASSEMBLY Travel Stop Screws (13) - Slip the o-ring (14) over the flat
end of the screw until it is 5-7 threads from the end. Thread
To identify component names and shapes and for the the screw into the hole in the body, flat end first. Repeat
numbers in parentheses ( ) below, refer to the exploded these steps for the second screw. Thread the lock nuts (12)
view of the actuator shown on Figure 3, page 12. onto the screws and tighten the nuts against the body. This
Easiest assembly will result from lubricating all bearings will seal the threads for testing. It is not necessary to set the
and seals as they are installed. The lubricant should be a travel stops at this time, as they may have to be reset when
high pressure or extreme pressure petroleum grease with the actuator is installed on the valve.
a lithium based thickener which meets the NLGI grade 2.
Grease which meets this specification should be available Pistons (2) - Install the bearing pad (10) on the back of
from any automotive supply store. the rack and the o-ring (19) and guide ring (11) in their
appropriate piston grooves. The o-ring goes in the groove
Pinion (3) - Install bearing rings (6 & 7) and o-rings (21 & nearest the rack. With the ports on the actuator body
22) in their appropriate grooves. Insert the pinion through toward you, turn the pinion so that the slot is approximately
the large hole in the center bottom of the body (1). With 45° to the right of perpendicular with the long side of the
the pinion part of the way into the body, slide the cam body. Grasp the pistons in the spring pockets so that the
(16) over the pinion being careful to align the punch mark piston in the right hand has the bearing pad toward you
on the cam with the punch mark(s) on the pinion. For and the piston in the left hand has the bearing pad away
normal installation and rotation (Fail Close), align the single from you. Slide the pistons into the body so that they both
marks. For Fail Open operation described in Method 2 on engage the teeth on the pinion at the same time. Apply
page 4, align the single mark on the cam with the two enough steady force to compress the o-ring into the body
marks on the pinion. For Fail Open operation described bore. At this point, you may continue pushing or use a
in Method 3 on page 4, align the single marks. Next, wrench on the top of the pinion to pull the pistons into the
install the spacer (15) above the cam. Then insert the pinion body.
through the hole at the top of the body and secure it with
the washer (9) and retaining ring (8).
7
FINAL ASSEMBLY AND TESTING

NOTICE
Three important parameters must be verified before

assembly may be continued.
The pinion must turn clockwise as the pistons moved Do not connect a compressed air supply to the actuator
toward the center of the body. that exceeds the pressure rating of the actuator (140 psig
/ 10 barg)
The 4 mm slot in the top of the pinion must be within
a few degrees of perpendicular to the long side of the Connect the compressed air supply to the actuator input
body. ports and cycle the actuator fully open and fully closed to
check for proper travel and absence of air leaks. Air supply
The piston faces must both be the same distance from lines should have a minimum inside diameter of 0.250” (6
the end of the body. mm). Restricted air supply lines, or any portion of the air
If all three parameters above have been verified, the end supply system powering the actuator (such as solenoid air
caps may be installed. valves or valve manifolds) can reduce actuation time, cause
unexpected popping of the valve, or even malfunction.
If any parameter above is not verified, use a wrench on the
pinion to drive the pistons out of the body and repeat the If compressed air is applied to Port A and the actuator
insertion process. It is not necessary to remove the pistons reaches the end of travel, there should be no air flow out of
from the body unless the answer to the first question is no. Port B, and vice versa. There should be no air flow between
It is only necessary to disengage the piston rack from the the end caps and the body, through the travel stops, or out
pinion. the top or the bottom of the pinion. A solution of soap and
water applied to the sealing points can indicate leaks that
are too small to be audible.
NOTICE
DISASSEMBLY
The assembly procedure described here is the standard
Fail Close method. For Fail Open actuators, refer to
Method 2 or Method 3 on page 4.
End Caps (4) - Install the o-ring (20) in the groove. Attach
Before disassembly of the actuator, the pneumatic
the end cap to the body with the 4 bolts (17) and washers
air supply must be completely disconnected from the
(18) making certain that the straight part of the o-ring
actuator, and all compressed air stored within the
groove is toward the bottom of the body. The air pressure
actuator must be released. Auxiliary devices connected
will not flow to the outboard side of the pistons if the
to the actuator, such as tubing, ball valves, solenoid air
straight part of the o-ring groove is at the top.
valves, valve positioners, etc. can block the release of air
Position Indicator (23) - Install the position indicator from within the actuator. Do not rely upon the features
pointer on the top of the pinion and secure it with the flat or controls of any auxiliary device to release the air from
head screw (24). Normally, the long axis of the pointer will inside the actuator to render it safe for disassembly.
be parallel to the groove in the pinion. If the actuator is
installed across the pipe line, as described in Method 1 on
page 4, the indicator should be turned so that it is in
line with the butterfly valve disc or port in the ball or plug
valve.
8
ADDING SPRING CARTRIDGES
Some actuators may have spring cartridges installed.

into the relaxed (fully extended) position. All compressed Before disassembly of the actuator, the pneumatic
air must be removed from inside the actuator (See air supply must be completely disconnected from the
warning on previous page 8) and the actuator pinion actuator, and all compressed air stored within the
must be allowed to rotate so the springs may be relaxed. actuator must be released. Auxiliary devices connected
Care must be taken to verify that any device connected to to the actuator, such as tubing, ball valves, solenoid air
the actuator, such as a valve mounted underneath, is not valves, valve positioners, etc. can block the release of air
preventing the movement of the springs to the relaxed from within the actuator. Do not rely upon the features
position. or controls of any auxiliary device to release the air from
inside the actuator to render it safe for disassembly.
Move the pinion to the fully closed (0°) position. Remove

If the actuator is installed on a valve, remove the actuator the end caps and insert the desired number of spring
from the valve, and move the actuator to a clean work cartridges into the end cap pockets, up to a maximum of
area. Remove the indicator pointer. Remove both end caps six cartridges per end cap.
by loosening the hex head end cap bolts. Remove both
pistons by rotating the pinion counter-clockwise until the
piston heads are protruding from the body. Pull the pistons NOTICE
out. Using snap-ring pliers, remove the pinion retaining
ring and acetal washer, then remove the pinion from the For proper operation, actuators equipped with Spring
body. The pinion bearings, o-rings, cam and spacer may Cartridges should have the spring cartridges installed in
then be removed. accordance with the positions shown in Figure 2.
Align the end cap with the body so the spring cartridges
fit into the piston pockets. Attach the end caps to the
body with the hex head end cap bolts. Tighten the bolts
gradually in a diagonal sequence.
Proceed to Final Assembly and Testing.
Figure 2
XX
2 SPRINGS 3 SPRINGS
XX = SIZE CODE EACH PISTON EACH PISTON
XX XX
4 SPRINGS 5 SPRINGS 6 SPRINGS

EACH PISTON EACH PISTON EACH PISTON
9
REMOVING SPRING CARTRIDGES
When removing end caps from an actuator containing

spring cartridges, the end cap bolts must be loosened
Before disassembly of the actuator, the pneumatic gradually in a diagonal sequence until the spring
air supply must be completely disconnected from the cartridges are completely relaxed (fully extended.) The
actuator, and all compressed air stored within the spring cartridges should reach the completely relaxed
actuator must be released. Auxiliary devices connected (fully extended) position while all four end cap bolts still
to the actuator, such as tubing, ball valves, solenoid air have some thread engagement with the actuator body.
valves, valve positioners, etc. can block the release of air Do not remove three end cap bolts completely from the
from within the actuator. Do not rely upon the features body and expect the remaining single bolt to hold the
or controls of any auxiliary device to release the air from spring cartridges in a compressed position.
inside the actuator to render it safe for disassembly.
Remove the spring cartridges. Replace the end caps and
tighten the end cap bolts gradually in a diagonal sequence.

into the relaxed (fully extended) position. All compressed
air must be removed from inside the actuator (See When replacing end caps onto an actuator containing
warning above) and the actuator pinion must be allowed spring cartridges, the end cap bolts must be tightened
to rotate so the springs may be relaxed. Care must be gradually in a diagonal sequence until the spring
taken to verify that any device connected to the actuator, cartridges are slightly compressed into their fail position.
such as a valve mounted underneath, is not preventing The spring cartridges should reach the slightly compressed
the movement of the springs to the relaxed position. fail position while all four end cap bolts have some thread
engagement with the actuator body. Do not attempt
An actuator with spring cartridges installed and no to tighten a single end cap bolt fully and compress the
compressed air connected will move to the spring fail spring cartridges while the other three bolts have not
position if the pinion is free to rotate. This may be either been installed.
fully closed (0°) or fully open (90°). In either case, when
the spring fail position is reached, remove the end caps Proceed to Final Assembly and Testing.
by gradually loosening the hex head end cap bolts in a
diagonal sequence.
10
GENERAL PNEUMATIC SYSTEM DIMENSIONAL DATA

RECOMMENDATIONS For Dimensions see Bray ES Drawings:
To maintain maximum efficiency with the Series 92/93 • ES11A-0460
actuator, as well as many other pneumatic devices, the • ES11A-0533
following suggestions are offered: • ES11A-0534
• ES12A-0533
• Air supply lines should be run in accordance with • ES12A-0534
a Standard Piping Practice, and should not have on www.bray.com
exaggerated loops, which may trap condensate.
• All pipe ends should be thoroughly cleaned and
deburred after cutting to ensure that the pipeline is
clear of cuttings.
• Where air pipelines are subjected to extremes of
temperature, the system should be fitted with air
drying equipment.
• If pipelines are hydraulically tested, the lines should be
“blown down” with high pressure air to clear all water
prior to connecting the lines to the actuator.
• Where a system is dependent on air filter equipment,
the air filters should be in positions that allow easy
access for maintenance and/or draining.
• Where pneumatic valve positioners or pneumatic
controllers are installed in a valve actuator assembly,
oil mist lubricated air should not be used unless the
manufacturer states specifically that the positioner or
controller is compatible with lubricated air. In general,
lubricated air is not recommended for a positioner.
• Where pipe fitting sealants or tapes are used, they
should be applied to the male threads only, and limited
to the first three threads. When applied to female
threads, excess compound or tape can be transmitted
into the actuator control lines and cause malfunctions
in downstream equipment.
• Lubricators should be installed downstream of
regulators.
• Eliminate or minimize sharp bends in the air supply
lines.
11
Figure 3:
Series 92/93 Exploded View
24
11
23 19
8
9
1
2
20
5 10
13 14 12 Item
Qty. Description
No
15 1 1 Body
2 2 Piston
3 1 Pinion
16
4 2 End Cap
12
21 5
max.
Spring Cartridge*
6 6 1 Upper Pinion Bearing*

7 1 Lower Pinion Bearing*
8 1 Retaining Ring
9 1 Washer, Acetal*
17 18 4
10 2 Bearing Pad, Acetal*
3 11 2 Guide Ring, Acetal*
12 2 Lock Nut
13 2 Travel Stop Screw
14 2 O-ring, Travel Stop
15 1 Spacer, Int. Travel Stop
7 16 1 Cam, Internal Travel Stop
22 17 8 Hex Head Cap Screw

18 8 Washer, Stainless Steel
19 2 O-ring, Piston
20 2 O-ring, End Cap
21 1 O-ring, Upper Pinion
22 1 O-ring, Lower Pinion
23 1 Position Indicator Pointer*
24 1 Flat Head Screw
*Extreme temperature trim actuator (-90U) uses proprietary components. Do not install other trim (Low, Standard, High) components.
Only install components designed for the designated actuator trim. Contact Bray for service requirements.
12
All statements, technical information, and
recommendations in this bulletin are for general use Bray Controls
only. Consult Bray representatives or factory for the
A Division of Bray International, Inc.
specific requirements and material selection for your
intended application. The right to change or modify 13333 Westland East Blvd.
product design or product without prior notice is reserved. Houston, Texas 77041
Patents issued and applied for worldwide. Tel: 281.894.5454 • www.bray.com
Bray® is a registered trademark of Bray International, Inc.
© 2016 Bray International, Inc. All rights reserved.
OM_92/93_07_2016
Z-Series: Metric Components
Service Manual
This service manual includes installation, operation, and maintenance instructions for
Ampco Pump Company’s Z-Series: ZCM and ZCHM. Failure to learn the correct procedures
for installing and servicing the pump from this manual could result in equipment failure.
Ampco Pumps Company
PUMP INSTALLATION
Receiving pumps:
Visually inspect shipping crate(s)/pallet(s) for damage. Ampco pumps will be shipped in
boxes labeled Ampco Pumps or in crates. If there is any damage it is imperative to notify the
driver at the time of delivery. Failure to do so will make it difficult, if not impossible, to file a
damage claim and Ampco Pumps will not be held accountable. Please contact Ampco Pumps
shipping department with damage details ASAP.
Once unpacked, carefully inspect the pump for any damage that may have occurred during
shipping. Attempt to turn the impeller, it should turn freely. There should be a little noise from
the seal which is normal. If there is metal-to-metal contact when the impeller is turned then
shipping damage is likely. Leave the protective covers on the inlet and discharge connections
until the pump is installed and is ready to be connected to the piping to stop debris from
getting into the pump.
Pump Location
Use the following pump location guidelines to help ensure proper pump performance:
 Locate the pump so that the shortest and most direct possible suction piping can be
used.
 To facilitate priming, ensure a steady flow, and provide positive suction head, locate
the pump below system level, when possible.
 Ensure the NPSH available to the suction end is always equal-to or greater-than the
specified NPSH required on the pump performance curve by considering the pump’s
location in relation to the entire system.
Foundation (if applicable)
The base attached to the pumping unit has pre-drilled mounting holes so that the
pumping unit can be fixed to a foundation, providing a permanent rigid support. The
foundation is necessary in order to absorb vibration, strain, and shock on the pumping unit.
The foundation should be about 6 inches longer and wider than the pump base and have a
depth of about 20 times the diameter of the foundation bolts.
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Ampco Pumps Company
General Piping Notes
 Pipe hangars or other supports must be used at proper intervals to ensure proper piping
support near the pump. Do not use the pump to support piping!
 When flange bolts are tightened no strain should be transmitted to the pump, thus
suction and discharge piping should be supported independent of the pump and care
should be taken that the pump and piping are properly aligned.
 Piping must be as straight as possible. Avoid all unnecessary bends and fittings. When
bends are necessary use 45 or long-sweep 90 pipe fittings in order to decrease minor
friction losses.
 Make sure all flanged joints have matching inside diameters and properly aligned
mounting holes – especially close to the pump.
 Do not force piping when making connections. This can cause the impeller to rub
on the casing or premature seal failure.
Suction Piping
It is very important that suction piping be selected and installed such that it minimizes
pressure loss and allows sufficient liquid flow into the pump. A proper suction piping system
design can eliminate many NPSH problems. The following precautions should be followed to
ensure a proper suction piping system.
 Suction piping must be kept as direct as possible. It is suggested that any elbows be
kept at least 5 pipe diameters away from the pump’s suction flange.
 Suction piping length should be at least ten times the pipe diameter overall.
 When suction piping has a larger diameter than the pump suction opening an eccentric
reducer must be used, with the taper oriented down. (Note: Do not use a concentric
reducer)
 Suction piping must never have a smaller diameter than the pump suction opening.
 When possible, horizontal suction piping should follow an even gradient.
 For suction lift conditions it is recommended that the suction piping have a gradual
upward slope approaching the pump. For positive suction head the suction piping
should have a gradual downward slope approaching the pump.
2
Ampco Pumps Company
 High point such as loops or arcs must be avoided as they may create air pockets,
throttle the system, and produce erratic pumping.
 A valve must be installed in the suction piping in order to isolate the pump during
shutdown and maintenance, and to facilitate pump removal. If two or more pumps are
connected to a single suction line, each pump should be isolated by a separate valve.
 Gate valves need to be positioned so that air pockets are not produced. If NPSH is
critical, globe valves should not be used. (Note: During operation all valves
installed on the suction line must be at full open)
 To enable the pump operator to monitor pump performance, properly sized pressure
gauges may be installed in gauge taps on pump suction and discharge nozzles.
Pressure gauges will also indicate the presence of cavitation, vapor binding, or other
unstable operation by showing wide fluctuations in suction and discharge pressures.
For these reasons Ampco highly recommends gauges.
Discharge Piping
To ensure proper pump performance the following precautions regarding discharge

piping should be followed:
 If the discharge piping distance is short the piping can be the same diameter as the
pump discharge opening.
 Long horizontal lengths of discharge piping should maintain an even gradient.
 A valve needs to be installed near the pump’s discharge opening to prime and start the
pump, as well as to isolate the pump during shutdown, maintenance, and to facilitate
pump removal.
 High points should be avoided in discharge piping as they can entrap air or gas and
retard pump operation.
 If liquid hammer might exist, such as when check valves are used, the discharge gate
valve should be closed prior to pump shutdown.
3
Ampco Pumps Company
Priming
The Z-Series pump is not a self-priming pump and must be completely filled
with the pumping liquid before operation. If the system has a positive suction head priming
can be done by opening the valve in the suction piping as well as the pump’s air vents to allow
the liquid to enter the pump casing. Rotate the shaft by hand to free entrapped air from the
impeller and then ensure that all air has been forced out by the liquid before closing the air
vents. If the pump has a suction lift, priming must be done by using foot valves, ejectors or
manual filling of the pump casing.
CAUTION!
Running the pump dry will result in
serious damage to the mechanical seal.
Pre-Start Checklist
Before operating the Z-Series pump ensure that all of the following requirements are met
o Check that all motor and starting device wirings match the wiring diagram.
o Make sure the shaft rotates clockwise when viewed from behind the motor.
o Refer to motor instructions before starting if the motor has not been operated over an
extended period of time.
o Make sure that that voltage, phase, and line circuit frequency match what is specified
on the motor data plate.
o Turn shaft by hand to make sure it rotates freely.
o Tighten all gauge and drain tap plugs. When not in use, close the gauge cocks on
pumps fitted with pressure gauges.
o Check that all flange bolts are tightened and the suction and discharge piping is not
leaking.
Pump Operation
WARNING
Operating the pump without an approved
coupling guard installed could result in
operating personnel injury.
Start Up Instructions
1. Set the suction line gate valve to full open and close the discharge line gate valve.
2. Fill the suction line and prime the pump.
3. Start the motor and immediately check the pump and suction piping for leaks.
4. As soon as the pump reaches operating speed, open the discharge gate slowly until
complete system flow is achieved. There may be valve chatter during transient period
4
Ampco Pumps Company
during valve adjustment. Be aware that the pump’s motor is specified for the flow and
pressure specified by the customer and that higher flow rates could damage the motor.
5. Check for leaks in the discharge piping.
6. (For pumps with pressure gauges) Open gauge cocks and record pressure reading.
Check that the pump is performing as specified by the performance curve.
Shut Down Instructions
(Note: If the pump will be shut down for an extended period refer to the Extended Duration
Shutdown)
1. Slowly close the discharge piping gate valve. (Closing valve too quickly can cause
hydraulic shock)
2. Turn off power supply to the pump.
Short Duration Shutdown
For short shutdown periods the pump can remain filled but make sure the pump is
fully primed prior to restarting. If the pump is subject to freezing conditions then the pump
exterior should be insulated or heated and the fluid within the pump casing must be kept
moving in order to prevent freezing.
Extended Duration Shutdown
For extended duration shutdowns close the suction piping gate valve or if no suction
valve is installed then drain the suction line to stop liquid flow to the suction nozzle. Remove
pump drain and vent tap plugs as required and completely drain the pump casing. If the pump
will be subjected to freezing conditions during shutdown then all liquid must be completely
blown out of all passages and pockets using compressed air or the pump must be filled with an
antifreeze solution to prevent damage.
Assembly – ZCM/ZCHM
*Refer to the parts list appended to this

manual for the part name and quantity
corresponding to each number in Figure 9.
1) Begin with the bare motor. Ensure that the

shaft and C-face areas are clean.
2) Attach the stub shaft [6] and locking collar

[7] to the motor and the motor adapter [5] as
shown in Figure 1.
Figure 1: Step 2 Illustration
5
Ampco Pumps Company
3) Measure the stub shafts axial location with

respect to the outer-most face on the adapter
as shown in Figure 2. This will dictate the
impeller clearance to the pump casing. Once
the dimension is set, tighten the collar screw
to 20 ft-lbs [27 Nm]. Ensure that the collar [7]
remains all the way against the shoulder on
the stub shaft [6] (in the outboard direction).
Once the stub shaft’s axial location is set, do
not remove the screw unless you believe it is
Figure 3: Step 4.1, stationary seal into stuffing box
not in its original location.
Figure 4: Step 4.2, cover mounted to adapter
5) The shaft sleeve [12] should now be

prepped by applying the seal and o-rings
[13+14]. Use temporary rubber emulsion or
water and push on the rotating seal portion
[15+18+19] of the elastomer bellows seal
onto the shaft sleeve [12]. Put the o-ring(s)
Figure 2: Shaft to adapter measurement [13+14] into their grooves in the shaft sleeve
and then place the seal spring into the
rotating seal element. Once the shaft sleeve is
prepped, push it onto the stub shaft until it
4) The remaining pump assembly is now ready seats against the
to be performed. (For double seal assembly shoulder.
refer to instructions listed in Appendix B) First
the stationary seal [16+17] must be pressed
into the cover or stuffing box [4]. Temporary
rubber emulsion or water should be used on
the elastomer, and the seal should be pressed
in by hand. Attach the cover to the pump
adapter [5], or attach the stuffing box to the
cover. Then place the cover in the pump Figure 5: Stub shaft preparation
adapter. This may require screws with the
large flat covers. 6) Place the casing gasket [9] onto its spot on
the cover [4].
6
Ampco Pumps Company
please repeat step 2 and ensure you have the

correct measurement.
Figure 6: Cover gasket on to cover
7) Place the key [22] into the stub shaft [6]

and align it so it also engages in the shaft
sleeve [12]. If you have a stepped key, the
taller side goes toward the motor. Install the
impeller [3] onto the shaft [6]. Apply the
gasket or o-ring [11] and torque the impeller
screw to 50-60 ft-lbs [68-81 Nm]. Use blue
thread-locker on the threads. Figure 8: Step 8 illustration
Figure 7: Step 7 illustration
8) Ensure the impeller does not rub against

the cover by turning it by hand. You are now
ready to attach the pump casing [1]. Have the
screws ready and apply the casing to the
cover. Tighten all the casing screws in an
alternating fashion to 25 ft-lbs [34 Nm].
Again, check the pump for rubbing by rotating

the stub shaft. If the impeller contacts, look
into the suction flange on the pump and see if
it is bound against the front wear ring. If it is,
7
Ampco Pumps Company
Figure 9: Type 21 seal cross section parts diagram
8
Appendix: A
Parts List
Number Description Qty. per pump

1 Pump Casing 1
2 Casing Wear Ring 1
3 Impeller 1
4 Rear cover 1
5 Motor Adapter 1
6 Stub Shaft 1
7 Shaft Collar 1
8 Adapter Guard 2
9 Cover Gasket 1
10 Impeller Screw 1
11 Impeller O-Ring 1
12 Shaft Sleeve 1
13 Shaft Sleeve O-Ring 1 1
14 Shaft Sleeve O-Ring 2 1
15 Seal: Spring 1
16 Seal: Cup 1
17 Seal: Seat 1
18 Seal: Face 1
19 Seal: Retainer 1
20 Cover screws 8
21 Motor 1
22 Shaft Key 1
9
Appendix: B
Double Seal Assembly Instructions

*Refer to Figure 11 for part numbers referenced within double seal assembly instructions.
The double seal-supplied pumps require sub-assembly of the stuffing box prior to installation
on the pump. Below are the steps required (Refer to Figure 10 and Figure 11):
1. Press the inboard stationary seal [2] into the inner cavity of the stuffing box [1]
(DX8307347)
2. Press the outboard stationary seal [7] into the gland [9] (DX8307337)
3. Prepare the shaft sleeve [3] (DX8307367):
(Refer to Figure 9)
a. With the flanged edge facing the inboard direction (toward the impeller) first
put the shaft sleeve through the seal face in step 1. Apply the inboard rotating
seal [4] onto the shaft sleeve with the use of temporary rubber emulsion
lubricant or clean water. You must do this sideways as gravity will allow the
inboard seal face to drop out of the bellows.
b. Place the spring [5] onto the shaft sleeve and make sure it seats around the
inboard seal from step 3a.
c. Apply the outboard rotating seal [6] onto the shaft sleeve in the reverse direction
of the inboard seal again using temporary rubber emulsion lubricant or clean
water.
Figure 10: Double Seal
10
Appendix: B
Double Seal Assembly Instructions

4. Place the gland [9] with the outboard stationary seal so that it locates on its pilot in
the rear of the stuffing box. Do not forget the o-ring [8] (GX5042814)
5. Tighten the 4 screws [11/10] (GX5501110) evenly and carefully.
6. Prepare the shaft sleeve: Place the O-ring in the groove inside the sleeve, and the O-ring on
the shoulder’s face– the double seal sub-assembly is now complete and can be
assembled onto the pump. Slide the shaft sleeve onto the stub shaft until it seats on
the shoulder of the shaft.
Continue pump assembly with step 6.
Figure 11: Double seal parts list
Number Description Qty. per pump

1 Stuffing Box 1
2 Inboard Stationary Seal 1
3 Shaft Sleeve 1
4 Inboard Rotating Seal 1
5 Seal Spring 1
6 Outboard Rotating Seal 1
7 Outboard Stationary Seal 1
8 Gland O-Ring 2
9 Gland 1
10 Washer 1
11 Hex Screw 1
11
CERTIFICATES
Certificate No:
TAP000001C
Revision No:
2
This is to certify:
That the Ballast Water Management System
with type designation(s)

Trojan Marinex BWT™ Model 150, Model 250, Model 500, Model 750, Model 1000, Model 1250,
Model 1500, Model 150Ex, Model 250Ex, Model 500Ex, Model 750Ex, Model 1000Ex, Model
1250Ex, Model 1500Ex
Issued to
Trojan Technologies
London ON, Canada
is found to comply with

Resolution MEPC.174(58)
DNV GL rules for classification – Ships
DNV GL class programme DNVGL-CP-0209 – Type approval – Ballast water management
systems
Application :
This is to certify that the Ballast Water Management System listed above has been examined
and tested in accordance with the requirements of the specifications contained in Guidelines
contained in Resolution MEPC.174(58) and DNV GL Rules stated above. This Certificate is valid
only for the Ballast Water Management System referred to above.
This Certificate is issued on behalf of the Norwegian Maritime Directorate.
Product(s) approved by this certificate is/are accepted for installation on all vessels classed
by DNV GL.
Operating media:
This Certificate is valid until 2018-06-30.


Issued at Høvik on 2017-01-25

for DNV GL
DNV GL local station: Montreal Digitally Signed By:
Sæle-Nilsen, Dag
Location: DNV GL Høvik, Norway
Approval Engineer: Tone Knudsen Fiskeseth Signing Date: 25.01.2017
Dag Sæle-Nilsen
Head of Section
This Certificate is subject to terms and conditions overleaf. Any significant change in design or construction may render this Certificate invalid.
The validity date relates to the Type Approval Certificate and not to the approval of equipment/systems installed.
Form code: TA 1411a Revision: 2015-05 www.dnvgl.com Page 1 of 8

© DNV GL 2014. DNV GL and the Horizon Graphic are trademarks of DNV GL AS.
Job Id: 262.1-009316-4
Certificate No: TAP000001C
Revision No: 2
Type and model designation

Trojan Marinex BWTTM
Model 150, Model 250, Model 500, Model 750, Model 1000, Model 1250, Model 1500,
Model 150Ex, Model 250 Ex, Model 500Ex, Model 750Ex, Model 1000Ex, Model 1250Ex, Model 1500Ex
Place of production: Trojan Technologies, London, Canada
Equipment / assembly drawings

Type Description Dwg Nr. Rev.
Piping and instrumentation diagram P&ID, MARINEX OVERVIEW 928002 G
Standard System
Wiring diagram WD,MRX OVERVIEW 150/ 250 CB 506542 K
Wiring diagram WD,MRX OVERVIEW 500/ 750 - OR 506276 E
Wiring diagram WD,MRX OVERVIEW 500/750CB 507257G C
Wiring diagram WD,MRX OVERVIEW 1000-1500 OR 506776 D
Wiring diagram WD,MRX OVERVIEW 1000-1500CB 507252G B
Ex-System
Wiring diagram WD,MRX OVERVIEW 150/ 250Ex 508073 C
Wiring diagram WD,MRX OVERVIEW 500/750Ex 508093 C
Wiring diagram WD,MRX OVERVIEW 1000-1500Ex 508113 C
Equipment / assembly drawings – Inline Driver Configuration

Standard System
Piping and instrumentation diagram P&ID, MARINEX INLINE 928002 G
Wiring diagram WD, MRX OVERVIEW INLINE MX0305 F
Product description
Separation by filtration and ultraviolet germicidal irradiation
Treatment sequence:
 Ballast water uptake: filtration and UV disinfection
 Ballast water discharge: UV disinfection

Job Id: 262.1-009316-4
Revision No: 2
Application / limitation
System Treatment Rated Capacity1 (m3/h)
Trojan Marinex BWTTM Model 150 or 150Ex 150
TM
Trojan Marinex BWT Model 500 or 500Ex 500
TM
TM
1) TRC is defined as net flow out of the treatment system, a net flow exceeding the given value implies
that the ballast water is not treated in accordance with this certificate.
UV intensity below 2 mw/cm2, corresponding to an UV transmission of 44% for these systems, implies
that the ballast water is not treated in accordance with this certificate.
Salinity or temperature of the water is not limiting conditions for the ballast water treatment system.
Several treatment units can be installed in parallel for higher flow rates. The flow rates through
individual treatment units must have flow control and the arrangement must be approved by DNV GL on
a case by case basis.
Stripping operation can be performed with unfiltered drive water. The flow rate for the UV treatment
shall not exceed 1/3 of TRC during stripping operation.
Operational specifications for the different components
Flow Meter and Flow Control Valve

The type approved system must be installed with a flow meter and a flow control valve, as per the
approved P&ID.
Information regarding the selected components shall be part of the documentation related to the specific
installation, either by a reference to a valid type approval certificate or technical documentation.
Filter Element
Multiple filter meshes, listed in Technical Specification – Marinex Filter Mesh, revision 1, dated 2013-11-
19, are approved for manufacture of filter candle part# 506723-32.

Job Id: 262.1-009316-4
Revision No: 2
Control Equipment
The type approved system includes the following control units and sensors:
Lamp Driver Cabinet Configuration
Name Applicable Models Model name Software revision

Control Power Model 150, 250 CPC ASSY, MRX PLC
Cabinet Model 150Ex, 250Ex 150/250 or 040.079.001.xxxx.xxx
CPC ASSY, MRX HMI
150/250Ex 040.038.001.xxxx.xxx
Model 500, 750 CPC ASSY, MRX
500/750
Model 1000, 1250, 1500 CPC ASSY, MRX 1000-
1500
Control Cabinet Model 500, 750 CC ASSY, MRX 500/750 PLC
Model 500Ex, 750Ex or 040.079.001.xxxx.xxx
CC ASSY, MRX HMI
500/750Ex 040.038.001.xxxx.xxx
Model 1000, 1250, 1500 CC ASSY, MRX 1000-
Model 1000Ex, 1250Ex, 1500 or
1500Ex CC ASSY, MRX 1000-
1500Ex
Power Distribution Model 500, 750 PDC ASSY, MRX NA
Cabinet Model 500Ex, 750Ex 500/750 or
PDC ASSY, MRX
500/750Ex
Model 1000, 1250, 1500 PDC ASSY, MRX 1000-
Model 1000Ex, 1250Ex, 1500 or
1500Ex PDC ASSY, MRX 1000-
1500Ex
Auxiliary Control All Models AUX CONTROL ASSY, HMI
Cabinet MRX 042.038.001.xxxx.xxx
Lamp Driver All models LDC ASSY, MRX AC or NA
Cabinet LDC ASSY, MRX LC or
LDC ASSY, MRX AC Ex
or
LDC ASSY, MRX LC Ex
or
LDC ASSY, MRX LC DBL
Hydraulic Cabinet All models HC ASSY, MRX NA
HC ASSY, MRX Ex
UV Sensor All models IL Metronic NA
Sensortechnik GmbH
SUV 20.2 Y2 C or
EX2C SUV20.2 A1 Y2
B1C

Job Id: 262.1-009316-4
Revision No: 2
InLine Driver Configuration
Name Applicable Models Model name Software revision

Control Cabinet All models CC ASSY, MRX PLC
040.071.001.xxx.xxx
HMI
040.031.001.xxx.xxx
Power Distribution Model 150, 250, 500, PDC ASSY, MRX 150 - NA
Cabinet 750 750
Model 1000, 1250, 1500 PDC ASSY, MRX 1000 -

1500
Auxilliary Control All Models AUX CONTROL ASSY, HMI
Cabinet MRX 040.031.001.xxx.xxx
UV Sensor All models IL Metronic NA
Sensortechnik GmbH
SUV 20.2 Y2 C or
EX2C SUV20.2 A1 Y2
B1C
All changes in software are to be recorded as long as the system is in use on-board. Major changes in
the software, defined in “Software Revision Control Standard, rev 1.0”, are to be approved before being
installed in the computer. Based on the modification, a certification of application functions may be
required for the particular vessel.
Explosion proof version Trojan Marinex

The Trojan Marinex Ex BWT system is designed for use in zone 1 hazardous area, group IIC T4.
The system is built up by components, individually certified, suitable for the use in the classified zone.
Ex-certification is not covered by this certificate. Installation in hazardous area is to be approved in each
case according to the Rules and Ex-Certification/ Special Condition for Safe Use listed in valid Ex-
certificate issued by a notified/recognized Certification Body.
Documents approval
The following documentation is to be submitted for approval in each case.
 Piping and Instrumentation Diagram (P&ID) of the ballast system including the treatment system
installation
 Power supply arrangement
 Description confirming the arrangement of alarms for bypass of the BWMS system (as part of
Ballast Water Management Plan)
 Interface description specifying external signals including alarms for failure

Job Id: 262.1-009316-4
Revision No: 2
 List of Ex equipment according to Pt.4, Ch.8, Sec.11, B100 if the system is to be installed in
hazardous zone
Type approval documentation
Biological test reports

 Test Plan – Biological efficacy performance evaluation of Ballast Water Management System
Trojan Marinex BWT 500 in land-based test, dated 2013-09-06
 Final report – Performance evaluation in land-based test facility Trojan Marinex BWT 500, dated
November 2013
 Final report - Performance evaluation in land-based test facility Trojan Marinex BWT 1250, dated
March 2014
 Test Quality Assurance Plan, Project Charlie, Volume I: Project Plan, 2012-05-09, revision A,
dated 2013-03-16
 Final Shipboard Report According to International Maritime Organization Guideline 8, Trojan
Marinex BWT 250, revision 1, dated 2013-12-12
 Final Shipboard Report According to International Maritime Organization Guideline 8 – summary
report for the Trojan Marinex™ BWT 250, dated 2013-12-12
 Performance evaluation in land - based test facility - summary report Trojan MarinexTM BWT 500
Filtration and UV disinfection, dated 2013-12-16
Environmental test reports

 Environmental and vibration test report, report number 100384932DET-018R, 101339850DET-
001a, 101339850DET-001b, 101382725DET-001, and 101382725DET-002, dated 2013-11-07
 Conducted Low Frequency Immunity test report, report number 101386177BOX-002, dated
2013-11-07
 EMC TEST REPORT, report number 100369176BOX-004, dated 2013-12-05
 DELTA Test Report – Test for Marine Type Approval of Trojan MarinexTM, report number DANAK-
19/15017, revision A
 DELTA Test Report - Supplementary test for Marine Type Approval of Trojan Marinex BWTTM,
report number DANAK-19/15190
 DELTA Test Report – Test for Marine Type Approval of Trojan MarinexTM, report number DANAK-
19/16513, dated 31 May 2016
System descriptive documentation

 Trojan Marinex™ BWT Operation and Maintenance User Manual, Original Instructions. Edition 5.
Document number DC280101-05-xx
 Trojan Marinex™ BWT Operation and Maintenance User Manual, Original Instructions. Edition 7.
Document number DC280101-07-xx (inline version)

Job Id: 262.1-009316-4
Revision No: 2
 Trojan Marinex™ BWT Installation Manual, Edition 7, document number DC2803xx-xx-xx

 Technical Manual Ballast Water Treatment (BWT) Models: 250, 500, report number 2013-10-08
v01
 Software Revision Control Standard, rev 1.0
 Controls Philosophy (CP), revision 1.5, dated 2015-05-28
 Factory Acceptance Test, revision 1.2
 Factory Acceptance Test, revision 2.2 (inline model)
 Technical Specification - Marinex Filter Mesh, revision 1, dated 2013-11-19
 Equipment Scaling Calculations, report nr. DS0075, revision A
 Equipment Scaling Calculations, report nr. DS0075, revision B (including inline model)
 Commisioning checklist, revision 1.9-01/2017
 Commisioning checklist, revision 1.3-09/2016 (inline version)
 Wiring diagrams: WD, MRX CC 150-1500 INLINE, 507579G rev.C; WD, MRX AUX CNTL CAB
INLINE, 507588 rev.B; WD, MRX PDC 1000-1500 INLINE, 507585G rev.C and WD, MRX PDC
150-750 INLINE, 507582G rev.C
Tests carried out

 Land-based testing in accordance with Resolution MEPC.174(58)
 Shipboard testing in accordance with Resolution MEPC.174(58)
 Scaling in accordance with BWM.2/Circ.33
 Type test of the control and automation system witnessed by DNV
 Testing in accordance with environmental test specification for instrumentation and automation
equipment, DNV Standard for Certification No. 2.4 (April 2006) and Resolution MEPC.174(58)
The Trojan Marinex BWTTM Model 250 was used for shipboard tests, Model 500 was used for land-based
tests and Model 1250 was used for scaling tests.
Testing parameters for the land-based and shipboard tests are described in the summary final test
reports following this certificate.
Marking of product
For traceability of this type approval, each treatment system is to be marked with:
 Manufacturer’s name or trade mark
 Type designation
 Serial number

Job Id: 262.1-009316-4
Revision No: 2
Periodical assessment
DNV GL’s surveyor is to be given permission to perform Periodical Assessments at any time during the
validity of this certificate and at least every second year. The arrangement is to be in accordance with
procedure described in DNVGL-CP-0338 Section 4.
The scope of periodical assessment includes:

 Ensure that type approved documentation is available
 Inspection of factory samples, selected at random from the production line (where practicable)
 Review of production and inspection routines, including test records from product sample tests
and control routines
 Ensuring that systems, software versions, components and/or materials used comply with type
approved documents and/or referenced system, software, component and material specifications
 Review of possible changes in design of systems, software versions, components, materials
and/or performance, and make sure that such changes do not affect the type approval given
 Ensuring traceability between manufacturer’s product type marking and the type approval
certificate
Copy of the type approval certificate

A copy of this type approval certificate should be carried on-board a vessel fitted with this ballast water
management system at all times. An annex containing the summary reports of the test results of land-
based and shipboard tests should be available for inspection on-board the vessel.

Certificate No:
TAA000019B
TYPE APPROVAL CERTIFICATE Revision No:
1
This is to certify:
That the Flow Transmitter
with type designation(s)

ProcessMaster Series FEP300 and FEP500
Issued to
ABB Engineering (Shanghai) Ltd.
Shanghai, China
is found to comply with

DNV GL rules for classification – Ships, offshore units, and high speed and light craft
Application :
Product(s) approved by this certificate is/are accepted for installation on all vessels classed
by DNV GL.
Location classes:
Temperature D
Humidity B
Vibration B
EMC A
Enclosure C/D
Issued at Hamburg on 2017-09-19

for DNV GL
This Certificate is valid until 2022-07-19.
DNV GL local station: Shanghai
Approval Engineer: Dariusz Lesniewski Joannis Papanuskas

Head of Section
This Certificate is subject to terms and conditions overleaf. Any significant change in design or construction may render this Certificate invalid.
The validity date relates to the Type Approval Certificate and not to the approval of equipment/systems installed.
Form code: TA 251 Revision: 2016-12 www.dnvgl.com Page 1 of 3
© DNV GL 2014. DNV GL and the Horizon Graphic are trademarks of DNV GL AS.
Job Id: 262.1-026954-1
Certificate No: TAA000019B
Revision No: 1
Product description
ProcessMaster electromagnetic flowmeter series FEP300 and series FEP500, comprising the following
models:
Model no.
FEP311 Compact design without explosion protection
FEP315 Compact design with explosion protection
FEP321 Remote design – Flowmeter sensor without explosion protection
FEP325 Remote design – Flowmeter sensor with explosion protection
FET321 Remote design – Transmitter without explosion protection
FET325 Remote design – Transmitter with explosion protection
FEP511 Compact design without explosion protection
FEP515 Compact design with explosion protection
FEP521 Remote design – Flowmeter sensor without explosion protection
FEP525 Remote design – Flowmeter sensor with explosion protection
FET521 Remote design – Transmitter without explosion protection
FET525 Remote design – Transmitter with explosion protection
Technical data
FEP300 measured value error: Standard 0.4% of rate, optional 0.2% of rate
FEP500 measured value error: Standard 0.3% of rate, optional 0.2% of rate
Transmitter housing and sensor material: Aluminium (Al) or stainless steel (SST)
Power supply specification: 100…230VAC 50/60Hz, 24VAC 50/60Hz or 24VDC
External communication protocols: Profibus PA, Foundation Fieldbus or HART 4-20 mA.
For further details, see respective data sheets as listed under Type Approval documentation.
Place(s) of manufacture
ABB Engineering (Shanghai) Co., Ltd.
Shanghai, China
ABB Automation Products GmbH

Göttingen, Germany
ABB Limited
Salterbeck Trading Estate
Workington, Cumbria CA14 5DS, UK
Application/Limitation
The Type Approval covers hardware listed under Product description. When the hardware is used in
applications to be classed by DNV GL, documentation for the actual application is to be submitted for
approval by the manufacturer of the application system in each case. Reference is made to DNV GL
Rules for Ships Pt.4 Ch.9 Control and Monitoring Systems.
Ex-certification is not covered by this certificate. Application in hazardous area to be approved in each
case according to the Rules and Ex-Certification/ Special Condition for Safe Use listed in valid Ex-
certificate issued by a notified/recognized Certification Body.
Ex-loops are to be documented according to the requirements in Pt.4 Ch.8 Sec.11.
Type Approval documentation

Drawings
Al housing: D323D628B01, D379D171B02, D379D172B02
SST housing: 3KQZ407019U0001, 3KQZ407021U0101, 3KQZ407023U0101

Job Id: 262.1-026954-1
Certificate No: TAA000019B
Revision No: 1
Technical documentation
Data sheet FEP300 – DS/FEP300-EN Rev. J
Data sheet FEP500 – DS/FEP500-EN Rev. C
Operating instructions FEX300, FEX500 – OI/FEX300/FEX500-EN Rev. F
Change notice for ProcessMaster FEP and FET – RAR_DNV_0033 dated 2013-12-05
Test reports
ProcessMaster DNV Test Outline dated Sep 2012
TÜV Nord test report no.08 799 353785-001 dated 2008-01-09 (IP enclosure FEP311/FEP321)
TÜV Nord test report no.08 799 353785-002 dated 2008-01-09 (IP enclosure FEP311/FEP321)
SITIIAS test report no. A12-067-WT-01 dated 2012-12-10 (EMC/Env. FEP311 230VAC/60Hz)
SITIIAS test report no. A12-067-WT-02 dated 2012-12-10 (EMC/Env. FEP325/FET325 24VDC)
SITIIAS test report no. A12-067-WT-03 dated 2012-12-10 (EMC/Env. FEP321/FET321 100VAC/50Hz)
SITIIAS test report no. A12-067-WT-04 dated 2012-12-10 (EMC/Env. FEP321/FET321 24VAC/50Hz)
Type approval periodical assessment report issued at Shanghai on 2017-05-31
Type approval periodical assessment report issued at Magdeburg on 2017-08-23
Type approval periodical assessment report issued at Workington on 2017-09-06
Tests carried out

Applicable tests according to class guideline DNVGL-CG-0339, November 2016.
Hydrostatic pressure test at 150% of design pressure.
Marking of product
The products to be marked with:
- manufacturer name
- model name
- serial number
- power supply ratings
Periodical assessment
The scope of the periodical assessment is to verify that the conditions stipulated for the type are
complied with, and that no alterations are made to the product design or choice of systems, software
versions, components and/or materials.
The main elements of the assessment are:
· Ensure that type approved documentation is available
· Inspection of factory samples, selected at random from the production line (where practicable)
· Review of production and inspection routines, including test records from product sample tests and
control routines
· Ensuring that systems, software versions, components and/or materials used comply with type
approved documents and/or referenced system, software, component and material specifications
· Review of possible changes in design of systems, software versions, components, materials and/or
performance, and make sure that such changes do not affect the type approval given
· Ensuring traceability between manufacturer’s product type marking and the type approval certificate
Periodical assessment is to be performed at least every second year and at renewal of this certificate.
END OF CERTIFICATE

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FINAL PACKAGE

GEA CRM No.: 30034667

Trojan Marinex™ Original Instructions

Trojan Marinex™ Original Instructions

HEAD OFFICE - CANADA

If you are unable to reach your local

Trojan Marinex™ Original Instructions

Trojan MarinexTM BWT

Operation is fully-automated and can be controlled

The Trojan Marinex BWT consists of the following principal components;

Electrical and Control Cabinets

Environmental Advantages of Trojan Marinex

Version 4 July 2017 1

Automatic Filter Backwash System

Version 4 July 2017 2

Ultraviolet Intensity (UVI) Sensor

Automatic Lamp Cleaning System

Power Distribution and Control Cabinets

Version 4 July 2017 3

Remote Control and Monitoring

Assembly & Manufacturing

Version 4 July 2017 4

Ship Automation System

Ready Ballast System Request Stop Ready

Operation Mode: Deballasting

Ship Automation System

System Stop Ready

Operation Mode: Tank Stripping

Version 4 July 2017 5

Version 4 July 2017 6

Technical Data Sheet - Standard Product - Inline Driver Configuration

System Pressure Loss (with clean filters) 0.2 bar

Control Cabinet: Power Distribution Cabinet (Select One):

Filter Mesh 32 µm, Super Duplex

Powered by Trojan Marinex BWT Power Distribution Cabinet

Power (kW) 0.18

Type of Duty S1 (IEC) 100%

Technical Data Sheet - Standard Product - Inline Driver Configuration

Maximum Working Pressure (bar) 68

Technical Data Sheet - Standard Product - Inline Driver Configuration

F13 F14 F15 F16

P12 P7 P24 P19 P8

© Trojan Technologies, 2017. All rights reserved. Printed in Canada. DC280101-07-04

2.2 Precautionary Labels

Hg This symbol indicates there is Mercury present.

This symbol indicates a potential pinch hazard.

This symbol indicates a fork lift hazard.

This symbol indicates a potential crush hazard.

This symbol indicates gloves must be worn.

This symbol indicates safety boots must be worn.

Personal Protective Equipment Required.

• ALWAYS use appropriate eye, hand, and foot protection.

• ALWAYS follow plant safety procedures and protocols.

2.4 Safety Features

3.1 Patents and Permissions

3.2 Abbreviations and Acronyms

HORIZONTAL INSTALLATION VERTICAL INSTALLATION

Figure 1 Treatment Unit (Connection View)

Figure 2 Treatment Unit

Figure 3 Inline TrojanUV Solo Lamp and Filter

Figure 4 Lamp Connection View Figure 5 Power Cable Connection View

Figure 6 Junction Box

3.3.1.1 Automatic UV Lamp Cleaning System

Figure 7 Treatment Unit