Manual de Operaciones Turbina de Vapor .

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Operating Manual
Steam turbine
Customer Alstom
Kassel
Order number
Engine type SST-050 (AF 4 Gs)
Engine number 4.144.242
Engine control Speed control
Year of construction 2009
Release date 10.2009
This operating manual is legally protected and may be used, especially reproduced, distributed or made available to third parties in
any other way only with our consent.
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The operating manual contains important notes and notes on

safety.
Please read carefully before commissioning.
The operating manual must by all means be available on the

turbine site.
Siemens Turbomachinery Equipment GmbH

Postfach 17 28 Heßheimer Straße 2
67207 Frankenthal 67227 Frankenthal
Deutschland Deutschland
Phone ++49 (0) 6233 / 85 - 0

Fax ++49 (0) 6233 / 85 - 2660
E-Mail turbines-frankenthal.energy@siemens.com
Net www.siemens.com/agkkk
Version history
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Version Date Description State
0.9 10.2009 Preliminary until Start-up preliminary
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1/1
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Part A
Operating Instructions
Turbine SST-050
(AF 4 Gs)
Engine 1
P&I pos. 1
Part number 41300001300
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A - Operating Instructions
Content
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Chapter Title
1 General
1.1 Preface
1.2 Copyright and trademark rights
1.3 Notes for the user
1.4 Staff qualification and training
2 Safety
2.1 General
2.2 Marking of notes
2.3 Notes on safety for operators/users
2.4 Notes on safety for operation
2.5 Notes on safety for maintenance
2.6 Notes on special danger
2.6.1 Electric energy
2.6.2 Steam
2.6.3 Hydraulics
2.6.4 Noise
2.6.5 Oils, greases and other chemical substances
2.7 Use for the purpose intended
2.8 Residual risk
3 Transport and storage
3.1 Transport with hoists
3.2 Storage and conservation
4 Description of the turbine
4.1 Design
4.1.1 Turbine rotor
4.1.2 Turbine housing and nozzle system
4.1.3 Shaft seal
4.2 Gearbox
4.3 Oil supply unit
4.4 Control system
4.4.1 Valves
4.4.2 Speed governor
4.5 Protective device
4.5.1 Trip valve
4.5.2 Overspeed
4.5.3 Lube oil pressure
4.5.4 Steam pressures and temperatures (customer side)
4.5.5 Oil temperature downstream of oil cooler
4.5.6 Bearing temperature - turbine (at the gearbox)
4.6 Monitoring units
4.7 Quick starting mechanism
4.7.1 Operation
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A - Operating Instructions
Content
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Chapter Title
5 Operating data
Pressure indications
5.1 Operating data and limit value
5.2 Design
5.3 Oil and bearing data
5.4 Required steam quality for turbine operation
6 Commissioning and operation
6.1 Commissioning
6.2 EMERGENCY STOP
6.2.1 Press the red knob at the local trip transmitter
6.2.2 via safety switching-off:
6.3 Start-up
6.4 Monitoring
6.5 Shut down procedure
6.6 Emergency shutdown system check
7 Maintenance of the turbine
7.1 Maintenance of the turbine
7.1.1 Maintenance work
7.1.2 Additional maintenance work (Safety inspection)
7.2 Oil instructions
7.2.1 Monitoring the oil quality
7.2.2 Oil maintenance
7.2.3 Oil change
7.2.4 Cleaning of the oil pipes
7.2.5 Filling the oil supply unit
7.3 Installation instructions for flanged joints
7.4 Rules for standstill
8 Troubles, causes and their elimination
9 Disposal and environmental protection
10 Spare parts
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1 General
1.1 Preface
This SIEMENS- turbine corresponds to the state-of-the-art. It has been
manufactured with utmost care and is subject to a constant quality control.
By means of these operating instructions we are furnishing you with the required
notes for commissioning/start-up, operation and maintenance of the turbine.
When these notes are observed danger will be avoided, repair charges and
downtime minimized and the reliability and service life of the turbine increased.
The operating manual must be constantly available on the turbine site.
Every person entrusted with work on the turbine must have read and understood
the operating instructions and especially the notes on safety. The turbine may be
operated by authorized staff only.
The turbine nameplate shows the most important data, which must be indicated
in every inquiry, subsequent order and particularly spare parts orders.
Should you require any further information and notes which are not included in
these operating manual or in the case of damage please do not hesitate to
contact the SIEMENS- Turbine Service Dept.
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1.2 Copyright and trademark rights
These operating instructions are protected by copyright and may be used,
especially copied, distributed or otherwise made available to third parties only
with our approval.
Infringements are punishable and will result in damages having to be paid.
We reserve all rights to use industrial property rights.
1.3 Notes for the user

The operating instructions are an important part of the turbine.
The user must see to it that the operating staff take note of these guidelines.
The national and international rules for the prevention of accidents and
environmental protection as well as the approved rules for safe and proper work
must be observed.
The user must add these rules to the operating instructions, including information
regarding obligations to perform supervisory and reporting functions to take into
account particulars of the plant, e.g., regarding work organization, work
procedures and staff employed.
When hazardous substances must be handled, the user is obligated to make

available/see to it that personal protective clothing is worn and to check that
traffic rules are adhered to.
Without the approval of SIEMENS the user may not carry out any changes on the
turbine, no extensions or modifications on the turbine or its accessory units which
might affect the safety.
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This also applies to the installation and setting of safety devices and valves as
well as welding on supporting components.
The user may employ only authorized staff.
Responsibilities of the staff for operation and maintenance must be clearly

defined.
The user must check that the work is carried out by the staff safely and without
danger, observing the operating instructions.
The user must maintain any dates specified or indicated in the operating
instructions for recurrent tests/inspections.
The user must fully acquaint the staff of the place and use of fire extinguishing
devices. The fire alarm and fire fighting possibilities must be followed.
The user may use only spares which correspond to the technical demands
determined by SIEMENS.
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1.4 Staff qualification and training
The staff for operating, maintenance and inspections must be adequately
qualified for this work.
The user must clearly define the responsibilities, competence and the staff
supervision. Should the staff not have the required knowledge and skill it must be
trained and instructed accordingly. If required, this may be done by expert
SIEMENS staff on behalf of the user.
Authorized staff are persons who were authorized by SIEMENS to do the

required work due to their special training/instructing.
The user is obligated to see to it that his staff have read and understood the
operating instructions - this applies especially to chapter 2 "Safety".
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2 Safety
2.1 General
This turbine is state-of-the-art. It was manufactured with utmost care in
accordance with the approved safety rules.
With these operating instructions we furnish you with important notes on

commissioning/start-up, operation and maintenance of the turbine.
Therefore, the operating instructions must definitely be read and understood by
the SIEMENS expert staff and the responsible authorized staff/operator before
commissioning/start-up. These instructions must be observed in all respects to:
Prevent extreme danger for the operator and third parties, ensure the operating
safety of the turbine and rule out loss of use and detrimental influences on the
environment due to improper handling.
The operating instructions must be constantly available at the turbine site.
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2.2 Marking of notes
The non-observance of notes on safety included in these operating instructions
can result in danger of personal injury.
Notes on safety included in these operating instructions are marked as follows:
Danger!
This symbol points to a potential danger for the life and health of
persons. The non-observance of these notes may have serious
effects detrimental to health up to critical injuries.
All warnings must be observed without fail!
Attention!
This symbol provides important notes for the proper handling of the
turbine. The non-observance of these notes may lead to the turbine
being damaged and its functions being affected.
All p r e v e n t i v e m e a s u r e s resulting there from must
be strictly adhered to.
Danger!
This symbol is a warning against electric voltage.
Work on electric equipment may be carried out by authorized electrics
experts only.
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Note!
This symbol stands for a procedure of special interest or
importance.
All notes must be adhered to in the interest of a use of the turbine for
the intended purpose.
Information signs and symbols fitted directly to the turbine such e.g.
 Arrow indicating direction of rotation,

 Danger signs,
 Markings, etc.
must be observed without fail.
They must not be removed and are to be maintained in a perfectly

legible condition.
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2.3 Notes on safety for operators/users
Before doing work on the turbine, the staff entrusted with this work must have
read and understood the operating instructions, especially the chapter about the
notes on safety.
Note!
During the job it is too late!
This applies especially to staff doing work on the turbine only
occasionally.
The operating instructions must be constantly available on the turbine site.
The turbine must only be used when in a technically perfect condition and for the
purpose for which it was intended whilst paying full attention to safety regulations,
dangers and the operating instructions.
For damage and accidents resulting from the non-observance of the operating
instructions SIEMENS will not assume any liability.
The national rules for the prevention of accidents and environmental protection
applicable in the country and place of installation as well as the approved rules
for safe and proper work must be observed.
The staff must not wear their long hair loosely, loose clothing or jewels including
rings.
There is the risk of injuries caused by becoming trapped or pulled or sucked-in by
rotating parts.
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The user must ensure that the staff wears personal protective clothing. Besides
safety boots and gloves this also includes personal protective equipment required
for company reasons with regard to the protection of labour.
First-aid equipment (first-aid kit, etc.) must be stored in close proximity.
Work on or with the turbine may be carried out by authorized staff only.
No personnel under minimum legal age are permitted to perform work of any
nature.
Staff to be trained or instructed or receiving general training may handle the

turbine only under the supervision of an experienced person.
When maintaining or inspecting the turbine and the safety devices the notes for
maintenance must be adhered to.
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2.4 Notes on safety for operation
The turbine may be commissioned/started-up only in a safe and functioning
condition.
Any method of work which may not be entirely safe must not be carried out.
Before starting with the work the operating staff must make itself acquainted with
the area where the turbine is situated.
The turbine may be put into operation only when all protective and safety devices
such as e.g. detachable protective devices and emergency stop devices are
available and fully operative.
Safety-relevant functions are to be monitored constantly.
Danger!
Trouble, which may affect the turbine safety (exceeding/failure to
reach limit values) such as
 Overspeed,
 Steam pressure,
 Steam temperature,
 Bearing temperature,
 Lube oil pressure
 Vibrations
etc. must be eliminated immediately.
The turbine may be restarted only when the cause for the trouble has
been eliminated.
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Danger!
Blocking functions, in particular those of valves, is strictly
prohibited.
The turbine must be checked for visible damage and defects at regular intervals
acc. to the specifications in para 7.
Changes (including those of the operating behaviour) must be reported
immediately to the plant responsible (e.g. works management).
Danger!
If required, the turbine is to be stopped immediately and secured.
Maintenance work may be carried out by authorized staff only.
We recommend to have erection, commissioning, maintenance and revisions

carried out by authorized expert SIEMENS staff only. This also applies in case of
trouble.
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2.5 Notes on safety for maintenance
Before carrying-out maintenance work the operating staff must be advised
accordingly. A supervisor must be named.
An adequate workshop equipment for the maintenance work to be carried out is

absolutely necessary.
Maintenance and inspection activities as well as inspection dates specified in the

operating instructions must be done/maintained. This work may be carried out by
authorized staff only.
Work on electrical units or equipments of the turbine may only be carried out by
an authorized electrics expert or by persons instructed adequately under the
supervision of an electrics expert in accordance with the electro technical
provisions.
Hoses (hydraulic or energy) must be replaced at specified intervals even if no

safety-relevant defects can be seen.
A large area around the maintenance place must be secured to the extent
required.
Only authorized staff with special knowledge and experience in the field of
hydraulics may do work on hydraulic systems.
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Danger!
When the turbine is completely switched-off for maintenance/repair
work it must be secured against inadvertent switching-on.
 Close main command unit and remove the key.
 Close all shut-off devices on the live and exhaust steam sides of
the turbine.
 Attach a danger sign to the main switch.
Clean the turbine, especially its connections and screw connections at the
beginning of maintenance and repair work from oil, operating supplies, dirt or
maintenance compounds. Do not use any aggressive cleaning agents. Only use
fluff-free cleaning rags.
Cleaning the turbine using a high-pressure cleaner is not permissible.
After cleaning, check all oil pipes for leakages, loose connections, abrasion and
damage. Eliminate detected defects immediately.
Tighten loose screw connections during maintenance/repair work to the specified

torque.
Danger!
When safety devices must be removed for maintenance and repair
same must be remounted and checked for their functioning
immediately after completion of the maintenance and repair work.
This work may be carried out by authorized staff only.
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For work above head height always use steps, ladders, working platforms
which are safety-approved. The turbine and especially the pipes and other
components supplied by SIEMENS must not be used for climbing and/or
standing on for work above the unit.
For maintenance work at great height safety harnesses must be worn.
All handles, steps, railings, platforms, stages, ladders must be kept free from dirt,
snow and ice.
When exchanging individual parts or larger assembly groups fix same carefully to
hoists and secure them such that they cannot cause any danger.
Only use suitable and technically perfect hoists and suspension devices with an
adequate carrying power.
Do not stay or work under suspended loads.
Only experienced persons may be entrusted with the slinging of loads and
instructing of crane operators.
The instructing person must be in the range of sight of the operator or in speech
communication with him.
A safe and environmentally friendly disposal of operating supplies as well as

replacement parts must be ensured.
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2.6 Notes on special danger
2.6.1 Electric energy

In the case of trouble with the electric power supply switch the turbine off
immediately.
Use only original fuses with the specified amperage.
Work on electric units or turbine equipment may be done only by an electrics

expert or persons instructed under the supervision of an electrics expert in
accordance with the electro technical provisions.
Components on which maintenance and inspection work is carried out must be

dead. First check that the components are dead, then earth, short-circuit and
insulate adjoining alive parts.
The electric equipment of the turbine must be inspected visually at regular

intervals. In case of defects such as loose connections or burnt cables the turbine
must be switched-off immediately to eliminate these defects.
Do not carry out any work on alive parts.
When work must be done on alive parts there must always be a second person
who activates the emergency stop/main switch with voltage release in case of
emergency. Bar the working area with a red-white cordon and a danger sign. Use
only voltage-insulated tools.
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2.6.2 Steam
Work on pipes and fittings in contact with steam may be carried out only by
persons having special knowledge and experience in the field of pipings and
fittings.
Check all pipes and screw connections at regular intervals for leakage and any
visible damage. In the case of damage or leakage the turbine must be stopped
immediately and all shut-off devices on the live and exhaust steam sides closed.
Damage and leakages must be eliminated without delay.
Danger!
Escaping hot steam may lead to serious scalding, burning and
injuries.
2.6.3 Hydraulics
Work on hydraulic units may be carried out only by persons having special
knowledge and experience with hydraulics.
All pipes, hoses and screw connections must be checked for leakages and visible
damage at regular intervals. In the case of damage or leakage the turbine must
be stopped immediately and all shut-off devices on the live and exhaust steam
sides closed. Damage or leakages must be eliminated immediately.
Danger!
Escaping oil may lead to injuries and fire.
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2.6.4 Noise
The legal stipulations must be observed.
Danger!
Personal ear protection must be worn.
2.6.5 Oils, greases and other chemical substances

When handling oils, greases and other chemical substances pay attention to the
safety instructions and safety data sheets of the manufacturers applying to the
product regarding storing, handling, use and disposal.
Be cautious when handling hot or etching operating supplies (danger of

burning/scalding).
Only wear protective equipment (protective goggles, gloves, rubber boots and
protective clothing) made of material suitable for the work with corrosives.
Never store hazardous substances in tanks or containers of food. Only use

containers approved for the substances in question and mark same.
During the work with chemical substances eating, drinking and smoking is
prohibited.
If the substances come in contact with the skin, thoroughly wash the affected
areas and apply a skin protection, e.g. appropriate skin cream.
We recommend putting on protective clothing to cover all skin before
commencing work.
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2.7 Use for the purpose intended
The turbine may be used exclusively for the application determined in the
contract documentation.
The technical data of the turbine must be observed and maintained. The limit
values indicated in the technical data may by no means be exceeded/not
reached.
The limit values set may not be changed without SIEMENS's approval.
Another use or a use beyond the specified use is not in accordance with the
intended purpose.
The turbine users are solely responsible for damage resulting there from. This
also applies to changes made by the users themselves on the turbine.
The use for the intended purpose also includes the observance of the following
notes
 on safety,
 on operation,
 on maintenance
described in the operating instructions.
The non-observance of the notes in the operating instructions will lead to the
exclusion of all compensation claims.
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2.8 Residual risk
There is always a residual risk when operating the turbine, even when all safety
provisions are adhered to.
All persons working on and with the turbine must be aware of these residual
risks. They must follow the instructions which prevent that these residual risks will
lead to accidents or damage.
Danger!
Serious injuries can result from the after-running of the rotating
shaft end.
Due to the mass moment of inertia it takes some moving parts a
certain time to come to a complete standstill. Therefore, work may be
carried out on the turbine only when all moving parts have come to a
complete standstill.
The coupling guard may be removed only after standstill of the
moving shaft end.
All shut-off devices on the live and exhaust steam sides of the turbine
must be closed.
Danger!
Serious injuries may result from hot oil escaping under
pressure.
Before doing work on pipes or assembly groups the oil system must
be pressure less.
Remove the fuse for the electric oil pump in the control cabinet to
avoid inadvertent starting of this pump.
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Danger!
Hands and arms may be burnt
 at the turbine housing,
 at the control valve casings,
 at the steam drainage pipes.
When there are higher outdoor temperatures one has to reckon with a
higher turbine surface temperature.
The cooling-down time for the parts in contact with steam must be
observed.
Wear safety gloves when working on the turbine.
Danger!
Work on electric equipment may be carried out by authorized
electrics experts only.
Components on which maintenance and repair work is done must be
dead. First check that the parts are dead, then earth, short-circuit and
insulate adjoining alive parts.
Danger!
Oil and waste containing oil present a high danger potential for
the environment. They must be deposited by specialized
companies.
Oil and waste containing oil must be collected in special containers.
Have these containers deposited properly.
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3 Transport and storage
3.1 Transport with hoists

The turbine is packed in different ways depending on its size, the customer
demands and the transport way.
Live and exhaust steam branches as well as all other openings are closed with
plugs/stop plugs.
Special attention has to be paid to signs and symbols on the crates.
On closed crates the sling places are marked. Sling belts or ropes always in the
places marked as the center of gravity (mass) cannot be recognized in the case
of closed crates.
For the sling points and the center of gravity (mass) of the turbine please refer to
the installation plan.
For the total weight of the parts to be transported please refer to the shipping
documents.
Danger!
For all transport procedures attention must be paid without fail
to the general technical provisions and the rules for the
prevention of accidents applicable.
Danger!
Only well trained specialists may be entrusted with transport
and lifting jobs.
For the selection and fixing of cranes and hoists follow exclusively the
instructions given by a person responsible. This also applies to the
instructions (signals) given during transport.
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Danger!
Improper lifting may lead to critical injuries (bruises).
1. Use only hoists and suspension devices with an adequate

carrying power.
2. Do not exceed the permissible load of cranes and hoists.
3. Do not use any chains.
4. Only use ropes or belts suited for the total weight of the turbine
and which are in a technically perfect condition.
5. Staying in the dangerous area and work under suspended loads
is prohibited.
6. Transporting persons together with the load is not permitted.
7. Make sure that ropes or belts are firmy attached to the specified
lifting eyes at the base plate and at the sling means.
8. Lift the turbine from the ground slowly and without tilting. The
ropes or belts must be evenly tensioned.
9. No damage may occur on the turbine or any components fitted to
it due to tightened ropes or belts.
10. Loads may only be lowered at the slowest speed of the hoist.
Ensure that the equipment is not bumped when setting down on
the ground or against other objects.
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3.2 Storage and conservation
Climatic condition Storage Durability of the conservation

(Standard)
max. with seaworthy without seaworthy
packing welded packing in normal
1)
into plastic packing
2)
sheeting
1)
normal climate in a dry room 12 months 6 months
country or city air without special
industrial influence,
1)
3)
industrial atmosphere with little outdoors 6 months 2 months
chemical influence
1)
Aggressive climate in a dry room 12 months 2 months
industrial atmosphere
with medium and high chemical
influence
1) 3)
humid and hot climate (tropics), outdoors 6 months 1 month
dry and hot climate (desert)
This information is based on experience and is not guaranteed.

The turbine must be recon served at the latest when the listed periods of time
have expired. This work may only be done by authorized staff.
1)
The cases have to be stored on a dry, solid ground. They must be protected against moisture, rodents
and vermin. High temperature variations must be avoided.
2)
The plastic sheeting may not be damaged. The indicator will turn pink when the inserted silica gel cannot
absorb any additional moisture. Then the packing and conservation must be renewed before the
specified periods of time have passed.
3)
Cases without seaworthy packing may be stored outdoors only under a roof, adequately protected
against rain.
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4 Description of the turbine
4.1 Design
The steam turbine is a single-stage turbine of impulse design with axial flow
single-row blading.
4.1.1 Turbine rotor

The turbine rotor consisting of turbine wheel and turbine shaft is mounted in two
bearings. The turbine wheel is overhung, i.e., outside the bearings and is fixed to
the turbine shaft via a self-centering serration in a way which enables it to be
detached.
Danger!
The turbine wheel / shaft connection is of utmost importance for
the turbine safety.
In the case of improper handling there may be danger for the life
and health of persons and considerable damage to the turbine.
Dismounting/mounting may only be done by authorized staff.
4.1.2 Turbine housing and nozzle system

The turbine housing contains a ring channel. The nozzles are fitted to the axial
openings of this channel.
The turbine housing is centrically fixed to the gearbox housing. The housing is
vertically split. Turbine wheel, nozzle system and shaft seal are all easily
accessible.
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4.1.3 Shaft seal
A carbon ring seal with vapour and leakage steam drainage seals the exhaust
steam chamber of the turbine housing from the outside atmosphere at the shaft
passage.
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4.2 Gearbox
The system comprises a single-stage helical spur gearbox. The oil tight closed
gearbox housing is horizontally split. The upper half is provided with an inspection
opening.
Turbine and gear shafts are accommodated in pressure-oil lubricated sleeve

bearings.
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4.3 Oil supply unit
The main oil pump driven via an auxiliary drive supplies the turbine with control
and lube oil. It sucks oil from the reservoir and supplies it via cooler and filter to
the
 control devices,
 bearings,
 toothed parts and
 cooling of all heat-emitting areas.
An auxiliary oil pump is available for starting and stopping.
A second auxiliary oil pump is available for recooling the bearing areas when
stopping the turbine.
Attention!
An optimum cooling effect can only be achieved when the specified
flow direction of the water oil cooler is maintained. Cooling water
supply and drainage must not be mixed up.
The water-side operating pressure depends on the user and must not
exceed 10 bar.
When there is a risk of frost and in case of longer standstills of

the turbine the cooling water must be drained. Blow-out water
remainders using compressed air.
Should pipes have to be fitted to the turbine on the site same have to
be thoroughly cleaned before they are fitted to the oil supply unit. The
pipes must be free from corrosion and must be absolutely clean.
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4.4 Control system
4.4.1 Valves
Hydraulic automatic control valve is used for the turbine control.
Danger!
Blocking valve is strictly prohibited.
4.4.2 Speed governor

A cantilever spring speed governor, which hydraulically activates the servomotor
of the control valve, keeps the turbine speed constant.
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4.5 Protective device
The turbine is equipped with all necessary protective devices. When the turbine
is used for its intended purpose and the safety notes given in these operating
instructions are followed there will be no risk for the safety and health of the
operator/user.
Danger!
The protective devices must neither be blocked nor removed nor
may settings be changed.
4.5.1 Trip valve

The trip valve is opened or closed by a flanged oil-hydraulically actuated servo-
motor.
Note!
The trip valve functions separately from the control system.
Danger!
Blocking the valve is strictly prohibited.
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4.5.2 Overspeed
The turbine is equipped with a mechanic/hydraulic overspeed protection. This
consists of an emergency trip bolt built into the turbine shaft and the trip
transmitter. When overspeed is reached the trip bolt is moved out by centrifugal
force, the trip transmitter is actuated and the steam valve is shut.
Danger!
The protective devices must neither be blocked nor removed nor
may settings be changed.
4.5.3 Lube oil pressure

When the lube oil pressure drops inadmissibly the turbine is stopped via the
pressure measuring unit.
4.5.4 Steam pressures and temperatures (customer side)

When the limit values are exceeded the turbine is stopped via the protective
device.
4.5.5 Oil temperature downstream of oil cooler

When the limit values are exceeded the turbine is stopped via the protective
device.
4.5.6 Bearing temperature - turbine (at the gearbox)

When the limit value is exceeded the turbine is stopped via the protective device.
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4.6 Monitoring units
Important functions such as
 Pressures,
 Temperatures
 Speed and
 Vibrations
are monitored.
For the supply limits please refer to the control and instrument scheme with
interlock scheme.
Note!
It is the main purpose of the monitoring units to recognize changes
and to avoid damage to the turbine by switching same off on time.
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4.7 Quick starting mechanism
(See also the control and instrument diagram)
The quick starting mechanism starts the turbine automatically when there is a
power failure or when the electric quick starting oil pump stops. The mechanism
consists of electric oil pump, change-over valve, control valve, and aux. turbo oil
pump.
4.7.1 Operation
When the electric oil pump is running, the oil pressure keeps the ball in the left
part of the change-over valve. Moreover, it keeps the control valve closed against
the spring force. The steam flow to the aux. turbo oil pump is interrupted.
When there is a power failure or the electric oil pump is switched-off by hand or
automatically (for instance via signal transmitter), the oil in the control valve flows
off through the throttle bore in the change-over valve. The control valve is opened
by spring force and the aux. turbo oil pump cuts-in.
The oil conveyed by the aux. turbo oil pump reaches the control valve via the
speed governor. The valve is opened by the oil pressure, so that steam flows to
the turbine. The turbine accelerates automatically to the preset speed, which is
maintained by means of the speed governor.
When the turbine is in operation, the turbine oil pump conveys the necessary oil.
The oil presses the ball in the change-over valve to the right, the control valve is
closed and the aux. turbo oil pump is stopped again.
Note!
The perfect functioning of the quick starting mechanism must be
checked at regular intervals.
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5 Operating data
Pressure indications
Pressures indicated in "bar" are gauge pressures..
Only pressures marked "abs" are absolute pressures.
05 - 006 en
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5.1 Operating data and limit value
The machine may be operated with other data only with SIEMENS 's consent.
Power at the coupling normal 488.0 kW

max. 550.0 kW
Secondary speed min. 2700 rpm

normal 3000 rpm
max. 3150 rpm
Trip speed min. --- rpm
normal 3300 rpm
max. --- rpm
Gear transmission ratio 3.49
Live steam pressure min. (limit value) 60.0 bar

min. (operation) --- bar
normal (operation) 65.0 bar
max. (operation) --- bar
max. (limit value) 65.1 bar
Live steam temperature min. (limit value) 450 °C

min. (operation) --- °C
normal (operation) 500 °C
max. (operation) --- °C
max. (limit value) 510 °C
05 - 006 en
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Exhaust steam pressure min. (limit value) 0.00 bar
min. (operation) --- bar
normal (operation) 0.20 bar
max. (operation) --- bar
max. (limit value) 1.20 bar
Exhaust steam temperature max. (limit value) 344 °C
Leakage steam pressure max. 0.00 bar

Leakage steam to be led off pressure less
For the direction of rotation refer to the installation plan
Noise pressure level with normal data 96.4 dB (A)

Sound power level with normal data 108.8 dB (A)
Remark:
The sound power indications are based on the sound intensity measuring method to
the enveloping measurement surface procedure.
The measuring surface noise pressure levels were determined on the basis of the
sound power levels, taking into account a correction of + 2 dB (A).
This correction value takes into account that the sound waves penetrate measuring
surfaces not only vertically.
05 - 006 en
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5.2 Design
See steam flow diagram no.: 4144242-DD *
With a lower live steam pressure, a lower live steam temperature or a higher exhaust
steam back pressure the design power is not achieved.
* For the steam flow diagram please refer to part B of the operating manual
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5.3 Oil and bearing data
Oil: Lube oil (turbine oil)

to DIN 51515-1 (L-TD 46)
(no zinc additives)
DIN 51 515 -1 edition Jun 2001
Damage loading step FZG test method A/ 8.3/ 90 for relative
(FZG- load stage) scuffing load-carrying capacity of oils 6-7
(ISO 14635-1:2000)
Oil filling: see installation drawing
The initial oil filling is no part of the SIEMENS scope of supply.
Oil temperature at the °C
oil cooler outlet: normal 45 + 5
during starting >5 °C
Control oil pressure: 10 ...12 bar
Lube oil pressure: normal 1,0 …2,5 bar
during starting > 1,0 bar
Bearing temperature: normal < 80 °C
stopping the turbine at > 90 °C
measuring in the oil flow with local thermometers without contacting device
For the alarm and shut-off values please refer to the control and instrument
scheme and the interlock plan, part B of the operating manual.
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5.4 Required steam quality for turbine operation
Conductivity measured at 25°C in  0.2 µS/cm in continuous operation

the condensed specimen behind
strongly acid cation exchanger and
CO2 removal.
Silic acid (SiO2) < 0.02 mg/kg in continuous operation

Total iron content (Fe) < 0.02 mg/kg in continuous operation
Sodium + Potassium (Na + K) < 0.01 mg/kg in continuous operation
Copper (Cu) < 0.003 mg/kg in continuous operation
Oxygen (O2) < 0.02 mg/kg in continuous operation
Chloride (CI-) < 0.01 mg/kg in continuous operation
Ph value 9.2 - 9.6 in continuous operation
Attention!
The steam at the turbine inlet must be absolutely dry (x=1 in the h-s diagram), i.e., the
customers must install an effective mist and dirt collector, e.g., a cyclone in the live
steam pipe.
Unsteady operation conditions such as e.g. starting of the boiler must also be
taken into account.
Attention!
Should no effective mist and dirt collector be provided for on the site or should
this device not function warranty claims for erosion damage on the turbine are
excluded.
Attention!
All other chemical elements or compounds in the steam are inadmissible.
4951 100 03 11
08.03 05 - 011 en
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6 Commissioning and operation
6.1 Commissioning
The entire unit must be installed and aligned properly and the pipes laid and
connected correctly. Within the scope of the entire documentation the following
leaflets were already made available:
 INSTRUCTIONS for the surrounding area of steam turbines
Danger!
Damage on the turbine/total unit due to improper work.
The turbine/the entire unit may be commissioned by authorized staff
only.
Attention!
The customers must make sure that the turbine cannot be driven
by the machine. In the discharge pipe of the machine a non-
return flap and a shut-off slide must be installed. For each
stopping of the unit the shut-off slide in this discharge pipe must
be closed immediately.
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Danger!
All protective devices and emergency stop units must be fitted
and function.
Before commissioning of the turbine make sure that all work is done properly.
 The quality of the concrete foundation is in accordance with the instructions.

 Fixing the entire unit on the foundation, checking shims and alignment.
 Piping connections are to be connected acc. to the information given on the
installation drawing such that the max. admissible forces and torques are not
exceeded.
 Setting of the electric, hydraulic and mechanic protective devices.
 Checking the interlock system for it’s functioning.
 Tightness of all connections.
 Coupling guard is fitted.
etc.
06 - 001 en
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Attention!
Gearbox, oil reservoir and oil system are conserved on the
insides to the VSI method (VSI = Vapor Space Inhibited).
The components and the oil system must be kept closed right up
to commissioning/start-up.
Before commissioning/start-up drain the VSI oil from the oil reservoir
and have it disposed properly.
Fill the oil reservoir with oil up to the marking "normal" at the sight glass
(for the oil quality please refer to para 5.3, oil instructions see para 7.2).
Danger!
The customers must make sure that condensate escaping
during commissioning c a n n o t get into the waste water.
The condensate may contain oil (conservation oil from the turbine, the
live and exhaust steam pipes, the steam valves, etc.).
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6.2 EMERGENCY STOP
6.2.1 Press the red knob at the local trip transmitter
or
6.2.2 via safety switching-off:

 lube oil pressure,
 oil temperature downstream of oil cooler
 steam temperatures and pressures
 high bearing temperature
which results in the steam valve of the turbine to shut via the tripping mechanism.
For the limit values, please refer to the control and instrument scheme and the
interlock scheme.
Remark!
Then take all steps described in para 6.5.
Danger!
The turbine may be restarted only when it has come to a
standstill and the reason for the trouble eliminated.
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6.3 Start-up
Please refer to the control and instrument scheme and the interlock scheme.
Remark!
For start-up the operating instructions of the machine must also be
followed.
Danger!
During commissioning or start-up after revisions a tripping test (three
times) must be carried out (see para 6.6).
Remark!
When the turbine servomotor hand wheel is turned fully to the left or
right to the stop it should be turned back a quarter revolution. This
prevents the hand wheel from jamming due to temperate effects.
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6.3.1 Open the shut-off valve in the steam pipe to the aux. turbo oil pump.
6.3.2 Check that the steam valve of the turbine is shut by turning the hand wheel at the
servomotor fully to the right.
6.3.3 Open all drain valves on the live and exhaust steam sides.
6.3.4 Open the shut-off fitting in the exhaust steam pipe of the customers.
6.3.5 Open the shut-off fitting in the live steam pipe of the customers.
6.3.6 When opening the live steam shut-off device in the live steam pipe any
condensate escapes through the drainage pipes.
When the min. live steam temperature is reached (see para 5.1) one assumes
that there is no more condensate in the turbine.
6.3.7 Throttle the drain valves.
6.3.8 Start up turbine by turning the hand wheel at the servomotor fully to the left. Then
turn approx. 10 revolutions to the right.
3.3.9 When the oil temperature rises to > 40°C open the cooling water supply until a
constant oil temperature of 45 ± 5°C has been reached at the oil cooler outlet.
6.3.10 Close all drain valves.

The shut-off valves upstream and downstream of steam traps remain open.
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6.4 Monitoring
During continuous operation the turbine states

 Operating behaviour,
 Oil temperature,
 Speed setting,
 Tightness on the oil and steam sides
must be checked at regular intervals acc. to para 7.
Remark!
In the case of trouble the turbine must be stopped and the
reason for the trouble eliminated.
See also chapter 8 of the operating instructions.
Danger!
Trouble influencing the turbine safety (exceeding or failure to reach
limit values), such as
 Overspeed,
 Steam pressure,
 Steam temperature,
 Oil temperature,
 Lube oil pressure,
 Vibrations
etc. must be eliminated immediately.
The turbine must not be restarted before the reason for the trouble is
eliminated.
Danger!
Blocking any functions, especially of valves, is strictly
prohibited.
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6.5 Shut down procedure
6.5.1 Turn the hand wheel of the steam valve servomotor fully to the right.
6.5.2 Close the shut-off fitting in the live steam pipe of the customers.
6.5.3 Close the shut-off fitting in the exhaust steam pipe of the customers.
6.5.4 Switch off turbo- auxiliary oil pump.
6.5.5 Close the cooling water inlet.
6.5.6 Open the drain valves.
Attention!
When the turbine unit is closed down temporarily adequate measures
have to be taken.
The required conservation measures to be taken must definitely
be agreed upon with SIEMENS.
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6.6 Emergency shutdown system check
Attention!
In the case of generator drive, a trip test may be carried out only at no
load, in the case of pump or compressor drive only with uncoupled
machine.
6.6.1 Commissioning of the turbine according to Section 6.3.
6.6.2 Turn the steam valve servo-motor hand wheel to the right until the speed of the
turbine reduces slightly.
6.6.3 Unscrew the cap screw (1) on the control cylinder cover of the servo motor up to
the stop pin (2).
6.6.4 Turn the steam valve servo-motor hand wheel slowly to the left until the
emergency stop speed is reached.
Attention!
When the tripping mechanism does not react within the permissible
tolerance (see 5.1 of the operating data; trip speed max.), the speed
may not be increased any further. The turbine must be stopped to
para 6.5 and the reason determined. This work may be done by
authorized staff only.
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6.6.5 After a trip is initiated, turn the steam valve servo-motor hand wheel fully to the
right.
6.6.6 Reset the emergency trip transmitter only after the speed has returned to < 50%.
This is done by pulling out the red knob on the emergency trip transmitter.
6.6.7 After checking the emergency shut down function, the cap screw (1) on the
servo-motor must by screwed in again completely.
Danger!
In the case of a malfunction the turbine must be stopped and the
reason eliminated.
Repair work may be done by authorized staff only.
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6.7 Preparing for rapid start
Remark!
The turbine is commissioned according to Section 6.3.
Shut down the turbine as follows, without changing the control settings:
6.7.1 Turn the hand wheel of the steam valve servo-motor fully to the right.
6.7.2 After cooling, shut down the turbo-auxiliary oil pump by activating the fast start pump.
6.7.3 Turn the hand wheel of the steam valve servo-motor fully to the left.
Remark!
Turbine rapid start takes place automatically when the fast start
pump is shut down.
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7 Maintenance of the turbine
7.1 Maintenance of the turbine

Carry out the maintenance and inspection work specified in the operating
instructions by maintaining the respective intervals. This work may be done by
qualified/authorized staff only.
To carry out maintenance work shop floor equipment suitable for this work is
absolutely necessary.
Before carrying-out special work and maintenance work the operating staff must
be advised accordingly. A supervisor must be named.
When handling oils, greases and other chemical substances observe the safety
instructions and safety data sheets of the manufacturers regarding storage,
handling, use and disposal applying to the product.
A safe and environmentally friendly disposal of operating supplies as well as

replacement parts must be ensured.
Only use spare parts which meet the technical demands determined by
SIEMENS. We grant a warranty only for original spare parts supplied by us.
07 - 010 en
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Danger!
Clean the turbine and its periphery at regular intervals.
Oil, operating supplies, dirt and in particular dust deposits must be
removed.
Do not use any aggressive cleaning agents.
Only use fluff-free cleaning rags.
Attention!
Entering water leads to damage and corrosion inside the turbine.
Cleaning the turbine using a high-pressure cleaning device is not
permitted.
Danger!
Be careful when working on parts in contact with steam:
"risk of burning or scalding".
System sections and discharge pipes to be opened must be made

pressure less before starting with the repair work.
Shut-offs must be secured against inadvertent opening (fix danger
sign).
The cooling-down times of the parts in contact with steam must be

maintained.
Work on the electric supply may be carried out by an electrics expert

only. Electric instruments must be secured against inadvertent
switching-on (lock main switch and remove the key, fix a danger sign
to prevent switching-on).
The national and international rules for the prevention of accidents

and the environmental protection as well as the rules for safe and
proper work must be observed.
07 - 010 en
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7.1.1 Maintenance work
In addition to the regular monitoring of the turbine during operation and the
maintenance recommendations of sub-suppliers (see accessories) the following
maintenance work must be carried out:
Item no. Designation (Where) Maintenance interval Scope of check (What) Elimination
control (When) (Who)
and
instr.
scheme
60 Oil cooler continuously Cleaning qualified staff
63 Oil filter continuously Locally, check of the qualified staff

64 differential pressure
Twin oil filter: When the
differential pressure
exceeds > 1.5 bar
change-over to the other
filter chamber and clean
the disconnected oil filter
--- Oil quality every 3 months Check - water in the oil qualified staff
--- Turbine and its periphery every 3 months Cleaning qualified staff
--- Emergency stop devices every 3 months Functional check qualified staff
--- Checking the emergency every 3 months Tripping check qualified staff
shutdown function
--- Machine alignment after 20,00 Check authorized staff

operating hours
3 years at the latest
--- Gaps and clearances after 20,000 operating Check authorized staff
hours
07 - 010 en
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Item no. Designation (Where) Maintenance interval Scope of check (What) Elimination
control (When) (Who)
and
instr.
scheme
--- Steam-side seals after 20,000 operating Check authorized staff
hours
--- Oil-side seals after 20,000 operating Check authorized staff

hours
--- Control and trip mechanism after 20,000 operating Check authorized staff
hours
--- All drain pipes after 20,000 operating cleaning and checking authorized staff
hours for clogging
Note!
For warranty reasons, we recommend to record the maintenance
intervals (every 3 months).
Enter the turbine no. indicated on our performance plate in the
respective box.
Please send the completed form „7.1.3 Wartung/ check“ by fax to
SIEMENS.
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7.1.2 Additional maintenance work (Safety inspection)
Item no. Designation (Where) Maintenance Scope of check (What) Elimination

control interval (Who)
and (When)
instr.
scheme
--- Valve housing, after 100,000 Check authorized staff
Turbine housing and operating hours
exhaust steam housing 12 years at the latest
--- Turbine wheel and after 100,000 Check authorized staff

turbine wheel connection operating hours
--- Turbine shaft and gear shaft after 100,000 Check authorized staff
operating hours
--- Control and trip mechanism after 100,000 Check authorized staff
operating hours
Note!
After this safety inspection we recommend to repeat these
inspections every 3 years.
07 - 010 en
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7.2 Oil instructions
Use only the oil specified for the steam turbine.
Do by no means add any defoaming additives (molybdenum disulfide MoS2
and/or EP-additives) later on.
Oil: Lube oil (turbine oil) to DIN 51515-1

(L-TD 46) (no zinc additives)
DIN 51 515 -1 edition Jun 2001
FZG- load stage FZG test method A/ 8.3/ 90 for
relative scuffing load-carrying 6-7
capacity of oils (ISO 14635-1:2000)
7.2.1 Monitoring the oil quality

When water is found in the oil the turbine must be stopped. Drain the water at the
deepest point of the oil reservoir together with the oil until clear oil oozes out.
When an oil separator is available same can be used for removing the water.
The reason for the penetrating water must be determined and eliminated.
7.2.2 Oil maintenance

We recommend to have the oil checked every 6 months by the technical service
of the oil suppliers. These checks contribute considerably to the operating safety.
07 - 003 en
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7.2.3 Oil change
An oil change must be made when the oil examination by the oil suppliers shows
that the oil is no longer suitable for further use.
Attention!
Do by no means add oil of another quality to the oil filling.
7.2.4 Cleaning of the oil pipes

All oil pipes and the oil reservoir must be completely clean. Firm foreign matter
such as sand, fly ash, dust, cleaning rag fluffs, etc. may by no means remain in
the parts in contact with oil (mechanical cleaning). New connecting pipes to the
oil reservoir which are manufactured must be free from corrosion and perfectly
clean.
Attention!
For cleaning use only fluff-free cleaning rags.
7.2.5 Filling the oil supply unit

Do not fill the oil in directly but through a fine-mesh sieve. When an oil seperator
is available use same for filling.
By no means add oil of another quality to the oil filling.
Remark!
Record filled-in oil type, oil company, oil quantity and filling
date.
07 - 003 en
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7.3 Installation instructions for flanged joints
(Live and exhaust stam flanges)
Danger!
Be careful when working on parts in contact with steam:
"danger of burning or scalding"
Maintain the cooling-down times of the parts in contact with steam.
This work may be done by authorized staff only.
1. Coat threads on all sides and the nut contact surfaces with the lubricant
NEVER SEEZ.
2. Tighten to the specified torques using a ratchet torque wrench.
3. First tigthen the bolts/nuts "crosswise". Then check the tightening torques
by retightening one after the other.
4. All seals subject to temperature changes (graphite-, grooved and graphitized

grooved seals) may not be reused after use and dismounting (e.g. test run,
revisions, etc.) and must be replaced by new ones.
5. When replacing seals, any damage on flanges must be eliminated.
Remark!
For the tightening torques please refer to part B of the operating
manual. Only the page with the language applicable to you is
supplied in the attached drawings.
07 - 002 en
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7.4 Rules for standstill
Attention!
When the turbine unit is closed down temporarily adequate measures
have to be taken.
The required conservation measures to be taken must definitely
be agreed upon with SIEMENS.
07 - 008 en
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8 Troubles, causes and their elimination
Trouble shooting on the turbine may be carried out only by especially trained staff
using adequate tools and devices.
Danger!
Danger to life for unqualified staff when doing work on the
turbine at their own discretion.
The turbine may be opened and spares installed by authorized staff

only to ensure the safety of the turbine.
This applies especially to all control and safety devices.
Danger!
The rules for the prevention of accidents and for the environmental
protection applicable in the country/place of installation must be
observed.
To remedy a trouble the reason for the trouble must be found as quickly as
possible. Systematic trouble shooting saves time and money as it accelerates the
determination of the reason for the trouble, it reduces repairs on the unit and
downtime and often prevents that known damage processes repeat.
08 - 001 en
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The table hereunder shall help to find the reason for the trouble and to eliminate same:
Trouble (Where) Reason (What) Elimination Elimination

(Who)
Oil pressure too low Dirty oil filter Clean the filter qualified staff
Leakage in the oil Seal leaking areas qualified staff

system replace sealing elements, retighten
pipe connections
Misadjusted or defective Readjust qualified staff

overflow valve install new parts
Misadjusted lube oil Readjust qualified staff

throttle
Defective oil pump Install new oil pump authorized staff
Damaged bearing Replace the bearings authorized staff

check the rotor for concentricity
Oil temperature too high Check cooling effect of oil cooler qualified staff
Oil level in the oil Refill oil qualified staff

reservoir too low
Bearing temperature Oil temperature too high Check cooling effect of oil cooler qualified staff
too high
Oil viscosity too high Oil change, using specified oil qualified staff
(see para 5.3)
Damaged bearing Replace the bearings authorized staff

Check the rotor for concentricity
Leaking oil seal at

servomotor Wear Replace seal authorized staff
08 - 001 en
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Trouble (Where) Reason (What) Elimination Elimination
(Who)
Speed hunts Control piston in the Open servomotor authorized staff

servomotor dirty Clean inner parts
Leaking steam valve Wear Replace shaft sealing gland authorized staff
Valve spindle jams in Deposits on the valve Clean valve spindle authorized staff
the steam valve spindle or in the sealing Replace sealing gland packing
gland packing
Water in the oil Leaking shaft sealing Replace shaft sealing gland authorized staff
gland
Unsmooth running Bearing damage Replace the bearings authorized staff

Check the turbine rotor for
concentricity
Unbalance in the turbine Dynamically balance turbine rotor authorized staff

rotor
08 - 001 en
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9 Disposal and environmental protection
During maintenance work the following waste may occur, e.g.:

 Ancillary materials such as oils, greases and other oil and grease containing
waste,
 Cleaning and maintenance compounds,
 Waste water and solid remnants as well as
 Other waste, such as worn components and accessories.
Danger!
This waste is a high danger potential for our environment. The
disposal must be made by specialized companies.
Have this waste disposed only by companies having an adequate

approval.
The users are solely responsible for the waste disposal.
This also applies to the turbine with all appertaining components when they are
shut-down as old units. The disposal must be made in accordance with the laws
and regulations applicable at the time of shut-down.
It is considered sensible to check which materials can be recycled. You should
also do this in view of the environment.
09 - 001 en
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10 Spare parts
The readiness of the turbine for operation is ensured by keeping the most
important wear and spare parts on stock.
The parts list and drawings are the basis for inquiries and orders for spare parts.
For this list please refer to part B of the operating manual.
The parts list contains items suitable only for this turbine. Other items
on the drawing are irrelevant to this order.
In the column "Ersatzteilcode" (spare parts code) on the parts lists there are
codes which mean:
1 Part belongs to the set of seals

3 Part for a 3-year operation (20,000 operating hours, at the longest 3 years)
6 Part for a 6-year operation (40,000 operating hours, at the longest 6 years).
The parts for a three-year operation include the set of seals, the parts for a six-
year operation also include the parts for a three-year operation.
The set of seals is part of the parts for a three-year operation, the parts for a
three-year operation are part of the parts for a six-year operation.
10 - 001 en
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When placing a spare parts order please always indicate the following in the
interest of a quick processing of your spare parts order:
Remark!
Machine no.:
Parts list no.:
Item no.:
and designation of the spare part.
When placing an order for spare parts for the automatic nozzle group valves
please indicate for which nozzle group the parts are required.
We recommend you to order turbine wheel, shaft and all parts on or in the
shaft together as these parts are assembled in the works and balanced
together dynamically.
We warrant only for original spare parts supplied by us.
Attention!
We wish to point out expressly that spare parts and accessories
which were not supplied by us are neither checked nor released by
us. The installation and/or the use of such products may change the
design characteristics of the turbine in a negative way, thus affecting
the active or passive safety.
For damage occurring as a result of the use of spare parts and
accessories which are no original parts we will not assume any
liability or warranty.
10 - 001 en
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_______________________________________________________________
Part B
Drawings, Part lists
Turbine SST-050
(AF 4 Gs)
Engine 1
P&I pos. 1
________________________________________________________________________________________
B - Drawings, Part lists
Content
_______________________________________________________________
Pos. Content Drawing Part list
___._ P&I-Schematic DW-Z-161760-A
___._ Installation drawing DW-Z-161759
___._ Steam flow and performance diagram DW-4144242_DD
___._ Guidelines for surrounding area of steam turbDOC-305432
___._ Guidelines for electrical installations DOC-305426
___._ Assembly instructions for flanged connections
Valve housing DW-49000380237-A
Turbine housing DW-49000380314-A
___._ Piping-accessory parts PL-4-360002-331
___._ Piping-steam and oil DW-Z-162026 PL-4-360002-332
001.0 Turbine AF 4 DW-41400014000-C PL-41400001300
001.0 Turbine housing DW-41401014000 PL-41401013327
001.0 Turbine rotor PL-4-120001-781
001.0 Shaft gland DW-41401804000 PL-41401800010
012.0 Control and trip valve DW-41401104600 PL-4-110001-491
014.0 Actuator for control and trip valve DW-49004304002 PL-4-430001-136
017.0 Trip governor and release DW-49000264000
DW-49003904000 PL-49003900034
021.0 Bar spring speed governor DW-41404001002-C
DW-42403000102 PL-42403000102
090.0 Auxiliary turbo oil pump DW-49003404000 PL-4-340000-047
099.0 Gear box DW-41440264000 PL-4-231300-033
099.0 Gear shaft DW-41402304000 PL-41442301501
________________________________________________________________________________________
1/1
Installation specifications
for the surrounding area of
steam turbines

Postfach 17 28 Heßheimer Straße 2
Germany Germany
Phone ++49 (0) 6233 / 85 - 0

Fax ++49 (0) 6233 / 85 - 2660
4951 910 03 35
T_-B1_._ - Guidelines for surrounding

03.09 area of steam turbines - Seite 1 von 26
TABLE OF CONTENTS
Page
1 FIELD OF APPLICATION..................................................................................................... 3
2 INTRODUCTION .................................................................................................................. 4
2.1 Safety instructions ...................................................................................................... 5
3 DESIGN OF THE FOUNDATION AND installation of steam turbines.................................. 6
3.1 Design of the foundation ............................................................................................ 6
3.2 Installation of steam turbines...................................................................................... 6
4 ALIGNING TURBINE AND DRIVEN MACHINE................................................................... 8
5 DESIGN OF THE STEAM PIPES......................................................................................... 8
5.1 Arrangement............................................................................................................... 9
5.1.1 Live steam pipe..................................................................................................... 10
5.1.2 Exhaust steam pipe.................................................................................................. 11
5.2 Forces and moments of the steam pipes ................................................................. 12
5.3 Connecting the steam pipes..................................................................................... 12
5.4 Steam pipe drainage ................................................................................................ 13
5.5 Preheating pipe ........................................................................................................ 14
6 VALVES AND FITTINGS.................................................................................................... 17
6.1 Live steam pipe ........................................................................................................ 17
6.1.1 Double shut-off ......................................................................................................... 18
6.2 Exhaust steam pipe.................................................................................................. 18
6.3 Extraction pipes in case of extraction turbines ......................................................... 19
7 Cleaning the live steam PIPE ............................................................................................. 20
7.1 Blowing out and evaluation based on check plates.................................................. 20
7.2 Blow-out prerequisites.............................................................................................. 21
8 DESIGN OF THE TURBINE DRAINAGE SYSTEMS, LEAKAGE STEAM AND VAPOUR
PIPES......................................................................................................................................... 22
8.1 Drainage with back pressure pipes .......................................................................... 22
8.2 Leakage steam pipe ................................................................................................. 23
8.3 Vapour pipe .............................................................................................................. 24
8.4 Drainage with condensing turbines .......................................................................... 24
9 ARRANGEMENT OF THE TEMPERATURE MEASURING BRANCHES ......................... 25
4951 910 03 35

1 FIELD OF APPLICATION
These installation specifications are applicable for all turbines of the type:
Information on the layout of the surrounding area of the turbine and on

components not pertaining to SIEMENS’s scope of supply is included in these
installation specifications.
For SIEMENS’s scope of supply please refer to the order confirmation.
It is exclusively incumbent upon the contract awarder to comply with these

installation specifications.
4951 910 03 35

2 INTRODUCTION
The correct installation of the complete unit is prerequisite for perfect operation.
Accessibility for maintenance work and easy operation must be ensured.
Suitable lifting appliances must be available for installation and maintenance

work to be carried out at a later date.
The turbine unit, especially the piping and other parts of

Attention! the installation delivered by SIEMENS, must not be
climbed or stand on when working on the unit.
For working on the complete turbine unit ladders,
scaffolds etc. have to be used.
The final customer has to prevent the running of the turbine by the driven
machine.
The binding regulations on accident prevention and environmental protection in

the country of erection and utilisation site must be observed.
4951 910 03 35

2.1 Safety instructions
This symbol indicates a potential danger to people’s

life and health. Non-observance of these indications may
Danger! have serious or even life-threatening consequences on
health.
This symbol indicates a proper execution.

Attention! Non-observance of these indications may lead to damage
to property.
4951 910 03 35

3 DESIGN OF THE FOUNDATION AND INSTALLATION OF STEAM TURBINES
3.1 Design of the foundation
The foundation must be designed such that the static and dynamic loads of the
turbine and driven machine are absorbed. Moreover, the minimum distance
1)
between natural frequencies and operating speed as specified per DIN 4024
must be maintained. Vibrations originating in the surrounding area must not
cause non-permissible vibration amplitude at the unit.
The basis for this evaluation are the vibration amplitudes at the machine rotors,
particularly in the bearing areas.
Following disturbances the foundation must be free from damages impairing the
further normal operation of the unit. In order to attain the prerequisites mentioned
above the static and dynamic loads have to be calculated pursuant to the rules
1)
set forth in DIN 4024 .
1) or an equivalent foreign standard, whereby the latest edition applies
3.2 Installation of steam turbines
Siemens guarantee vibration levels of 2.3 mm/s for new turbines according to
DIN / ISO 10816-3, category 1, zone A.
If the rotational speed of the turbine is greater than 15000 1/min, then DIN ISO
10816-1, Class III with a level of 1.8 mm/s applies.
The numerical values mentioned are RMS values and apply when the turbine is
mounted onto a rigid foundation. A foundation is to be considered as being rigid if
there are no critical resonances within a range of +/- 25% around the operating
speed.
4951 910 03 35

To prove that there is no resonance the customers must calculate or have
calculated the dynamical and statically foundation loads.
The calculations are of special importance if the unit is mounted onto a flexible
bottom (building structure). The combination of the unit stiff nesses and the
building structure may affect the vibration levels, if there is a coupling resonance
near the operating speed. If it cannot be avoided that there is no adequate safety
margin between operating speed and resonance the unit must be mounted in a
vibration-isolated way.
If the generator is e.g. not mounted on a concrete socle but on a flexible steel
base frame the stiffnesses of the base frame must also be taken into
consideration for the dynamical calculation of the foundations. This is of
importance if the turbo unit is mounted onto a flexible bottom in the building as
the stiffness of the surrounding area has a considerable influence on the natural
frequency of the base frame and reduces same so that the machine may be
operated near the resonance range.
If in the case of complaints the calculations and proof required above

cannot be provided any warranty claims will expire and repairs by
SIEMENS will be at the customers‘ charge.
4951 910 03 35

4 ALIGNING TURBINE AND DRIVEN MACHINE
We recommend that installation and alignment work be carried out by authorised

and qualified specialists; otherwise SIEMENS does not assume any guarantee
for the perfect functioning and is not liable for any damages arising from incorrect
alignment.
The alignment will be carried out in accordance with the manufacturer’s

indications.
The result has to be recorded.
Since alterations may occur after putting into service as

Attention! well (e.g. lowering of the foundation), the alignment
should be checked from time to time.
5 DESIGN OF THE STEAM PIPES
The steam quality must be absolutely dry under any

circumstances (x=1 in the h-s-diagram), which means that
an effective drop and dirt separator (i.e. a cyclone) should
Attention!
be installed into the live steam pipe work.
Allowance must be made for non-steady state

operating condition such as are the start-up of the
boiler.
Attention! If an effective drop and dirt separator is not installed

on site or the installation becomes non-functional,
then any liability claim for corrosion-erosion to the
turbine is inadmissible.
4951 910 03 35

5.1 Arrangement
Water resp. condensate in the turbine causes serious

damages.
The steam pipes have to be planned and arranged such that water or
condensate coming from the pipe cannot enter the turbine during start-up or in
continuous operation.
Water can get into the turbine when the boiler foams, surges, and splutters or
when condensate lies in areas outwith the steam flow or in steam pipes without
drainage, and is carried along by the steam.
Attention when working on parts carrying steam:
"Danger of being burned and/or being scorched"
Before commencing work depressurise parts of the

system to be opened and pressure pipes. Secure stop-
valves against inadvertent opening (Affix warning plate!).
4951 910 03 35

5.1.1 Live steam pipe
The steam pipe coming from the steam generator should preferably be led to the
turbine via a steam distributor (see illustration 1).
Illustration 1
1 Main steam pipe

2 Steam for turbine and consumer
3 Reserve connection
4 Towards the condensation collector
5 Drainage when starting and
blowing-out possibility
Branches from the main steam pipe to the turbine have to be led upwards.
Horizontal pipe sections have to be laid with drop of approximately 1 to 2% in the

direction of the steam flow.
In horizontal pipes, built-in U-bend expansion joints and Lyra-type bends must
be installed horizontally.
"Dead" steam areas within the upstream pipe work are to be avoided (for
example, pipe work branches pointing downwards, with isolating valve/blanking).
4951 910 03 35

5.1.2 Exhaust steam pipe
For the configuration of the components downstream

Attention! of the turbine the exhaust steam temperature has to
be taken into account in the neutral of the turbine.
When using an air capacitor, we recommend that a water injection be installed

between turbine and air capacitor.
A pipe section pointing vertically upwards, fitted directly to the exhaust steam
flange of the turbine, should not be longer than 2 - 3 m, so that condensate
flowing back into the turbine is prevented. Should the vertical steam pipe section
have to be longer, a horizontal steam pipe section with suitable drainage has to
be installed as well.
Horizontal steam pipe sections have to be laid with drop of approximately 1 to 2

% in the direction of the steam flow.
In horizontal steam pipes, built-in U-bend expansion joints and Lyra-type bends
must be installed horizontally.
Areas out with the steam flow have to be avoided.
4951 910 03 35

5.2 Forces and moments of the steam pipes
No matter whether the steam pipes are cold or hot,

Attention! non-permissible forces and moments must not act
upon the live and exhaust steam flanges of the
turbine.
Please refer to the installation plan for the permissible forces and
moments, as well as for the displacement of the branches.
When laying the steam pipes, pre-stresses, position of supports and of

suspensions, position of potential expansion joints, as well as any other
constructive information on the lay-out indicated in the workshop drawing of the
company having designed the pipes, must be followed most exactly in order to
exclude deviations from the calculated forces and moments.
5.3 Connecting the steam pipes
The diameter of the deviation from parallelism may not exceed 0.2 mm before
the flanges are connected. If the deviations are bigger, the steam pipes have to
be re-aligned until the minimum values are reached.
When steam pipes with large nominal diameters are re-

Attention! aligned, there is a danger that due to preheating near a
flange there will be uneven sealing areas.
Re-aligning of steam pipes by preheating must not be

Danger! carried out in case of raw materials, such as 13 Cr Mo 44
etc., due to the danger of stress cracks!
Please refer to the installation plan for the permissible forces and
moments, as well as for the displacement of the branches.
4951 910 03 35

5.4 Steam pipe drainage
Steam pipes must be drained automatically at the following points:
o Upstream of all points from where pipes continue vertically upwards

o At deep points
o At pipe ends
o In straight pipes approximately every 100 m
o Upstream or downstream of shut-off devices, non-return devices, orifices,
etc. (see illustration 3).
Fix draining openings so that there is no risk of scorchin

Danger! and no reduction of vision due to the outflow of steam.
The freezing in of the drainage pipes must be excluded.

For the construction of the drainage system and the nominal diameters of the
drainage pipes, please refer to illustration 2 below. When dimensioning the
condensate drainage pipes downstream of the steam traps, allow for any steam
which may collect afterwards.
4951 910 03 35

Illustration 2
1 Steam pipe, e.g. 12 bar

2 High-pressure steam pipe,
e.g. 50 bar
3 Drainage to the atmosphere
4 Condensation collector
Nominal diameters of the steam and drainage pipes
D1 mm 50 65 80 100 125 150 200 250 300 350 400 450 500 600
in 2 2 1/ 2 3 4 5 6 8 10 12 14 16 18 20 24
D2 mm 50 65 80 80 80 100 150 150 200 200 200 250 250 250
in 2 2 1/ 2 3 3 3 4 6 6 8 8 8 10 10 10
L mm for all DN L > 250
DN1 mm 20 20 20 20 20 20 20 20 20 20 20 20 20 20
DN2 mm 20 25 25 40 40 40 40 50 50 50 50 50 50 50
5.5 Preheating pipe
A drainage in the live steam pipe has to be designed directly upstream of the
turbine.
It must be set such that the minimal temperature is reached prior to starting of
the turbine. It may be led into a steam collector.
Please refer to the service instructions „Technical data“ for the minimum steam
temperature permissible for starting.
4951 910 03 35

5.6 Blow-off pipe: Start-up with back pressure (see illustr. 3)
5.6.1 Back pressure lower than 6 bar (g)

Start-up of the turbine without additional measures possible.
5.6.2 Back pressure higher than 6 bar (g) and lower than 11 bar (g)
The following measures are necessary:
- Install check valve in the exhaust steam pipe following the

Attention! turbine (as far away as possible from the turbine).
- Open exhaust steam pipe drainage completely before
starting up the turbine and leave open until 50 % of
nominal speed is reached
5.6.3 Back pressure higher than 11 bar (g)

The following measures are necessary:
- Install check valve in the exhaust steam pipe following the

Attention! turbine.
- A blow off pipe DN 100 or 4" resp. with manual shut-off
valve is to be installed by the customer between the
turbine and the check valve.
The blow-off pipe is to be lead outdoors over the roof.
- The shut-off valve must be opened before starting up the
turbine and remain open until 50 % of the nominal speed
is reached.
The exhaust steam drains are also to be opened.
- A pressure switch is provided by SIEMENS between
blow-off pipe and the turbine.
The turbine is locked against start-up to prevent the
turbine being started up with a back pressure of > 6 bar
(g) as this would lead to greater wear of the bearings.
4951 910 03 35

Abb. 3
1 Blow-off pipe
2 Stop valve
3 Check valve
4 Blow-off pipe (DN 100 or 4"; lead outdoors over the roof)
5 Manual shut off valve
6 Vent pipe
7 Drainage pipe
8 Safety valve
9 SIEMENS end of supplies
10 automatic drainage
11 Live steam pipe
4951 910 03 35

6 VALVES AND FITTINGS
6.1 Live steam pipe
On the basis of the specified rating data, the turbine and valve chambers are
designed such that they are suitable for the respective pressure stages.
The contractor has to ensure that the permitted pressure

Attention! in the live steam pipe and consequently in the turbine is
not exceeded.
Attention! A shut-off device must be fitted upstream of the steam

separator.
The steam quality must be absolutely dry under any

circumstances (x=1 in the h-s-diagram), which means that
Attention! an effective drop and dirt separator (i.e. a cyclone) should
be installed into the live steam pipe work.
Allowance must be made for non-steady state
operating condition such as are the start-up of the
boiler.
If an effective drop and dirt separator is not installed
Attention!
on site or the installation becomes non-functional,
then any liability claim for corrosion-erosion to the
turbine is inadmissible.
The drop and dirt trap has to be placed between shut-off device and turbine.
4951 910 03 35

6.1.1 Double shut-off
When the turbine is not in continuous operation, a double shut-off system

comprising leakage and drainage pipes must be fitted in the live steam pipe.
The double shut-off system must be installed upstream of the drop and dirt
separator.
It must be ensured that vapours cannot get into the turbine via the drainage pipe
through the drop and dirt separator.
6.2 Exhaust steam pipe
A shut-off device must be installed downstream of the

Attention! turbine.
A full flow safety valve between turbine and shut-off device will be additionally
required, if the live steam or blow-off pressure in the live steam system exceeds
the highest pressure permissible for the exhaust steam system.
Please refer to the service instructions for the highest pressure permissible for
the exhaust steam cylinder.
The contractor must ensure that the safety valve will be fitted
Attention! in such a way that it can blow off all the exhaust steam
arising from the turbine, in which the back pressure must not
exceed the highest pressure permissible.
When the turbine is ready to cut-in and the live and exhaust steam shut-off
devices are open, or when it is connected to an exhaust steam system in which
the pressure exceeds 6 bar, a non-return device must be fitted in the exhaust
4951 910 03 35

steam pipe of the turbine. If the non-return device is fitted between turbine and
shut-off device, the full flow safety valve must be installed between turbine and
non-return device.
Non-return device and full flow safety valves are

Attention! safety devices and must be regularly serviced and
checked.
When the turbine is not in continuous operation, a double shut-off system

comprising leakage and drainage pipes, as fitted in the live steam pipe, must be
installed.
6.3 Extraction pipes in case of extraction turbines
A non-return valve and a shut-off device must be

Danger! installed between high-pressure turbine and low-
pressure turbine.
4951 910 03 35

7 CLEANING THE LIVE STEAM PIPE
Before being connected to the flange of the turbine, the entire live steam line
must be cleaned of dirt such as roll scale, rust, cinder, welding beads and oxide
layers. This is effected by grinding the welded seams internally and by blowing
out the line carefully with steam.
Blowing out the distributors and reduction stations from the boiler all the
way to the turbine before initial commissioning of the turbine with steam is
the final cleansing of the live steam line by the customer.
7.1 Blowing out and evaluation based on check plates
Blowing out and evaluating the check plates is effected according to

VGB R-513.
An acoustic sound level of approx. 120 dB(A) may be

Danger! generated when blowing out, which may call for the
implementation of a noise absorber.
Purity criteria for the blow-out mirror

recommended size for blow-out 40 x 40 mm
mirror
Material St 37 (soft construction steel)
possibly Alu, Cu, Austenitic steel
2
Impact volume and density on 40 x 40 mm (St 37)
smaller than > 1,0 mm
less than 4 > 0,5 mm
less than 10 > 0,2 mm
Diameter of blow-out line corresponds to the line to be blown out
4951 910 03 35

7.2 Blow-out prerequisites
Observe the binding regulations on accident

prevention and environment protection applicable in
Danger! the country of erection and the utilisation site.
Attention when working on parts carrying steam:

"Danger of being burned and/or being scorched"
Do not insulate newly installed piping to achieve shorter cooling times.
Dismantle the steam sieve and dirt pan and the drop and dirt separator. Install a
transition piece in place of the drop and dirt separator or make a direct
connection between the lines. When using a transition piece, etch it before
blowing out or clean thoroughly by mechanical means.
The blow-out line must be fastened securely during blow out to withstand
the strong reaction forces.
To avoid accidents, the steam outlet from the blow-

Danger! out line must be secured spaciously.
4951 910 03 35

8 DESIGN OF THE TURBINE DRAINAGE SYSTEMS, LEAKAGE STEAM AND
VAPOUR PIPES
8.1 Drainage with back pressure pipes
The drainage system fitted to the turbine is exclusively for the turbine.
The live steam and jet chamber drainage pipes can be led individually or as a
common line, via a steam collector, with drop into the atmosphere.
The exhaust steam drainage pipes must be led with drop into the atmosphere
separately.
All drainage systems of turbines rated to cut-in automatically are equipped with
automatic steam traps, the perfect function of which has to be checked regularly.
When the turbine is at standstill and the drain valves are open, steam is not
allowed to go back in the opposite direction into the turbine through the
drainage pipe.
Fix draining openings so that there is no risk of scorching

Danger! and no reduction of vision due to the outflow of steam.
4951 910 03 35

8.2 Leakage steam pipe
Depending upon the turbine rating, the leakage steam can be led into a low-
pressure system or, without pressure, into the atmosphere,
The „highest leakage steam pressure permissible“ has been calculated in
accordance with the data on exhaust steam pressure and turbine speed (please
refer to the service instructions “Technical data”).
When the pressure in the steam system is lower than the permissible leakage
steam pressure, the leakage steam pipe may be connected to this system
(please refer to illustration 4).
Illustration 4
Limit of supply
SIEMENS
1 Leakage steam pipe from the turbine

2 Shut-off valve
3 Drainage valve at the lowest point
4 Pipes to be led into the low-pressure system (collecting pipe)
by the customer
If no suitable steam system is available, the leakage steam pipe must be led with
drop into the atmosphere, a steam collector or a steam capacitor.
The losses in the leakage steam pipe must not exceed 0.1 to 0,2 bar.
4951 910 03 35

8.3 Vapour pipe
The vapour pipe, without shut-off valve, has to be led with drop into the
atmosphere, a steam collector or a steam capacitor.
The vapour pipe must be laid with a correspondingly bigger cross-section

to avoid backwater.
It is of particular importance that leakage steam and

vapour pipes are arranged separately from each other.
Attention! They must not be laid together with the drainage pipe
or end below the water level.
Please refer to the installation plan for the minimum pipe
cross-sections.
Make sure that steam cannot flow into the shaft sealing
Attention! gland when the turbine is at standstill and when the leakage
steam and vapour pipes are connected to steam collectors
or steam capacitors.
8.4 Drainage with condensing turbines
The drainage pipes must be designed in accordance with the manufacturer’s

indications pursuant to the R&I-schemes.
If floating ring seals are used, the leakage steam and vapour pipes may be
omitted.
4951 910 03 35

9 ARRANGEMENT OF THE TEMPERATURE MEASURING BRANCHES
Perfect measuring points to control the live steam temperature must be provided.
Such measuring points must be arranged in the live steam pipe, directly
upstream of the turbine. Connecting points for a mechanical and an electric
thermometer must be welded-in. The measuring set-ups have to be in
accordance with the VDI-guidelines 3512, sheet 2 (please refer to illustration 5).
4951 910 03 35

Measuring set-up with welded-in protective tube and built-in branch
Illustr. 5
1 Built-in branch
2 Welded-in protective tube DIN 43763 Form D
3 Tube DIN 43763
suitable for:
4 Connecting head DIN 43729
5 Gauge slide DIN 43735 or 43762
6 Glass thermometer DIN 16174 Form D and E
for industrial purposes DIN 16189 Form D and E
Ø d1 rough-drilled, reamed to G7 after welding.
Only the underlined dimensions are recommended. The supplier of the

operational apparatus must check on the other ones.
4951 910 03 35

Installation Guidelines
For the electric installation

of electrical and control equipments
in machinery and control cabinets

Postfach 17 28 Hessheimer Straße 2
Germany Germany
Phone ++49 (0) 6233 / 85 - 0

Fax ++49 (0) 6233 / 85 - 2660
4951 910 03 42
03.09 20-002 en
Page 1 of 30
CONTENTS
Page
1. Machine Installation ......................................................................................... 4
1.1 Technical data for machine control lines ........................................................ 4
1.2 General Information ........................................................................................... 6
1.3 Installation Paths - in the field, in machines, on cable trays and in ducts.............. 7
1.4 Explosion protection ........................................................................................ 8
2. Control cabinet installation ............................................................................. 9

2.1 Installation paths in cabinets, control desks, and control stations ..................... 10
2.2 Installation of low-energy signal lines for measurement and control systems..... 11
2.3 Explosion protection ........................................................................................ 12
3. Voith control components ............................................................................... 12

3.1 Installation of Voith control components ............................................................. 12
3.2 Technical data of the Voith control components .................................................. 14
4. Power supply for Voith control components ................................................ 16

4.1 Quality of the power supply ................................................................................. 17
5. Supplementary guidelines for the Woodward controller .............................. 18

5.1 Installation of the Woodward controller ............................................................ 18
5.2 Protection of the Woodward controller against electrostatic discharge .............. 19
5.3 Power supply to the Woodward controller and Voith components ..................... 20
5.3.1 Quality of the power supply ................................................................................ 21
5.3.2 Power supply to the Woodward controller .......................................................... 22
5.3.3 Power sources of the Woodward controller ........................................................ 23
5.3.4 Screening and earthing ...................................................................................... 24
5.4 Technical data of the Woodward controller ....................................................... 25
6. Notes regarding the installation of SPC, operator panel,

valve co-ordinator, bus cable .......................................................................... 27
7. Earthing and potential equalization ............................................................... 28
8. Standards for the dimensioning and laying of low and medium-voltage

power lines provided for the generator connections.......................... 29
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03.09 20-002 en
Page 2 of 30
APPENDIX
Fig. 1 Detail: Erection

(SIEMENS drawing no.: 4901 002 04 00)
Fig. 2-1 System arrangement potential equalization

(SIEMENS drawing no.: 4901 002 04 01; sheet 1)


Fig. 3-1 Dimensions of the Woodward controller
Fig. 3-6 Controller wiring diagram
Fig. 3-7 Typical 505 E/A scheme
4951 910 03 42
03.09 20-002 en
Page 3 of 30
1. Machine installation
1.1 Technical data for machine control lines
Installation materials and electrical equipment must be selected in order to fulfil the
environmental requirements on the site.
Oil-resistant machine control lines must be used for turbo machinery as they are in part
fitted to an oil supply unit.
The use of the following machine control lines is recommended for the electrical
equipment to be installed:
Binary transmitters, e.g. proximity switch and analogy signalling systems

 H05VVC4V5-K (former: NYSLYCYÖ – J) or others corresponding to this
standard
 e.g. lines of Lapp, Ölflex - 140 CY type, Classic - 115 CY.
 e.g. lines of Siemens Protoflex type.
Power consumers
Drive motors, actuators, solenoid valves, etc.
Binary transmitters: switches: limit, pressure, temperature switches, etc.

 H05VV5-F (former: NYSLYÖ – J) or others corresponding to this standard:
 e.g. lines of Lapp, Ölflex - 140 type
 e.g. lines of Siemens Protoflex type.
The installed lines may only be used inside of buildings or in suitable protection tubes or
in ducts. If the lines are exposed to a high mechanical load, a steel wire braid version,
e.g. lines of Lapp Ölflex -140 SY type must be used.
If the relevant machines are installed outdoors, the respective lines must be enclosed in
tubes (enclosed installation) or lines corresponding to VDE 0298, Part 3 must be used.
If the machines operate in explosion-endangered areas, only standard lines
corresponding to VDE 0298, Part 3 may be employed.
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03.09 20-002 en
Page 4 of 30
Technical data for machine control lines
Line type H05VV5-F H05VVC4V5-K

(former: NYSLYÖ – J) (former: NYSLYCYÖ – J)
Nominal voltage Uo/U 300/500 V 300/500 V
Test voltage 3,000 V 3,000 V
Temperature range - 5°C...+70°C 5°C...+70°C

- flexible
Temperature range - 40°C...+70°C 40°C...+70°C

fixed installation
Minimum bending radius 15x 20x

Line diameter Line diameter
Screening Braiding of tinned copper

wire
Construction Fine-wired stranded cable in accordance with

VDE0295 made of polished E-Cu wires, twisted
layers of PVC-insulated strands, black with white
lettering, 1 insulated strand always to be
green/yellow, outer coating to be of a special PVC-
mixture.
4951 910 03 42
03.09 20-002 en
Page 5 of 30
1.2 General Information
In order to ensure mechanical protection of machine installations, small metal cable

ducts are to be provided for the main cable paths and metal protection tubes for the
connections to the individual electrical equipment units. Fitting these installation means
to other supply and pressure pipes (oil, water, steam, etc.) is to be avoided as far as
possible. For inaccessible areas the protection tubes may be installed in the open form
(no pipe bends).
The lines are connected to the electrical equipments through cable bushings or by
plugs. The protection tube with edge protector at each end and at the bends ends right
before the cable bushing or plug.
The screening of the lines coming from the turbo machine must be continuous right
through to the control cabinet by means of local terminal boxes using lead-through
terminals which must not be earthed. Any earth connection at the local electrical
equipment for screening purposes is prohibited. In the control cabinet the screening is to
be connected to earth potential using the shortest possible path and a large contact
area (low resistor).
For information regarding the connection to the earth potential, see section 7, "earthing
and potential equalization".
The screening must not be interrupted along the length of the installation. Any
interruptions required must be made properly.
Reference numbers are to be attached to the ends of the lines.
Control and signal lines as well as power lines (supply lines for motors and/or power
consumers such as heaters) must be laid on different routes.
Due attention must be paid to the installation instructions provided in respect of the
individual electrical equipments.
4951 910 03 42
03.09 20-002 en
Page 6 of 30
1.3 Installation Paths - in the field, in machines, on cable trays and in ducts
In order to minimise as far as possible any disturbing effects caused by inductive and
capacitive couplings between lines laid in parallel the supply lines for power consumers
should be laid at a distance of more than 300 mm from the control and signal lines.
In all situations it is recommendable to select an installation route over different levels.
Crossing cable tracks should always be right-angled.
Supply lines for power consumers are to be laid on cable trays separated from control
and signal lines.
The distance between the cable trays should be at least 300 mm. This also applies to the
laying of supply lines for power consumers as well as control and signal lines in ducts.
Cable trays and ducts are to be connected in a conductive way and earthed.
In narrow spaces and when lines are laid in parallel the control and signal lines must be
enclosed in metal protection tubes if inter-reactive effects from power lines or supply
lines on the control and signal lines are to be expected. These protection tubes are to be
earthed. Power lines may be enclosed in PVC ducts.
Example: Supply lines between phase control and consumer, etc.
Connecting lines for the vibration measurement probes are to be installed very carefully.
The lines should not be bent or subjected to pressure and they must be secured by
means of clips to avoid abrasion. The lines used dependent on the installed transformers
(5 m or 9 m in length) must not be shortened and the connections must be protected
against water and oil, e.g. by means of shrink hosing. Plug connections (in the case of
extensions) are to be protected after calibration only (setting of the probe gap). The
ambient temperature in the area of the transformer should lie between 20°C and max.
65°C. Screened lines should be used to connect transformer and terminal box or
evaluation unit.
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03.09 20-002 en
Page 7 of 30
In the case of explosion-protection measures, the identification markings of all electrical
equipments must be clearly readable and they must never be covered over when
painting the machine.
If the type of protection inherent safety EEXi is used the electrical equipment (such as
connection lines, terminal blocks, cable entries) should be light blue or identified as such.
In the case of terminal boxes and in control cabinets with different forms of circuits (those
with and without inherent safety features), there must be a clear separation between the
terminal blocks (with an inherent safety feature - light blue) and the cable ducts (with an
inherent safety feature - light blue). There must be a distance of at least 50 mm for the
terminal blocks or a 1.5 mm partition with a creep path of 50 mm around the partition in
order to satisfy the requirements of VDE 0170/0171.
The installation of inherently-safe circuits to the control cabinet must be carried out using
light-blue lines separated from non-inherently safe circuits.
1.4 Explosion protection
As a rule, the following guidelines/standards must be observed for explosion protection:
Directive 94/9/EG
Directive 93/68/EG
Directive 89/336/EG
DIN EN 50014 (VDE 0170/0171)
DIN EN 50020 (VDE 0170/0171)
DIN EN 60079-7.
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2. Control cabinet installation
The control cabinet must be wired using leads with a cross-section of more than
1.0 mm2.
In the case of 24 V DC supply systems, the cross-section should be 1.5 mm2 while for
transformer lines carrying up to 5A, a cross-section of at least 2.5 mm2 should be
employed.
The unambiguous VDE specifications or the customer specification should be used for
colour coding.
Relays, contactors and solenoid valves should be wired using the following protective
devices:
 Direct current - Inverse diode

 Alternating current - Varistor or RC element
24 Volt and 0 volt supply lines are to be connected to distribution bus bars.
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2.1 Installation Paths - in control cabinets, control desks and control stations
For low-energy signals such as, e.g.:
a) Unit signals (0/4....20 mA)

b) Resistance thermometers
c) Thermocouples
d) mV-transmitters
e) Oscillation monitoring systems
f) Axial displacement monitoring systems
g) Proximity switches
h) Contacts for connection to amplifier relays
i) Speed transmitters
j) Pressure regulating valves
etc.
screened lines are to be used which are housed in one or more ducts separated from the
other lines to the extent that this is possible (a to c where necessary).
The control and signal lines must be laid separately from power lines whenever this is
possible.
The lines must be laid potentially separated in separate ducts whenever this is possible.
The potential separation must also be taken into account for the terminal arrangement.
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2.2 Installation of low-energy signal lines for measurement and control systems
To control the speed of turbo machinery signal lines must be laid from the speed
transmitters and the pressure regulating valve to the controller in the control cabinet.
It is of utmost importance to ensure that there are no interferences from other control,
signal and supply lines which are connections to other electrical equipments. The
instructions set out in the wiring diagram regarding the wire selection must be followed.
Before using another line type SIEMENS must be asked for their approval.
If no local terminal box is available the connecting lines from the speed transmitter is led
directly to the input terminals of control cabinet, control desk or the controller. The
screening is to be set to earth potential.
Here should also be a strict separation of the line paths whenever possible. Due
attention is to be paid to the necessary distances between low-energy signal lines and
high-energy signal lines and/or current supply lines.
For more detailed information please refer to section 2.1 (Installation paths).
When connecting lines to the terminals it must be ensured that the insulation of lines and
strands is as short as possible (i.e. the insulation reaches as close as possible to the
terminal). Individual strands may not be led through the ducts in the form of loops.
To the extent that a certain reserve length of line is necessary, only the completely
screened line length is to be included in the installation as a reserve length.
Loop formation is to be avoided.
All other lines connected to the controller are to be screened whereas the screening
material is to be connected to a collecting bus bar, which is to be connected to the earth
potential in a low-resistance manner.
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2.3 Explosion protection
As a rule, the following guidelines/standards must be observed for explosion protection:
Directive 94/9/EG
Directive 93/68/EG
Directive 89/336/EG
DIN EN 50014 (VDE 0170/0171)
DIN EN 50020 (VDE 0170/0171)
DIN EN 60079-7.
3. Voith control components
3.1 Installation of Voith control components
The instruments can be installed in a control cabinet. The area in which the control
cabinet is installed should have a temperature between 15°C and max. 40°C and a
relative humidity of 70%.
The installation height of 1,600 mm above floor level proved to be satisfactory.
The distance between power control gears and energy distribution systems must be
adequate.
The control system must be accommodated in the control cabinet so as to be easily

accessible.
To facilitate electrical de-coupling of the external control lines coupling relays are to be
used to prevent interfering signals from reaching the controller. The relay condition can
be indicated by LEDs. It should be possible to activate the relay manually.
The controller terminal connector strip and the relays are to be connected by short
screened lines. The relays are to be wired with inverse diodes. Coupling relays are to be
installed as close as possible to the controller terminal connector strip.
The mounting frame is to be earthed with a line having a cross-section of at least 4 mm2.
Special attention has to be paid to the potentially separated laying of the lines.
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The over voltage protection must be installed in the control cabinet if it cannot be housed
in the mounting frame of the controller.
It is secured to a mounting rail. Due to the low protection type (IP20) it is preferable to
install the controller on the mounting plate which is located in the control cabinet.
The operating elements in the form of push-buttons and switches must then be installed
in the front of the control panel. When installing the controller in the front of the control
panel, the latter is to be provided with a lockable transparent front cover.
Due attention is to be paid to the technical data relating to the Voith control
components.
As an example, the installation of coupling relay and mounting frame is described in
Fig. 1 Detail: - Erection.
Note regarding the installation of speed transmitter lines:

When using speed transmitters with pre-amplifier (e.g. explosion protection type) the
transmitter lines firmly attached to the transmitter are to be laid separately in an
adequately dimensioned protection tube.
This will facilitate dismounting and remounting in case of a replacement.
Fig. 1 Detail: Erection (SIEMENS drawing no.: 4901 002 04 00)
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3.2 Technical data of the Voith control components
SC 800 / Relay Cards / Connection Module
General Data:
Permissible ambient temperature:
in operation - 10 to + 65°C
during transport and storage - 25 to + 80°C
Humidity classification: as per DIN 40 040 E
Protection classification: as per DIN 57 411/ III

VDE 0411
1)
Protection type: as per DIN 40 050/ IP OO
IEC 144
Vibration resistance:
Acceleration 4g
Shock loading 10 g
Dimensions:
Speed controller SC 800 21 TE/3HE in 19"-module
Connection module SC 800 230/50/80 mm W/H/D
Relay card 8TE/3HE in 19"-module
Installation location as desired
1)
Advanced protection type to IP 65 possible through special housing.
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SC 800 / Relay Cards / Connection Module
Electrical data:
Supply voltage 24 V DC
Voltage range 21 to 30 V DC
Permissible residual ripple + 1.2 V
Maximum permissible voltage

between OV and housing 30 V
Current drawn:
Speed Controller SC 800 Normal 0.32 A
Max. 0.5 A
Relay Card Min. 0.03 A

Max. 0.1 A
Analogy inputs and outputs:
Ohmic resistance 200 Ohm
Current 0/4 to 20 mA
Signal relay:
Switching capacity at 30 V 40 W
Ohmic load
Permissible switching current max. 1 A

Permissible switching voltage max. 30 V
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4. Power supply for Voith control components
As electronic control systems and safety circuits are used for turbine drives it is
necessary to make special demands on the power supply. It is recommended to install a
battery-backed power supply system, complete with charging system, the negative pole
of which is to be earthed.
The supply lines from the supply terminal strip in the control cabinet to the control system
must be twisted and led through the over voltage protection unit.
Switching proposals are contained in the standard diagrams.
0 Volt lines used for power consumers must not be connected with the 0 Volt
leads of signal lines, but to a separate bus bar.
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4.1 Quality of the power supply
Operating voltage Nominal : 24 V DC

Ripple at rated load : = < 1.2 V
Permissible voltage range at the terminal positions of the control and adjusting
instruments: 22...30 V DC abs.
AC leakage current from the operating voltage relative to earth potential: < 0.05 mA.
The cross-section of the connection between 0 Volt and earth should be at least 4 mm2
of copper.
The dimensions of the lines used for the power supply results from:
 number and type of the relays used

 number and fusing of the different circuits
 number and performance of the signalling unit
 power requirement for the pressure regulating valve and the overspeed tripping unit
ST 800, if any
in each case - 24 V x 2.5 A = 60W
 power requirement for the SC 800 speed controller
24 V x 0.3 A = 7.2 W
 power requirement for any pressure controller
 power requirement for the solenoid valve.
Whatever type of power supply unit is employed, it is necessary that the 0 Volt bus bar is
directly earthed.
In the case of a battery-backed supply the 0 Volt is earthed in the control cabinet if the
battery is close to the control cabinet and the charging unit is located in the control
cabinet. In the case of external battery supply, the 0 Volt must not be earthed in the
control cabinet.
However, the voltage between 0 Volt at the controller and the earth potential must not
exceed 30 V.
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5 Supplementary guidelines for the Woodward controller
5.1 Installation of the Woodward controller
The Woodward controller can be installed in the front of the control cabinet. See Fig. 3-1
for the front cut-out, fixing holes and dimensions of the controller.
The room in which the control cabinet is installed should have a temperature between
15°C and max. 40°C at a relative humidity of 70%.
An installation height above the floor of 1,600 mm has proved to be effective.
Sufficient separation should be provided between the power switching devices and the
energy distribution units.
The relays should be connected to inverse diodes. LEDs should be used to show the
condition of the relays. Manual operation of the relays should be possible.
Special attention should be paid to a potentially separated laying of the lines.

Low-current lines (terminals 52 to 121) must be laid separately from the lines (terminals
1 to 51).
Fig. 3-1 Dimensions of the Woodward controller
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5.2 Protection of the Woodward controller against electrostatic discharge
All electronic equipments are sensitive to statically influences, some components more
than others. In order to protect these components from statically damage, special protective
measures must be taken to reduce or preclude electrostatic discharge.
1. Before carrying out maintenance work on the electronic control system, it is essential
that personnel should discharge the static electricity on their bodies by touching and
holding an earthed metal object (pipe, cabinet, equipment, etc.).
2. Build-up of static electricity should be avoided by not wearing clothing made from
synthetic materials. Where possible, garments made from cotton and cotton mixtures
should be worn, since these materials do not store static electric charge to the extent
that synthetic materials do.
3. On no account should electronics cards (printed circuit boards) be taken out of the
control cabinet unless this is absolutely necessary. The following rules should be
observed when handling PCBs:
 never touch any part of the card except for the edges.
 never touch the boards, edge connectors or the individual components with
conducting devices or with the hands.
4. Keep plastic, vinyl and polystyrene foam materials away from the control system, the
electronic cards and the working area. Materials such as plastics, expanded
polystyrene cups, coffee cup holders, cigarette packets, cellophane packaging for
sweets, book covers or folders made of vinyl materials, plastic bottles and plastic
ashtrays generate and store static electric charges.
This also applies to the insertion and removal of bridges (jumpers) on the control board.
4951 910 03 42
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5.3 Power supply to the Woodward controller and Voith components
(see Fig. 3-6)
As electronic control systems and safety circuits are used for turbine drives it is
necessary to make special demands on the power supply. It is recommended to install a
battery-backed power supply system, complete with charging system, the negative pole
of which is to be earthed.
The supply lines must be twisted. The supply line to the ST 800 must be led through the
over voltage protection unit.
Switching proposals are contained in the standard diagrams.
0 Volt lines used for power consumers must not be connected with the 0 Volt
leads of signal lines, but to a separate bus bar.
Fig. 3-6 Controller wiring diagram
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5.3.1 Quality of the power supply
Operating voltage nominal : 24 V DC

Ripple at rated load : = < 1.2 V
Permissible voltage range at the terminal positions of the control and adjusting
instruments: 21...30 V DC abs.
AC leakage current from the operating voltage relative to earth potential: < 0.05 mA.
The cross-section of the connection between 0 Volt and earth should be at least 4 mm2
of copper.
The dimensions of the lines used for the power supply results from:
 number and type of the relays used

 number and fusing of the different circuits
 number and performance of the signalling unit
 power requirement for the pressure regulating valve and the overspeed tripping unit
ST 800, if any
in each case - 24 V x 2.5 A = 60W
 power requirement for the Woodward controller
24 V, max. 4 A, max. 100 W
 power requirement for any pressure controller
 power requirement for the solenoid valve.
Whatever type of power supply unit is employed, it is necessary that the 0 Volt bus bar is
directly earthed.
In the case of a battery-backed supply the 0 Volt is earthed in the control cabinet if the
battery is close to the control cabinet and the charging unit is located in the control
cabinet. In the case of external battery supply, the 0 Volt must not be earthed in the
control cabinet.
However, the voltage between 0 Volt at the ST 800 controller and the earth potential
must not exceed 30 V.
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5.3.2 Power supply to the Woodward controller and Voith components
The 505 power supply is rated for 18 to 32 V DC. The power supply can absorb transient
input power losses of about 25 milliseconds (roughly 1.5 Hz at 60 Hz). Input power
losses of more than about 25 milliseconds lead to switching off due to power failure.
Power consumption is less than 100 W.
The power supply delivers the current for the control system and any external
transducers. The 505 controller is rated for supply of power to all transducers via an
unearthed two-wire system. The only exception is the separate 4-20 mA input from the
Woodward effective power transducer, which has its own internal power supply.
18 ... 32 V DC (internal fuse 6.25, maximum current drain 77 VA)
The buffer time of the 505 control system in the event of a power failure depends on its
power supply and the prevailing power consumption. The time given below is based on
the worst condition (i.e. 18 V DC with a bandwidth between 18 and 32 V DC, in the event
of a power failure). This buffer time can be applied when the 505 control unit is fed by an
uninterruptible power supply (UPS), in order to determine whether the UPS switch-over
time is so short that a system shut-down is ruled out. The UPS switch-over times must
be shorter than the buffer time given below:
Power holding time

18 ... 32 V DC power supply 14 ms
The power supply is integrated into the 505 housing. The external wiring for the power
supply is through a terminal strip.
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5.3.3 Power sources of the Woodward controller (see Fig. 3-7)
Fig. 3-7 Typical 505E/A scheme
ATTENTION
The total current drawn through the terminals 55, 59, 63, 70 and 74 should not
exceed 200 mA, since otherwise the switch for the internal power supply of the
505 (CB1) opens and may lead to a CPU reset and switching off. The entire load
must be relieved from the terminals so that the switch can be reset.
The second power supply duct supplies 24 V DC +/- 10% @ 200 mA max. output power
to adjust the power outputs and the auxiliary equipment of the 505. The power
connections can be made through the terminals 85, 88, 91, 97, 100 and 103, while
terminal 78 is the common earth.
ATTENTION
The total current drawn through the terminals 85, 88, 91, 97, 100 and 104 should
not exceed 200 mA, since otherwise the switch for the internal power supply of the
505 (CB2) opens and this may lead to a CPU reset and switching off. The entire
load must be relieved from the terminals so that the switch can be reset.
Fig.: 3-8 Arrangement of fuses
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5.3.4 Screening and earthing
The wiring for each MPU (magnetic pick-up) and for every actuator must be separately
screened. We also recommend separate screening for each milliampere input. Contact
inputs 1 (terminals 57 - 86) can be bundled together within a single multi-pole cable with
overall screening. The screening should only be connected at one end (usually the
controller end). For relay and power cable wiring, no screening is usually required.
It should be ensured that all inputs and outputs including all screening are not earthed
outside the 505 housing. The terminal strip 123 (earth) is the only 505 connection point
that should be attached to an external earth.
For reasons of interference prevention, it is recommended that all low-voltage lines

(terminals 52 to 121) should be separated from all high-voltage lines (terminals 1 to 51).
The input power earth terminal No. 3 should also be connected to the external earth.
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5.4 Technical data for the Woodward controller
General data:
Permissible ambient temperature:

in operation: - 20 to +65°C
in transport and storage - 40 to +85°C
Humidity class: Lloyds type EN V2 Test 1
2 temperature cycles between 20 and 55°C,

95% relative humidity within 48 hours.
EMC: EN 50081-2 and EN 50082-2
Insulation type: IEC 529 IP 66
Vibration: 13 - 100 Hz 1g
Shock loading: 30 g 11 ms
Dimensions: see Fig. 3-1 (Appendix)
Electrical connections:
Plug-in terminal strip 2.5 mm2
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Technical data for the Woodward controller
Electrical data:
Supply voltage: 24 V DC
Voltage range: 21 to 30 V DC
Permissible residual ripple: 1.2 V
Max. permissible voltage

between 0V and housing 30 V
This data is dependent on the Voith components.
Power consumption: see section 5.3.1
6 analogy inputs:
Load 200 Ohm
Current 4 to 20 mA
The controller supplies 24 V DC for the first 5 analogy inputs to supply the two-wire
transducer
6 analogy outputs:
Load max. 600 Ohm
Current 4 to 20 mA
16 contact inputs:
Normally 24 V DC 2.5 mA
At least 14 V DC 1 mA
Minimum closing time of a contact 14 ms for signal recognition
6 relay outputs:
permissible switching current max. 5 A / 0.5 A
permissible switching voltage max. 28 V DC / 115 V AC
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6. Notes regarding the installation of SPC, operator panel, valve
coordinator, bus cable
The installation of SPC (CPU, input and output modules, switching cards) and of the
operator panel has to be carried out in accordance with the manufacturer’s indications in
the respective manuals.
The manual of the respective bus applies to the laying of cables.
The installation guidelines of the valve co-ordinator apply to its installation.
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7. Earthing and potential equalization
In compliance with the local regulations and the prevailing mains conditions, the electrical
equipment associated with the turbo machine should be earthed. Potential equalization
should be carried out.
In the case of turbo-generators, the zero conductor should be connected directly to earth
with half the external conductor cross-section (if required by mains type). The generator
housing and all other earthing points should be wired separately from the PE rail. For
systems set up according to the VDE regulations, the following applies in particular:
DIN VDE 0100, Teil 540

DIN EN 50178.
Apart from the electrical equipment, the following should be included in the potential
equalization:
 the base frame of the turbine
 the water pipes to the oil cooler
 the media supply pipes
 the steel structures
 the associated steam pipes
 the control and monitoring cabinets
 the generator housing (for generator systems)
 the negative terminal of the battery
The dimensions of the relevant potential equalization lines should be determined according
to the above regulations.
In figures 2-1 to 2-3 a turbo unit was used as an example and the wiring shown
schematically.
The connecting points and the wiring routes should be adopted analogously.
Fig. 2-1 System arrangement potential equalization (SIEMENS drawing no.: 4901 002 04 01; sheet 1)
4951 910 03 42
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8. Standards for the dimensioning and laying of low and medium-
voltage power cables provided for the generator connections
As a matter of principle, cable trays have to be connected with each other and with the
earth potential.
To avoid a damage to the cable insulation the supporting systems have to be provided
with edge protection both at the beginning and in the wiring corners.
In case of low and medium-voltage cables pipe clamps of nonmagnetic material have to
be fixed at a distance of one meter respectively.
In case of cable entries – e.g. out of a duct from below into the power control cabinet –
suitable cable cord strips (cable clamping rails) must always be provided. If laying takes
place in bends or entries and exits in terminal boxes and control cabinets the permitted
bending radii of the cables have to be observed.
When cables are laid on cable trays without sufficient distance, in pipes or badly
ventilated ducts, as well as at increased environmental temperatures, the reduction
factors according to VDE 0298 / DIN 57298 have to be taken into account.
Laying several systems per phase means that they have be laid symmetrically and
partitioned into collars, so that each collar consists of the phases L1, L2, L3 (and
possibly N) to counteract the formation of magnetic fields. If possible, the cross bonding
into symmetrical systems shall be carried out in the generator terminal box or in the
generator power switch.
The neutral is to be laid with half outer conductor cross section, if it is earthed outside
the generator or differently.
The suitability of the insulation material has to be guaranteed according to the location
and the conditions prevailing there.
Generally, suitable cable potheads have to be used at medium-voltage cables.
The cable screen must be led on earth potential on both sides. That the pressing of the
potheads must be carried out in accordance with the details of the manufacturer goes
4951 910 03 42
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without saying.
_________
>1
_________
>1
1 Cable tray
2 Cable clamps of nonmagnetic material
(aluminium)
The outer conductors must always be partitioned symmetrically into triple collars !
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Abkürzungen / Abbreviations Datum / Date
Teileliste Z-Pos = Zeichnungsposition / Drawing Item

M = Menge je Einheit / Quantity per unit
ME = Mengeneinheit / Code for unit of quantity (ME)
18.09.2009
Seite / Page no
Parts list ST = Stück / Each

L = Liter / Litre
KG = kg / Kilogramme
M = Meter / Metre
22
* = separate Teileliste / Separate parts list Gedruckt von: / Printed by

TREUG00C
Auftrags-Nr./ Job no. Benennung / Designation Zeichnung(en) / Drawing(s)
4144242/10 Zsb. Rohrleitung - Anbauteile Z-162026 /DRW/-

ASSY. PIPING
Maschinen-Nr. / Machine no. Materialnummer / Parts list no.
4-360002-331
Materialnummer / Part no. M Benennung / Designation Ersatzteilcode /
Z-Pos ME Werkstoff / Material Spare part code
4-340000-047 1,0 Zsb. Turbohilfsölpumpe 65 l/min

660 ST ASSEMBLY AUXILIARY TURBO OIL PUMP
2-470060-074 1,0 Mano.-Anordnung

670 ST PRESSURE GAUGE ARRANGEMENT
STAHL
49004723302 1,0 STUETZBL F.DR-AN.EINBAU

670 ST SUPPORT (SPEED INDICATOR)
00035430406 2,0 ZYLINDERSCHRAUBE MIT SCHLITZ

670 ST CYLINDER HEAD SCREW
4.8
3-415302-017 1,0 Bezeichnungsschild FRISCHDAMPF-E

670.1 ST LABELLING PLATES
PE 100
3-415302-015 1,0 Bezeichnungsschild ABDAMPF-E

PE 100
3-415302-021 3,0 Bezeichnungsschild SCHMOEL-E

PE 100
3-415302-020 1,0 Bezeichnungsschild STEUEROEL-E

PE 100
00030710536 1,0 OELSTANDSAUGE

680 ST OIL SIGHT GLASS
AL
49003483100 3,0 Dichtung 1

.. ST GASKET
REINZOLOID

18.09.2009
Seite / Page no

L = Liter / Litre
M = Meter / Metre
23

TREUG00C
4144242/10 Zsb. Rohrleitung - Dampf Z-162026 /DRW/-

ASSY. STEAM PIPING
4-360002-332
49003673429 1,0 SCHWEISSNIPPEL DN10

700 ST WELDING NIPPLE
13CRMO44V
00080250000 2,0 Dichtring A kammprofiliert/Reingraphit 1

701 ST Grooved-O-rings
13CRMO4-5/REINGR.
49003673302 2,0 Überwurfschraube DN 15

702 ST CAP SCREW
21 CRMO V 57 V
49003673402 1,0 Schweißnippel DN 15

703 ST WELDING NIPPLE
13 CRMO 44
43433600159504 1,0 ROHR 13,5 X 2,0

704 ST tube
13CRMO4-5
47003609121 1,0 ROHR 21,3 X 2,6

705 ST Pipe
13CRMO4-5
3-322421-001 1,0 Anschweiss-Rohrverschraubung

706 ST WELD-ON TUBE CONNECTION
13CRMO4-5
00032760005 1,0 T-FITTING DN 15

707 ST T-FITTING B2
13CRMO4-5
00032600010 1,0 VORSCHWEISSFLANSCH 1500 LB (13CRMO44)

708 ST WELDING NECK FLANGE
13CRMO4-5
00080250081 1,0 DICHTRING B 1

709 ST SEALING RING
13CRMO4-5
00035670031 4,0 SCHRAUBENBOLZEN FORM L

710 ST SCREW BOLT
21CRMOV5-7
00035680041 8,0 Sechskantmutter M20 NF Produktklasse T3

711 ST HEXAGONAL NUT
21 CRMO V 57
00030021506 1,0 ABSPERRVENTIL MIT FLANSCH

712 ST Shut-off valve with flange
13 CRMO 44
3-300101-032 1,0 Zwei-Zapfen-DG-Ventil (Nippel 13CrMo4-5)

713 ST SHUT-OFF VALVE
13CRMO4-5

18.09.2009
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L = Liter / Litre
M = Meter / Metre
24

TREUG00C

ASSY. STEAM PIPING
4-360002-333

403 ST Grooved-O-rings
13CRMO4-5/REINGR.
49003673444 1,0 Schweißnippel DN15

410 ST WELDING PIECE
15 MO 3
49003673302 1,0 Überwurfschraube DN 15

411 ST CAP SCREW
21 CRMO V 57 V
00018300006 0,0 ROHR

416 ST TUBE
16MO3+N
3-356702-113 4,0 Schraubenbolzen L

420 ST SCREW BOLT
21CRMOV5-7
00035680002 8,0 SECHSKANTMUTTER NF PRODUKTKLASSE T3

21 CRMO V 57
00080250081 1,0 DICHTRING B 1

422 ST SEALING RING
13CRMO4-5
00032510028 1,0 VORSCHWEISSFLANSCH 150 LB RF

16MO3 (15MO3)
00030021509 1,0 ABSPERRVENTIL MIT FLANSCH ANSI RF

424 ST SHUT OFF VALVE
13 CRMO 44
00032000008 1,0 REDUZIERSTUECK K

438 ST REDUCTION PIECE
16MO3
2-010042-002 1,0 Anschweißstutzen DN10

440 ST BUSHING
16MO3
00018300005 0,0 ROHR

441 ST TUBE
16MO3+N

.. ST BUSHING
16MO3

.. ST BUSHING
16MO3

18.09.2009
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M = Meter / Metre
25

TREUG00C

ASSY. STEAM PIPING
4-360002-333
2-702015-004 1,0 Bezeichnungsschild (DE-EN-FR-SP-IT)

.. ST LABELLING PLATES
EDELSTAHL

EDELSTAHL

EDELSTAHL
2-702015-020 1,0 Bezeichnungsschild

EDELSTAHL

18.09.2009
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M = Meter / Metre
26

TREUG00C
4144242/10 Zsb. Rohrleitung - Öl Z-162026 /DRW/-

ASSY. OIL PIPING
4-360002-334
41442323200 1,0 Handlochdeckel

2 ST COVER
S235JRG2
49003674349 2,0 Einschraubstutzen R3/8"-R1/2"

12 ST SCREW-IN BRANCH
ST 42 KG
00080360359 4,0 FUELLDICHTRING C 1

13 ST SEALING RING C
SF-CU
2-526200-050 2,0 Thermometer

15 ST THERMOMETER
3-308901-007 3,0 Schutzrohr

16 ST PROTECTIVE TUBE
C22.8
2-010041-001 3,0 Distanzbuchse

17 ST SPACER BUSHING
S235JRG1(UST37-2)
2-526200-071 1,0 Kontaktthermometer mit Fernleitung

18 ST THERMOMETER
4-500120-147 1,0 Halter

18 ST HOLDER
S235JRG1(UST37-2)
49003675057 1,0 FLANSCH DN 32/25

23 ST FLANGE
R ST 37-2
49003675056 3,0 FLANSCH DN 32

24 ST FLANGE
R ST 37-2
00080322302 4,0 DICHTUNG 1

25 ST GASKET
CENTELL.HD WS3822
00035190959 16,0 Zylinderschraube

8.8
00032510504 2,0 FLANSCH C

C22.8
00080320356 2,0 DICHTUNG 1

28 ST GASKET
CENTELLEN HD WS3822

18.09.2009
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M = Meter / Metre
27

TREUG00C

ASSY. OIL PIPING
4-360002-334
00035356782 8,0 SECHSKANTSCHRAUBE

29 ST HEXAGONAL BOLT
8.8
00035500451 8,0 Sechskantmutter M 16

29 ST HEXAGONAL NUT
8
49015260075 1,0 3/2 WEGE-MAGNETVENTIL G3/4"

30 ST SOLENOID VALVE
AUSF. BUNTMETALL
2-688100-676 1,0 Kühler

31 ST COOLER
00035360455 4,0 Sechskantschraube

8.8
19002896134 1,0 HALTERG. F. FILTER

36 ST Support for filter
ST
2-365010-133 1,0 Ölfilter

37 ST OIL FILTER
49003670102 1,0 ZSB EINSCHRAUBSTUTZEN

38 ST LUBE OIL THROTTLE W. NON-RETURN VALVE
00032280004 1,0 RUECKSCHLAGVENTIL

39 ST NON-RETURN VALVE
ST
4-345000-338 1,0 E-Pumpe

50 ST ELECTRIC OIL PUMP
49003690103 1,0 HALTERG 270X250 (E-PUMPE)

51 ST MOUNTING SUPPORT
RQ ST 37-2
49003300016 1,0 Zsb.Umschaltventil (Kugelausführung)

52 ST ASSY. SWITCH VALVE
49014723403 2,0 Zwischenstück 6-kt G1/4,G1/2

59 ST INTERMEDIATE PIECE
ST 42 KG
00080360303 2,0 FUELLDICHTRING FORM C 1

60 ST SEALING RING
SF-CU

18.09.2009
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M = Meter / Metre
28

TREUG00C

ASSY. OIL PIPING
4-360002-334
49013650175 1,0 EINFACH FILTER B

73 ST OIL FILTER
AL/ST
00032280005 1,0 RUECKSCHLAGVENTIL

74 ST NON-RETURN VALVE
ST
49003674312 1,0 EINSCHRBSTUTZEN R 1"/ R 3/4"

90 ST LUBE OIL THROTTLE WITH NON-RETURN VALVE
21 CRMO V 5 7 V
49005200005 1,0 Überströmventil NW15 ND12

91 ST ASSY. OVERFLOW VALVE
2-367070-054 2,0 Druckschalter 0,5-4 bar

92 ST PRESSURE SWITCH
19003670002 1,0 SCHMIEROELDROSSEL R1/2"

117 ST LUBE OIL THROTTLE
ST 42 KG
49002363501 1,0 SCHMIEROELVERTEILERSTUECK

119 ST Lube oil distributing piece
GG-20
49003773000 4,0 ovaler Flansch DN15 KKK.Nr.-5077

120 ST OVAL FLANGE
ST 37-2
49002383100 1,0 Dichtung Ø120/120x1 (Schmierölverteiler) 1

121 ST GASKET (FOR LUBE OIL DISTRIBUTING PIECE)
REINZOLOID
00080322251 5,0 Dichtung 1

122 ST GASKET
CENTELLEN HD WS3822

8.8
00035406365 4,0 Stiftschraube

124 ST STUD BOLT
5.8
00035500353 4,0 Sechskantmutter

8
3-303803-004 2,0 Kugelhahn

126 ST BALL VALVE
STAHL

18.09.2009
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M = Meter / Metre
29

TREUG00C

ASSY. OIL PIPING
4-360002-334
00018200997 0,0 ROHR (P235T2/ ST37.4)

189 ST TUBE
P235TR2+N
00018200757 0,0 ROHR (P235T2/ ST37.4)

190 ST TUBE
P235TR2+N
00018200408 0,0 ROHR (P235G1TH/ St 35.8)

191 ST TUBE
P235GH+N
00018200552 0,0 ROHR (P235T2/ ST37.4)

192 ST TUBE
P235TR2+N
00018200701 0,0 ROHR (P235T2/ ST37.4)

193 ST TUBE
P235TR2+N
00032760052 4,0 T
200 ST T-PIECE
P235GH+N
00032220209 6,0 ANSCHWEISS-VERSCHRAUBUNG

250 ST SCREWING TO BE WELDED ON
ST
00032220256 2,0 ANSCHWEISS-VERSCHRAUBUNG

253 ST SCREWING TO BE WELDED ON
ST
00032241705 3,0 Gerade Einschraubverschraubung

254 ST MALE STUD UNION
ST
00032240704 16,0 GERADE EINSCHRAUBVERSCHRAUBUNG GE

255 ST MALE STUD UNION GE
ST
00032240752 11,0 GERADE EINSCHRAUBVERSCHRAUBUNG

ST

ST

ST

ST 37.0

18.09.2009
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M = Meter / Metre
30

TREUG00C

ASSY. OIL PIPING
4-360002-334
00032290151 2,0 KOMPLETTER KONUS-REDUZIERANSCHLUSS

261 ST CONE REDUCTION
ST

ST

ST

P235GH+N
00032230148 7,0 T-VERSCHRAUBUNG

265 ST T-SCREW CONNECTION
ST

ST

ST

ST
00032190069 1,0 GERADE AUFSCHRAUBVERSCHRAUBUNG

270 ST Male stud union
ST
00032270057 1,0 EINSTELLBARE L-VERSCHRAUBUNG

280 ST L SCREWED CONNECTION
ST
00032200007 2,0 SCHWENKVERSCHRAUBUNG

287 ST SWIVELLING SCREW FITTING
ST

ST
00032210206 5,0 GERADE VERSCHRAUBUNG

.. ST SCREW CONNECTION
ST
3-322025-008 5,0 Zwischenstutzen

.. ST INTERMEDIATE CONNECTION PIECE
STAHL

18.09.2009
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L = Liter / Litre
M = Meter / Metre
31

TREUG00C

ASSY. OIL PIPING
4-360002-334
00032210252 5,0 GERADE VERSCHRAUBUNG

.. ST SCREW CONNECTION
ST
3-820401-011 10,0 Rohrschelle

.. ST PIPE CLAMP
POLYAMID
3-820401-015 10,0 Rohrschelle

.. ST PIPE CLAMP
POLYAMID
3-820401-017 5,0 Rohrschelle

.. ST PIPE CLAMP
POLYAMID
00082044300 5,0 ROHRSCHELLE

.. ST PIPE CLAMP
POLYAMID
00082045380 5,0 ROHRSCHELLE

.. ST PIPE CLAMP
POLYAMID

18.09.2009
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M = Meter / Metre
1

TREUG00C
4144242/10 Turbine AF4 G/Gs 41400014000 /DRW/C

Turbine AF4 G/Gs
41400001300
4-231300-033 1,0 Zsb. Getriebegehäuse AF4Gs Sondergrundie *

15 ST BEARING HOUSING, 2 PARTS
41441552000 1,0 Halslager 2-teilig 3

030 ST JOURNAL BEARING
41401552503 1,0 Hals- und Spurlager 3

031 ST Journal and Thrust Bearing
C45E+QT
41441552001 1,0 Halslager 2-teilig 3

032 ST JOURNAL BEARING
41401552501 1,0 Hals- und Spurlager 3

033 ST JOURNAL AND THRUST BEARING
41442301501 1,0 Zsb.Getriebewelle I=3.49 B=100 *

041 ST ASSY. GEAR SHAFT
4-120001-781 1,0 Zsb.Turbinenläufer 6 *

050 ST ASSY. TURBINE ROTOR
49002940012 1,0 Zahnradölpumpe 24cm³/U (Einbauölpumpe)

060 ST GEAR OIL PUMP
00040600653 1,0 RECHTECKRING KI PT 1

061 ST SQUARE SECTION RING
GG
00041050401 1,0 PASSFEDER A

062 ST PARALLEL KEYS
C45+C
41442954011 1,0 Antriebsrad z=136

063 ST DRIVE WHEEL
CK 35

8
00035850256 1,0 Scheibe mit Außennase

065 ST WASHER / DISC
ST 13 O3

8.8

18.09.2009
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L = Liter / Litre
M = Meter / Metre
2

TREUG00C

Turbine AF4 G/Gs
41400001300
00035820256 3,0 Scheibe mit Lappen

071 ST SAFETY PLATE
ST 13 O3
41442323305 1,0 Ölpumpendeckel

080 ST OIL PUMP COVER
GG-20
41442383105 1,0 Dichtung 1

081 ST GASKET
LOWOFLEX
00035191255 10,0 ZYLINDERSCHRAUBE

8.8
00035774455 2,0 Steckkerbstift

083 ST TAPER GROOVED DOWEL PIN
6.8

8.8
41404013503 1,0 Reglergehäuse

090 ST GOVERNOR CASING
GG-20

8.8
49014063302 1,0 Steuerzapfen

093 ST CONTROL PIVOT
GGG-40
49003323015 1,0 Zylinderschraubenfeder

094 ST CYLINDRICAL HELICAL
DRAHT 1,25 A
00035252554 1,0 VERSCHLUSSSCHRAUBE

095 ST LOCKING SCREW
ST
00080360205 1,0 Fülldichtring Form C 1

SF-CU
00035770207 1,0 Kegelkerbstift

097 ST TAPER GROVED PIN
6.8

6.8

18.09.2009
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L = Liter / Litre
M = Meter / Metre
3

TREUG00C

Turbine AF4 G/Gs
41400001300
49004063200 1,0 Spurlager 3

099 ST Thrust Bearing
GG-25
49003900034 1,0 Zsb.SS-Vermittler mit Kunststoffklinke *

110 ST ASSY. TRIP TRANSMITTER
49013933401 1,0 Scheibe 34

111 ST DISC
UST 37-2
00035405991 4,0 STIFTSCHRAUBE

112 ST STUD BOLT
5.8

8

ST
00080370305 4,0 DICHTRING FORM D 1

122 ST SEALING RING D
CU
42403000102 1,0 Drehzahlgeberantrieb *

130 ST Speed transmitter drive

6.8

8.8
49002374202 1,0 Blindflansch

136 ST BLIND FLANGE
U ST 37-2
00080320356 1,0 DICHTUNG 1

137 ST GASKET
CENTELLEN HD WS3822
41442323100 1,0 Ölfangdeckel kupplungsseitig

140 ST OIL COLLECTING COVER COUPLING SIDE

8.8

18.09.2009
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L = Liter / Litre
M = Meter / Metre
4

TREUG00C

Turbine AF4 G/Gs
41400001300
41442383101 1,0 Dichtung für Ölfangdeckel 1

142 ST GASKET
REINZOLOID
00041620605 1,0 RICHTUNGSPFEIL A 6X32

143 ST DIRECTION ARROW
ALU
00035778058 2,0 HALBRUNDKERBNAGEL

144 ST ROUND HEAD GROOVED PIN
U ST 36-2
4-702010-829 1,0 Turbinenbeschriftung

145 ST TURBINE LABELLING
00035778108 4,0 HALBRUNDKERBNAGEL

146 ST ROUND HEAD GROOVED PIN
A2

150 ST BLIND FLANGE
R ST 37-2
49003183000 1,0 Dichtung 1

151 ST GASKET
REINZOLOID

152 ST STUD BOLT
5.8

8
49001573200 1,0 Passstift

154 ST PIN
9SMN28+C KLASSE 4

155 ST BLIND FLANGE
U ST 37-2

160 ST SAFETY PLATE
ST 13 O3

8.8
49004083003 1,0 Dichtung 1

162 ST GASKET ¢100,5/140X0,25
REINZOLOID

18.09.2009
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L = Liter / Litre
M = Meter / Metre
5

TREUG00C

Turbine AF4 G/Gs
41400001300
49003183000 1,0 Dichtung 1

164 ST GASKET
REINZOLOID
41442323102 1,0 Ölfangdeckel 2-teilig turbinenseitig

170 ST OIL COLLECTING COVER TURBINE SIDE
41442383101 1,0 Dichtung für Ölfangdeckel 1

171 ST GASKET
REINZOLOID

8.8

180 ST BLIND FLANGE
U ST 37-2

8.8
41442383102 1,0 Dichtung zu Blindflansch 1

182 ST GASKET (Blind flange)
REINZOLOID
00030630052 2,0 THERMOMETER B M 160X63

190 ST THERMOMETER
MS

191 ST SEALING RING
SF-CU
49003650119 1,0 Belüftungsfilter PI 0140

192 ST VENTILATION FILTER
ST/MOL
49002373251 1,0 Entlüftungsstutzen M42x1.5

193 ST VENT BRANCH
ST 33-2
41442383103 1,0 Dichtung zu Handlochdeckel 1

200 ST GASKET
REINZOLOID

201 ST STUD BOLT
5.8
41442323200 1,0 Handlochdeckel

202 ST COVER
S235JRG2

18.09.2009
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L = Liter / Litre
M = Meter / Metre
6

TREUG00C

Turbine AF4 G/Gs
41400001300

8
41401033200 1,0 Zentrierring

210 ST CENTERING RING

211 ST STUD BOLT
5.6

212 ST STUD BOLT
5.6
00035500502 4,0 SECHSKANTMUTTER M 20

8

214 ST SAFETY PLATE
ST 13 O3
41401013327 1,0 Turbinengehäuse (3 Düsen rechts) *

220 ST Turbine casing (three nozzle right)
49001063100 4,0 Stiftschraube mit Dehnschaft

223 ST STUD BOLT
21 CRMO V 57 V
49001064000 4,0 Unterlegscheibe

224 ST SHIM
42 CRMO 4 V
00035680041 4,0 Sechskantmutter M20 NF Produktklasse T3

21 CRMO V 57
41401800010 1,0 Zsb.Wellenstopfbuchse

230 ST ASSY. CARBON-RING GLAND
00035340100 8,0 Sechskantschraube M 10 x 30

21 CRMO V 57

241 ST SAFETY PLATE
A2
00035340100 8,0 Sechskantschraube M 10 x 30

21 CRMO V 57

18.09.2009
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L = Liter / Litre
M = Meter / Metre
7

TREUG00C

Turbine AF4 G/Gs
41400001300
41401883003 1,0 Dichtung 1

244 ST GASKET Ø160/225 x 1,5
REINGRAPHIT
00080313051 1,0 DICHTRING A KAMMPROFILIERT/REINGRAPHIT 1

261 ST GASKET
13CRMO4-5/REINGR

262 ST gasket A 60X80X4 steel/graphite
13CRMO4-5/REINGR
4-111000-105 1,0 Ventilgehäuse

270 ST VALVE CASING
4-110001-491 1,0 Stellventil RS160 Hub=30mm *

275 ST ADJUSTING VALVE

276 ST GASKET A
13CRMO4-5/REINGRAPHIT
00035680024 24,0 SECHSKANTMUTTER NF PRODUKTKLASSE T3

21CRMOV5-7
41401083006 1,0 Dichtung 1

280 ST GASKET
GRAPHIT
40471020000 1,0 Turbinengehäusedeckel PN16

281 ST Turbine Casing Cover

282 ST Stud Bolt
21 CRMO V 57 V
41401663111 1,0 Umkehrkammer 5 rechts 6

283 ST REVERSING CHAMBER
EN-GJL-200

284 ST Reversing chamber
GG-20

285 ST Reversing chamber
GG-20
41401674002 4,0 Distanzstück

286 ST DISTANCE PIECE
R ST 37-2

18.09.2009
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L = Liter / Litre
M = Meter / Metre
8

TREUG00C

Turbine AF4 G/Gs
41400001300
00040750340 8,0 Paßscheibe

286 ST SHIM RING
ST 2 K 60

21 CRMO V 57

21 CRMO V 57 V
00040750354 6,0 Paßscheibe Ø12/18 x 0,5

288 ST SHIM RING
ST 2 K 60
41301613057 1,0 Düse 7/4 3

289 ST NOZZLE
X 20 CR 13 V
41301613063 1,0 Düse 8/4 3

290 ST NOZZLE
X 20 CR 13 V
41301613063 1,0 Düse 8/4 3

291 ST NOZZLE
X 20 CR 13 V
00080300703 4,0 Flachdichtung Form A kammprofiliert 1

293 ST SEALING RING
ST 30
41301673101 3,0 Düsen-Überwurfschraube 3

294 ST NOZZLE CAP SCREW
21 CRMO V 57 V
41301673201 1,0 Verschlußschraube

298 ST Screw Plug
21 CRMO V 5 7 V
4-360002-331 1,0 Zsb. Rohrleitung - Anbauteile *

.. ST ASSY. PIPING
4-360002-332 1,0 Zsb. Rohrleitung - Dampf *

.. ST ASSY. STEAM PIPING
13CRMO44
4-360002-333 1,0 Zsb. Rohrleitung - Dampf *

.. ST ASSY. STEAM PIPING
16MO3
4-360002-334 1,0 Zsb. Rohrleitung - Öl *

.. ST ASSY. OIL PIPING

18.09.2009
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L = Liter / Litre
M = Meter / Metre
9

TREUG00C

Turbine AF4 G/Gs
41400001300
41442345100 1,0 Paßfeder

656 ST KEY
NAXTRA 70
41404800003 1,0 Isolierung Blech/Mineralwolle AF4

710 ST ASSY. HEAT PROTECTION
49003483100 1,0 Dichtung 1

750 ST GASKET
REINZOLOID

751 ST STUD BOLT
5.8

8

753 ST Blind flange
S235JRG2

18.09.2009
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M = Meter / Metre
19

TREUG00C
4144242/10 Turbinengehäuse (3 Düsen rechts) 41401014000 /DRW/E

Turbine casing (three nozzle right) 41401097605 /DRW/-
41401013327
41401071002 2,0 Leckdampfabführung DN15

004 ST LEAKAGE STEAM DRAIN

18.09.2009
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L = Liter / Litre
M = Meter / Metre
14

TREUG00C
4144242/10 Zsb.Turbinenläufer
ASSY. TURBINE ROTOR
4-120001-781
41442330021 1,0 Turbinenwelle mit Ritzel I=3.49

001 ST TURBINE SHAFT WITH PINION
42CRMO4+QT
41442345101 1,0 Paßfeder (Naxtra)

003 ST KEY (Naxtra)
NAXTRA 70
00041051305 1,0 PASSFEDER A 8X 5X 32

C45+C

6.8
41401243104 1,0 Spurring

006 ST THRUST RING
CK 45 N
41401243202 1,0 Gegenspurring

007 ST COUNTER THRUST RING
CK 45 N
41402953004 1,0 Antriebsritzel z=39

008 ST DRIVE PINION
CK 45 N
00035810509 1,0 SICHERUNGSBLECH MIT INNENNASE

011 ST SAFETY PLATE, TONGUED INSIDE
ST 13 O3
41441283000 1,0 Wellenmutter

012 ST SHAFT NUT
C45
41441230005 1,0 Laufrad AF4 Drehrichtung rechts 6

013 ST Turbine Wheel
21 CRMOV 57 V
00035810458 1,0 Sicherungsblech mit Innennase

ST 13 O3
00035661256 1,0 Nutmutter

015 ST GROOVED NUT
21 CRMO V 5 7
49003823000 1,0 Schnellschlußbolzen ohne Bohrung

020 ST EMERGENCY BOLT
16 MNCR 5 G
49003833101 1,0 Führungsbuchse

021 ST GUIDE BUSH
GC-CUSN 7 ZNPB

18.09.2009
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L = Liter / Litre
M = Meter / Metre
15

TREUG00C
4144242/10 Zsb.Turbinenläufer
ASSY. TURBINE ROTOR
4-120001-781

022 ST CYLINDRICAL HELICAL SPRING
DRAHT 4,25 B
00035310058 1,0 Gewindestift m. Innenskt. m. Kegelstumpf

023 ST THREADED PIN
45H
00041180025 1,0 Beilage (Distanzscheibe)

025 ST SHIM (DISC)
DC03
00041180203 1,0 BEILAGE (Distanzscheibe)

028 ST SHIM (DISC)
DC03
49004033062 1,0 Reglerpendel

039 ST GOVERNOR PENDULUM
30 CRNIMO 8 G

6.8
00035830301 1,0 Scheibe B

ST
00035510202 1,0 Sechskantmutter M12 DIN 985

8
49004063000 1,0 Reglerbuchse

045 ST GOVERNOR BUSH
CK 45 N
00040790203 1,0 V-Ring J

046 ST V-RING
FED-ST
00080701817 1,0 LOCTITE 641

100 ST LOCTITE 641 GLUE

21.10.2009
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L = Liter / Litre
M = Meter / Metre
20

TREUG00C
4144242/10 Zsb.Wellenstopfbuchse 41401804000 /DRW/A

ASSY. CARBON-RING GLAND
41401800010
41401813106 1,0 Stopfbuchsgehäuse 5.1-8 bar

001 ST GLAND CASING
GG-20
41401855008 3,0 Kammerring 3

005 ST CHAMBER RING
X 5 CRNI 18 9
41401855009 2,0 Kammerring 3

006 ST CHAMBER RING
X 5 CRNI 18 9
41401833103 5,0 Kohlering 3-teilig 3

007 ST CARBON RING
FE 45 S
41401823100 1,0 Ringdruckfeder 3

008 ST ANNULAR PRESSURE SPRING
FEDERSTAHL
00035772102 3,0 Zylinderkerbstift

009 ST GROOVED STRAIGHT PIN
6.8
41401850000 1,0 Flanschring mit Abdichtblech

010 ST FLANGE RING

8.8
00035870206 24,0 Sicherungsscheibe

012 ST CIRCLIP
FED-ST

18.09.2009
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L = Liter / Litre
M = Meter / Metre
20

TREUG00C
4144242/10 Stellventil RS160 Hub=30mm 41401104600 /DRW/D

ADJUSTING VALVE
4-110001-491
4-430001-136 1,0 Stellmotor RS160 Hub=30mm *

001 ST SERVO MOTOR
41401154515 1,0 Ventilspindel 3

002 ST valve spindle
X 20 CR 13 V
41401155100 1,0 Überwurfschraube 2-teilig

003 ST Cap Screw
CK 35
4-114000-507 1,0 Kegel Ø=36 3

004 ST VALVE CONE
X20CR13
41401153101 1,0 Stopfbuchse DN65/80 PN160

005 ST GLAND BOX CASING
GS-17 CRMO 55
41301154205 1,0 Dampfsieb DN65/80

006 ST STEAM STRAINER
X 10 CRNITI 18 9
00080322154 2,0 DICHTUNG 1

007 ST GASKET
NOVAPRESS MULTI
49001173111 2,0 Kohlering 1

008 ST CARBON RING
KOHLE LE 967
49011183516 5,0 Dichtung 1

009 ST Gasket
REINGRAPHIT
49001173111 2,0 Kohlering 1

010 ST CARBON RING
KOHLE LE 967
41401154100 1,0 Stopfbuchsbrille

011 ST GLAND END COVER
S235JRG2

012 ST STUD BOLT
5.8

8
49001155202 1,0 Ventilkupplung

014 ST VALVE COUPLING
X 20 CR 13 V

18.09.2009
Seite / Page no

L = Liter / Litre
M = Meter / Metre
21

TREUG00C
4144242/10 Stellventil RS160 Hub=30mm 41401104600 /DRW/D

ADJUSTING VALVE
4-110001-491

8.8

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33

TREUG00C
4144242/10 Stellmotor RS160 Hub=30mm 49004304002 /DRW/A

SERVO MOTOR
4-430001-136
49004310003 1,0 Regelzylinder

001 ST CONTROL CYLINDER
GG-20

002 ST STUD BOLT
5.8

8

8.8
3-802501-033 1,0 Radialdichtring B 1

005 ST RADIAL SEAL RING
VITON
49004350222 1,0 Regelkolben

007 ST Regulating Piston
CK 15
00040730022 2,0 Rechteckring

008 ST SQUARE SECTION RING
GG
49004353636 1,0 Federteller

009 ST SPRING PLATE
CK 15
00035870206 1,0 Sicherungsscheibe

010 ST CIRCLIP
FED-ST
49004354801 1,0 Federhalter

011 ST SPRING SUPPORT
ST 42 KG
49004053207 1,0 Rückführfeder 6%

012 ST FEEDBACK SPRING
DRAHT 2,5 C
49004050500 1,0 Zsb. Rückführkolben

013 ST ASSY. FEEDBACK PISTON
49004053138 1,0 Rückführzylinder

017 ST FEEDBACK CYLINDER
CK 45 N
49004353734 1,0 Gewindespindel

018 ST Threaded Spindle
CK 45

18.09.2009
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34

TREUG00C

SERVO MOTOR
4-430001-136
00035594250 1,0 Spannstift

019 ST SPRING DOWEL PIN
ST
49024043000 1,0 Regelkolben

020 ST Control Piston
16 MNCR 5 G
00035770306 1,0 Kegelkerbstift

021 ST TAPER GROOVED PIN
6.8
49004043101 1,0 Regelbuchse

022 ST Control Bush
GG-25
00040710803 1,0 Sicherungsring für Bohrungen

023 ST CIRCLIP
FED ST
49004353200 1,0 Anschlagbuchse

024 ST Stop Bush
GG-25
49004310123 1,0 Regelzylinderdeckel

025 ST CONTROL CYLINDER COVER
GG-25
49004383004 1,0 Dichtung 1

026 ST GASKET
REINZOLOID

6.8
49004310207 1,0 Haube

028 ST HOOD
CK 35
49004383000 1,0 Dichtung 1

029 ST GASKET
REINZOLOID

8.8
49004374500 2,0 Hülse Ø25/30x12

032 ST Sleeve
ST 37.4
49004353606 1,0 Federteller

033 ST SPRING PLATE
GG-20

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35

TREUG00C

SERVO MOTOR
4-430001-136
00035430855 2,0 ZYLINDERSCHRAUBE MIT SCHLITZ

4.8
49004343008 1,0 Zylinderschraubenfeder 6%

DRAHT 4,5 A
49004354700 1,0 Federauflagering

036 ST SPRING SUPPORTING RING
U ST 37-2
4-434300-021 1,0 Zylinderschraubenfeder F1=245N

037 ST SPRING
EN 10270-1 SL
49004343011 1,0 Zylinderschraubenfeder P= 7358N

FED ST 65 SI 7
49004354601 1,0 Spindelverstellung wetterfest

040 ST SPINDLE ADJUSTER
X 20 CR 13 V
00041050252 1,0 PASSFEDER A

C45+C
00040710607 1,0 Sicherungsring für Bohrungen

042 ST CIRCLIP
FED ST
00040500155 1,0 Radialdichtring 1

72 NBR/902
00030820264 1,0 HANDRAD

044 ST HANDWHEEL
AL
00040700259 1,0 Sicherrungsring für Wellen

045 ST CIRCLIP
FED ST
49004153004 1,0 Nadel wetterfest

053 ST NEEDLE
X 20 CR 13 V
49004173000 1,0 Handrad

054 ST HANDWHEEL
10 S 20 KG

8

18.09.2009
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36

TREUG00C

SERVO MOTOR
4-430001-136
49004153200 1,0 Grundring

056 ST BOTTOM RING
ST 42 KG
49011183513 2,0 Dichtung 1

057 ST GASKET ¢ 8/14X5
GRAPHIT
49004153100 1,0 Überwurfschraube

058 ST CAP SCREW
ST 42 KG

8.8
00080370059 1,0 Dichtring Form D 1

064 ST Sealing ring D
CU

6.8
00041250036 1,0 KUGEL

067 ST BALL
WAELZLAGERSTAHL

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16

TREUG00C
4144242/10 Zsb.SS-Vermittler mit Kunststoffklinke 49003904000 /DRW/B

ASSY. TRIP TRANSMITTER
49003900034
49003913008 1,0 Schnellschlußvermittlergehäuse

001 ST TRIP TRANSMITTER CASING
GG-20
49003934404 1,0 Steuerbuchse

002 ST CONTROL BUSH
GG-25
49003934509 1,0 Steuerschieber

003 ST CONTROL SLIDE
CK 15

004 ST HEXAGON SCREW
ST 42 KG

SF-CU

DRAHT 3 A

007 ST SCREW PLUG
42CRMO4+QT

SF-CU

DRAHT 1,2 A
49003930002 1,0 Zsb. Auslösebolzen

010 ST RELEASE BOLT
00040710351 1,0 Sicherungsring

011 ST CIRCLIP
FED ST
00040500109 1,0 Radialdichtring 15 x 24 x 7 1

72 NBR/902
00041080206 1,0 KUGELKNOPF E ROT

013 ST BALL HEAD
PF/ST
49003933818 1,0 Schnellschlußklinke

014 ST TRIP PAWL
POLYAMID 6.6

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17

TREUG00C
4144242/10 Zsb.SS-Vermittler mit Kunststoffklinke 49003904000 /DRW/B

ASSY. TRIP TRANSMITTER
49003900034
00035760154 1,0 Bolzen ohne Kopf

015 ST BOLT
ST 50 K
49003944012 1,0 Biegefeder für Ausführg Axial-Auslösung

016 ST FLEXIBLE SPRING
FED ST 1,8 C
41363933400 4,0 Scheibe

017 ST DISC
ST
00035720309 2,0 Splint

018 ST SPLIT-PIN
ST
00082400400 2,0 Tellerfeder K-SS innengeschlitzt

019 ST DISC SPRING
FED-ST

ST

ST

ST

ST

CU

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18

TREUG00C
4144242/10 Drehzahlgeberantrieb 42403000102 /DRW/B

Speed transmitter drive
42403000102
42453013205 1,0 Geberhalter

002 ST TRANSMITTER SUPPORT
00035310058 1,0 Gewindestift m. Innenskt. m. Kegelstumpf

004 ST THREADED PIN
45H
49003051000 1,0 Federkupplung

005 ST SPRING COUPLING
00080341836 1,0 RUNDGUMMIDICHTUNG 1

007 ST RUBBER O-RING SEALING
GUMMI

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39

TREUG00C
4144242/10 Zsb. Turbohilfsölpumpe 65 l/min 49003404000 /DRW/D

ASSEMBLY AUXILIARY TURBO OIL PUMP
4-340000-047
49003423502 1,0 Pumpenkörper

001 ST PUMP CASE
49003435002 1,0 Pumpenrad treibend z=10

002 ST PUMP WHEEL DRIVING
00041050509 1,0 Passfeder A

C45+C
49003435102 1,0 Pumpenrad getrieben z=10

004 ST PUMP WHEEL,DRIVEN
49003433506 1,0 Lagerbuchse

005 ST BEARING BUSH
GC-CUSN 7 ZNPB

006 ST BEARING BUSH
GC-CUSN 7 ZNPB

007 ST BEARING BUSH
GC-CUSN 7 ZNPB
49003423700 1,0 Pumpendeckel

008 ST PUMP COVER
ST 37
00035356091 4,0 SECHSKANTSCHRAUBE

8.8

010 ST SAFETY PLATE
ST 13 O3
49003423608 1,0 Pumpenflansch

011 ST PUMP FLANGE
GG-20

ST

013 ST STUD BOLT
5.8

8

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40

TREUG00C

4-340000-047
49003434000 1,0 Radialdichtring 1

015 ST RADIAL SEALING RING
PTFE 529
49003433600 1,0 Spritzring

016 ST SPLASH RING
U ST 37-2
49003413000 1,0 THP-Gehäuse

017 ST TURBINE CASING
GG-20
49003433800 1,0 Kohlering 3

018 ST CARBON RING ¢25/50X20
KOHLE
49003433700 1,0 Haltering

019 ST RETAINING RING
ST 1303
49003433902 1,0 Laufrad

020 ST WHEEL FOR AUX. OIL PUMP
CK 35
00035690156 1,0 HUTMUTTER RI

021 ST COVER NUT
6
00035850158 1,0 Scheibe mit Außennase

ST 13 O3
49003483105 1,0 Dichtung 1

023 ST GASKET ¢ 240/290X1,5
GRAPHIT
49003413102 1,0 Abdampfgehäuse 1 Düse

024 ST EXHAUST STEAM CASING
GG-20

025 ST STUD BOLT
5.8

026 ST STUD BOLT
5.8

8

ST

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41

TREUG00C

4-340000-047
00080300400 1,0 FLACHDICHTRING FORM A KAMMPROFILIERT 1

029 ST SEALING RING FORM A
ST 30
49003773004 1,0 ovaler Flansch DN32

030 ST OVAL FLANGE
ST 37-2
00080324110 1,0 Dichtung 1

031 ST GASKET
REINGRAPHIT M. EDELSTAHL
00035356210 2,0 SECHSKANTSCHRAUBE M 12X 30

8.8
00041250049 1,0 Kugel

034 ST BALL
WAELZLAGERSTAHL
00035594153 1,0 Spannstift

035 ST SPRING DOWEL PIN
ST

036 ST SEALING RING
SF-CU
49003473306 1,0 Düse D0=3.2mm

037 ST NOZZLE
49005200408 1,0 Zsb. Steuerventil bis 130 bar Metallbalg

039 ST ASSY. CONTROL VALVE

040 ST STUD BOLT
21 CRMO V 57 V
00035500023 2,0 SECHSKANTMUTTER (MIT APZ 3.1)

24CRMO5 (1.7258)
41403493101 1,0 Saugrohr

044 ST SUCTION PIPE
ST 35

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10

TREUG00C
4144242/10 Zsb. Getriebegehäuse AF4Gs Sondergrundie 41442301009 /DRW/D

BEARING HOUSING, 2 PARTS
4-231300-033
4-231310-041 1,0 Getriebegehäuse-Unterteil Sondergrundier

001 ST BEARING HOUSING, LOWER PART
GG-20
41402313106 2,0 Lagerbügel

002 ST BEARING SUPPORT
GG-20
41442313101 2,0 Lagerbügel

003 ST BEARING SUPPORT
41442301009005 8,0 Stiftschraube gekürzt

005 ST STUD BOLT

8
00035870304 8,0 SICHERUNGSSCHEIBE S

007 ST CIRCLIP
FED-ST
49001573200 8,0 Passstift

008 ST PIN
9SMN28+C KLASSE 4

6.8
4-231320-022 1,0 Getriebegehäuse-Deckel Sondergrundierung

010 ST BEARING HOUSING, LID
GG-20

8.8

8.8
00035730153 6,0 KEGELSTIFT

013 ST TAPER PIN
ST
00035830202 6,0 Scheibe B

ST

8

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11

TREUG00C

4-231300-033
00035070106 3,0 SECHSKANTSCHRAUBE MIT ZAPFEN

016 ST HEX. HEAD SCREW WITH DOG POINT
8.8

ST GAL ZN GLCC
00080370305 1,0 DICHTRING FORM D 1

CU
00032241705 2,0 Gerade Einschraubverschraubung

ST
00018200408 0,0 ROHR (P235G1TH/ St 35.8)

021 ST TUBE
P235GH+N
00018200151 0,0 ROHR (P235T/ St 37.4)

022 ST TUBE
P235TR2
00018200151 0,0 ROHR (P235T/ St 37.4)

023 ST TUBE
P235TR2
00018200408 0,0 ROHR (P235G1TH/ St 35.8)

024 ST TUBE
P235GH+N

ST

027 ST SCREW PLUG
ST

CU

ST

CU
41442360000 1,0 Getriebeschmierung

031 ST GEAR LUBRICATING

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TREUG00C

4-231300-033
41443674100 1,0 Ermeto Dichtkantenring DKAZ 22

032 ST GASKET
ST

ST
00032180052 2,0 DROSSELFREIE SCHWENKVERSCHRAUBUNG

ST

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13

TREUG00C
4144242/10 Zsb.Getriebewelle I=3.49 B=100 41402304000 /DRW/A

ASSY. GEAR SHAFT
41442301501
41442331031 1,0 Getriebewelle mit Rad I=3.49

001 ST GEAR SHAFT WITH WHEEL
00080341950 1,0 RUNDGUMMIDICHTUNG 1

002 ST RUBBER O-RING SEALING
GUMMI
41441244100 1,0 Spritzring

003 ST SPLASH RING
CK 15
00035772201 2,0 Zylinderkerbstift

004 ST GROOVED STRAIGHT PIN
6.8
41401243103 1,0 Spurring

005 ST THRUST RING
CK 45 N
41401243203 1,0 Gegenspurring

006 ST COUNTER THRUST RING
CK 45 N
00035810509 1,0 SICHERUNGSBLECH MIT INNENNASE

ST 13 O3
00035661305 1,0 NUTMUTTER

008 ST GROOVED NUT
5
_______________________________________________________________
Part C
OEM - Accessories
Turbine SST-050
(AF 4 Gs)
Engine 1
P&I pos. 1
________________________________________________________________________________________
C - OEM-Accessory
Content
_______________________________________________________________
Pos. Content Part number Document
___._ Operating unit 4-680020-423 315185
034.0 Vibration speed sensor 1-682060-029 311205
036.0 Speed transmitter 4-470001-131 300620
037.0 Frequency-analog-converter 4-470000-501 307203
038.0 Speed indicator 4-470000-500 300629
038.0 Speed indicator 4-470000-500 315015
045.1 Solenoid valve 49015260075 300636
045.1 Solenoid valve 49015260075 300639
047.1 Pressure switch 2-367070-054 D-300172
058.0 Gear oil pump 49002940012 302751
058.0 Gear oil pump 49002940012 314983
058.0 Gear oil pump 49002940012 315128
058.0 Gear oil pump 49002940012 D-300435
059.0 Electric oil pump 4-345000-338 D-300413
060.0 Cooler 2-688100-676 311548
060.0 Cooler 2-688100-676 311617
063.x Oil filter 2-365010-133 300685
063.x Oil filter 2-365010-133 306165
064.x Clogging indicator 49013650175 300682
086.x Thermometer 2-526200-071 D-300083
086.x Thermometer 2-526200-071 D-300104
________________________________________________________________________________________
1/1
0 1 2 3 4 5 6 7 8 9
DAMPFTURBINE SST-050 (AF4 Gs)

STEAMTURBINE SST-050 (AF4 Gs)
Customer: Alstom
Project:
Plant:
Location:
P.O.No.: ....
Projekt No.: ..... Owner Doc.No.: ........
STE-No. : 4.144.242
Klemmenpläne
TERMINAL CONNECTION DIAGRAM
M:\schaltplan_wscad\0401\0401kl
Datum 16.10.09
Bearb. Noe STEAMTURBINE Siemens
Turbomachinery
Gepr. Noe ALSTOM 4.144.242 Equipment GmbH sheet 1
Zust. Änderung Datum Name Norm Urspr. Ers.f Ers.d Frankenthal DWG.nr. : 09-022-TCD of 9
0 1 2 3 4 5 6 7 8 9
+T M-59
+JB101
local
Controlroom
wired by customer
+C
DCS MCC
Datum 16.10.09
Turbomachinery
0 1 2 3 4 5 6 7 8 9
+T PS-47.1 PS-47.2 TIAH-87 TISH-87
Schmieröldruck MIN SchmieröldrucK MIN MIN
Lube oil pressure MIN lube oil pressure MIN MIN lube oil temperature
STE-Pos.47.1 STE-Pos.47.2 Pos.87
alarm trip
Wika
R5502 E830.21
+p P +p P
Proximity Switch
24VDC PNP
2 3 1 PE 2 3 1 PE 2 1 3 4 PE
PS-47.1 PS-47.2 TIAHSH-87

A B Typ A 1x2x1,3mm2 BK A B Typ A 1x2x1,3mm2 BK A1 B1 A2 B2 Typ A 2x2x1mm2 BK
M16 M16 M16
+JB101 PE/PA
4.0
-X29 1 2 PE 3 4 PE 5 6 7 8 PE
M25
+C
+24V
GND
+JB101
Datum 16.10.09
Turbomachinery
0 1 2 3 4 5 6 7 8 9
+T HZ-31
Not-Halt
Emergency Stop
STE-Pos 31
Moeller M22-PV
-S1
11
12
M20
HZ-31
Typ A 1x2x1,3mm2 BK
M16
PE/PA
3.8 6.7
-X29
+JB101 9 10 PE 11 12 13 PE
+C
+JB101
Datum 16.10.09
Turbomachinery
CO)*
0 1 2 3 4 5 6 7 8 9
VT-34
CO)* liquid tight flexible conduit 3/8"

+T
Gehäuseschwingung Getriebe
casevibration gearbox
STE-Pos 34
Metrix
ST5484E
S 4..20mA
I 0..12,7 mm/s
CO)*
M16
A
B
WH
BN
Sh
+JB101
-X30 1 2 S 4 5 6
+C
+ -
+JB101
Datum 16.10.09
Turbomachinery
CO)*
0 1 2 3 4 5 6 7 8 9
+T SE-36 ST-37
Drehzahlsensor Drehzahltransmitter
Speedprobe Speedtransmitter
STE-Pos.37
STE-Pos.36
Dr.Horn
G
EG 70.1/Z S 205
1a 2a 1b 2b PE
10VAC/1000rpm
SI-38
Typ A 1x2x1,3mm2 BK 1 2
rpm
SI-38
Speedindicator SE-36
Dr.Horn EA106.1 Typ A 1x2x1,3mm2 BK f/I-converter
STE-Pos.38 Dr.Horn EV189
M16
-X30 7 8 2 1 EV189
15
230VAC 10
+
16
9 PE/PA
+JB101 - 4.9 7.0
-A1 -X30 9 10 -X1 1 2 PE
+C
+ - PE
4..20mA = 0..xxxx rpm 220-230VAC

+JB101
Datum 16.10.09
Turbomachinery
0 1 2 3 4 5 6 7 8 9
Y-45.1 M-59
Magnetventil Schnellstartpumpe (Zuhaltepumpe)
+T Soleniod Valve Quick Start Pump
STE-Pos 45.1 STE-Pos.59
Herion
220-230VAC
app. 40W 380-400V 50Hz 0,18kW
app. 0,59A
1 PE 2
M
3
Y-45.1
1 PE 2 H07RN-F G1,5mm2 U V W PE
M20 NYY 3G1,5mm2
6.9 PE/PA +JB101

-X1 3 PE 4
+C PE MCC
220-230VAC
Datum 16.10.09
Turbomachinery
0 1 2 3 4 5 6 7 8 9
möglicher Leiterquerschnit
0,75-1,5mm2
possible conductor cross-section
Cable Type A 1x2x1,3mm2 RE-2Y(St)Y-fl Black Instrument-Cable Kerpen Kabel Germany

2x2x1mm2 flame retartent acc. IEC 60332 Part 3
300V / 70°C
A = BK pairs, collective screen
B = WH conductor isolation PE
Outer-Sheat PVC
Cable Type A 1P1,5mm2 A7x1-P0xxL-02 Instrument-Cable Anixter

2P0,75mm2 acc. BS5308 Part 1 Typ 1
A1 = BK flame retartent acc. IEC 60332 Part 3
B1 = BU 300/500V 65°C
A2 = GN (BK) pairs, collective screen
B2 = BN (GN) conductor isolation PE
Outer Sheat LSH
Farbcode IEC colour code IEC
IEC Farbcode
Outdoor Außenaufstellung ohne Dach

BU - blau
direkt bewittert
RD - Rot
WH - weiß
BK - schwarz
BR - braun
GY - grau
GN -grün
YE - gelb
PK - rosa
PU - violett
Datum 16.10.09
Turbomachinery
0 1 2 3 4 5 6 7 8 9
Junctionbox Design
Junctionbox
Polyester glass reinforced grey/black app. 340x176x150mm
Polyester glasfaserverstärkt grau/schwarz
Stahl Type 8146/0S73
Terminals Klemmen Phoenix UT2,5; UT4

4xM16
cable glands: Polyamid Grey Lapp Skintop
1xM16 gland for Anaconda 3/8"
150 mm
Kabelverschraubungen: Polyamid Grey Lapp Skintop

2xM20
fieldside: bottom left
3xM16 Blind
Feldseite: unten links
4xM20 Blind
customerside: bottom right undrilled
Kundenseite: unten rechts ungebohrt

176 mm
-X29 -X30 -X1 -A1

-JB101
340 mm
+JB101
Datum 16.10.09
Turbomachinery
Proximity Transmitters and Seismic Vibration Transmitters
ProvibTech
Proximity Vibration/Position/Phase Reference
Transmitters
Seismic Vibration Transmitters
ProvibTech, Inc. 11011 Brooklet Drive, Suite 360 ● Houston, Texas 77099 ● USA
Phone: +1-713-830-7601 ● Fax: +1-281-754-4972 ● sales@ProvibTech.com ● www.ProvibTech.com
TRANSMITTER-CAT-ENG-B-8704
ProvibTech Phone: +1-713-830-7601 ● Fax: +1-281-754-4972 ● sales@provibtech.com ● www.provibtech.com -1

ProvibTech’s Transmitter Selection Guide
Model Number TR1101 TR3101 TR4101 TM016

TR3102 TR4102
Acceleration (g's) ● ●
Velocity (ips/sec, mm/sec) ● ●
Displacement (mils, um) ● ● ●
Vibration Measurements
Radial Vibration TR3101 TR4101
Axial Position TR3102 TR4102
Phase Reference TR3102 TR4102
Case Vibration ● ●
Sensor Interfaces
Built in Accelerometer ●
Proximity Probe (5mm, 8mm, and 11mm) ● ●
Accelerometer ●
Velocity Transducer ●
Available Outputs
4-20mA Output ● ● ● ●
Buffered Output (3 meters) ● ●
Buffered Output (300 meters) ● ●
Available Features
Loop Powered (2- Wire) Transmitter ● ●
3-Wire Transmitter ● ●
Hazardous Rating (CSA, ATEX)
Explosion Proof, Class I, Class II, Div.1,
Groups (A-G), EExdIICT4 ●
Hazardous Rating (CSA, ATEX)
Intrinsically Safe, EExiaIICT4 ● ●
Hazardous Rating (CSA), non-incendive,
Class I, Div.2, Groups (A-D, T4) ●
Environmental Rating- NEMA 4 or IP65 ●
Low Pass and High Pass Filter ●
Warranty- 5 years ● ● ● ●
● = Complete Offering
ProvibTech Phone: +1-713-830-7601 ● Fax: +1-281-754-4972 ● sales@provibtech.com ● www.provibtech.com 1

TM016 Velocity/ Acceleration Vibration Transmitter
Introduction
The TM016 is a solid state loop powered transmitter which

provides a 4-20mA output proportional to the machine case
vibration level. The 4-20mA output interfaces directly to any
PLC or DCS for shutdown, alarm or trending. The TM016 is
easy to install on the machine case.
Applications include:
Motors
Pumps
Fans
Blowers
Engines
Compressors
Centrifuges
Generators
Turbochargers
Gear Boxes
TM016-D4
Features
Loop powered 4-20mA velocity or acceleration

(peak or RMS) output
Wide operating temperature range -40°C to +120C°
(-40°F to +248°F)
Stainless steel housing
NEMA4X, IP65 or IP67 environmental rating
Multiple hazardous area approvals
Frequency filter options
Wide selection of mounting studs
TM016-D0, D1

Electrical Physical
Overall vibration output: Temperature:

4-20mA, load (loop powered) Operation:
Accuracy: 3% Normal (G=0): -40oC to + 100oC (-40oF to +212oF)
Frequency response (+/- 3db): High (G=1): -40oC to + 120oC (-40oF to +248oF)
Acceleration: Storage: -50oC to + 125oC (-58oF to +257oF)
AAA= 200, 201, 202: 2 - 3,000 Hz Dimensions:
AAA= 782: 1 - 6,000 Hz Diameter: 38mm (1.5”)
Velocity: Height: Flying leads: 78mm (3.1”);
AAA= 000 to 162: 2 - 3,000 Hz Mil connectors: 87mm (3.4”)
AAA= 793: 2 - 6,000 Hz Weight:
AAA= 10-6,000 Hz (±3dB) 240g (0.5lb)
Transverse sensitivity: Output Connections:
< 5% 2-pin MIL-C-5015
Power supply: Flying leads: 2 or 4 wires
A= 782, 793, 788 1 NPT
3 - 10mA constant current Environmental:
18 - 30VDC power Flying leads: NEMA 4X, IP65
10 - 14V nominal bias voltage 2-pin connector: IP67
A= other options
12VDC - 30VDC
< 30mA
Maximum load resistance:
600 ohms @ 24VDC power supply
Isolation:
500Vrms, circuit to case
Case material:
Stainless steel
Output connection:
Flying leads:
2 cables for 4-20mA
2 cables for buffered output
Mil connector:
2 pins for 4-20mA
Buffered output:
100mV/g nominal
Maximum cable length 3m (10ft)
Filter option:
40dB/oct for hi-pass filter
40dB/oct for low-pass filter
Intrinsically safe:
ATEX: II 1G EEx iaIICT4 @Ta=-40oC to+100oC
(Ui=30V, Ii=110mA, Pi=825mW, Ci=51.7nF, Li=84uH)
PCEC: Ex iaIICT4
16 ProvibTech Phone: +1-713-830-7601 ● Fax: +1-281-754-4972 ● sales@provibtech.com ● www.provibtech.com

Order Information C: Hazardous Area and Approvals

C=1: CE
* Factory default
C=2*: CE
TM016-AAA-BCD-EF-G
CSA: Class I, Div. 1, Groups A, B, C & D
Class II, Div. 1, Groups E, F, G & T4@Ta=-40oC
AAA: Full Scale
to+120oC
AAA=000: 20mm/s (0.8ips), pk
ATEX: II 2G, EEx dIICT4
AAA=001: 20mm/s (0.8ips), rms
ATEX: II 1G, EEx iaIICT4
AAA=121: 25mm/s (1.0ips), pk
PCEC: Ex iaIICT4
AAA=122: 12.5mm/s (0.5ips), pk
Ex dIICT4
AAA=123: 50mm/s (2.0ips), pk
C=3*: CE
AAA=124: 125mm/s (5.0ips), pk
ATEX: II 1G EEx iaIICT4@Ta=-40oC to+100oC
AAA=132: 75mm/s (3.0ips), pk
PCEC: Ex iaIICT4
D: Connection
AAA=152: 12.5mm/s (0.5ips), rms
D=0: 4-20mA, flying leads
D=1: 4-20mA, flying leads with buffered output
D=4: 4-20mA, 2-PIN MIL connector (C=1, 3)
E: High-pass Filter
AAA=200: 5.0g, pk
E=0: None
AAA=201: 10g, pk
E=1: 5Hz
AAA=202: 20g, pk
E=2: 10Hz
AAA=782: 100mV/g, pk, Current mode (C=1, 2)
E=3: 20Hz
AAA=793: 4mV/mm/s (100mV/in/s), pk,
E=4: 50Hz
Current mode (C=1, 2)
E=5: 100Hz
AAA=788: 100mV/g, pk, Current mode (C=1, 2)
E=6: 200Hz
B: Mounting Adaptor
F: Low-pass Filter
B=0: 1/4” NPT
F=0: none
B=1: 1/2” NPT
F=1: 500Hz
B=2: 3/8-24UNF X 1/2’’
F=2: 1000Hz
B=3: 1/2-20UNF X 1/2’’
F=3: 2000Hz
B=4: M8x1-12
G: Temperature
B=5: M10x1.25-12
G=0: Normal temperature (-40oC to + 100oC)
G=1: High temperature (-40oC to + 120oC)
TM016-K1
Vibration transmitter kit includes:

TM016-D0 or -D1 with TM016-02
CE mark
CSA: Class I, Div. 1, Groups A, B, C & D
Class II, Div. 1, Groups E, F, G & T4
ATEX: II 2G, EEx dIICT4

Field-Wiring Diagram
Data
Acquisition TM016 V/A
Vibration Transmitter
PLC/DCS
12+
PLC/DCS TM0403 red
11- (MTL5041) 2+ TM016 V/A
Barrier black Vibration Transmitter
14+ 1-
24VDC Power
13-
Safe Area Hazardous Area
Note:
Other Barriers:
TM0404: (MTL 5042)
TM0406: (STAHL 9303/11-22-11)
TM0407: (STAHL 9160/13-11-11)

Accessories
(Standard cable length is 5 meters. XX = 05)
TM0702-XX: Aluminum MIL connector with XX meters cable, 6.35mm diameter.

< 120oC (250oF)
TM0703-XX: Sealed tight boot connector with XX meters cable, 6.35mm diameter.
< 120oC (250oF)
TM0704-XX: Stainless steel MIL connector with Armored XX meters cable,

4.83mm diameter. < 150oC (300oF)
TM0705-XX: Cornered MIL connector with XX meters cable, 6.35mm diameter.

o o
< 120 C (250 F)
TM016-01: Aluminum conduit elbow & reducer. 1” to 3/4” NPT

TM016-11: Aluminum conduit elbow & reducer with terminal block. 1” to 3/4” NPT
Class I, Div. 1, Groups B, C & D; Class II, Div. 1, Groups E, F & G and NEMA 4X, IP65
TM016-02: Stainless steel conduit elbow with terminal block. 1” to 3/4” NPT
Class I, Div. 1, Groups A, B, C, D & T4; Class II, Div. 1, Groups E, F& G and NEMA 4X, IP65
(works with TM016)
TM016-03: Stainless steel flange mounting adaptor with 1/2” NPT mount; 3 holes of 7mm
on the circle of 38mm (1.5”) in diameter
TM016-03:
TM900: Power converter

TM0200: 3-1/2 digit display unit

Accessories: TM900 Power Converter
The TM900 power converter is designed for the DTM

series transmitter-monitor and the TR 3-wire transmitter.
Each TM900 supports up to five DTM’s and eight TR
transmitters. The output of the power converter is
isolated from its input. Additionally, the output is
short-circuit protected and the input is ESD and fuse
protected.
Specifications
Electrical
AC Power Input:
90-250VAC@200mA
Power Output:
Voltage: 24VDC±5%
Environmental
Current: 800mA
Temperature:
Isolation:
Operation: -40oC to +75oC
1000VAC
Storage: -50oC to +100oC
Fuse:
Humidity:
2.0A, 250VAC
90% non-condensing
Capacity:
Each TM900 can power up to 5 DTM’s
Certifications
CE certified with EMI compliance
Physical CSA Div. 2; ATEX Zone 2 (pending)
Height: 75mm (2.95”)
Weight: 1.0kg (2.0 lbs)
Order Information
TM900–GX
GX: Mount
G0*: 35mm DIN-rail mount
G1: Plate mount
TM900 - DIN Rail Mount

TM900 Plate Mount

300620
300620
300620
307203
307203
307203
307203
® Horn Tacho- Indicator
Weather- and saltwater-proof
EA . . .
50030000
For remote tachometry, tacho-indicators in addition to generators are required.

HORN tacho-indicators are robust moving coil instruments of high accuracy,
field-proven under severe operating conditions and maintenance-free. For exter-
nallocations exposed to the weather, especially for shipboard use, indicators in
a.weatherproof and seawater-resistant light alloy casing are suitable. They are
available for flush or built-on mounting. For application in hazardous locations,
explosion-proof versions can be supplied.
Technical Data
Movement Moving coil meter movements, current dial). Other mounting positions as per drawing
consumption 1 mA at full needle deflection; below will be considered, provided the order
toe bearing and shock-proof pivot bearing specifies the angle of inclination of the scale
resp., ortoe bearing with spring-mounted with reference to the horizontal plane.
jewels for extremely severe operating Finish grey, textured, with a seawater- and acid-proof
conditions. enamel.
Needle- Needle black, dial white; graduations, Enclosure IP 66 (DIN 40050)
Scale inscription and figures conform to DIN 43802. Electrical Flat terminals to DIN 41000 , flood-protected
Calibration is normally carried out with reference to a connection (enclosure IP 66, DIN 40050). Forthe ship-
HORN tacho-generator; measuring range and building industry, the indicators are supplied
measured quantity can be selected at choice, with a screw cable gland M 24x1.5 (DIN 89280)
i.e. any indicating (measuring) range can be instead of the Pg 7 gland.
assigned to any speed range of the generator Explosion Following indicators are available in ignition
shaft. protection protection class (Ex) e G 5 (increased safety):
Reading ± 1 % related to the scale length. With a wire EA 108 . .. e, EA 188 .. . , EA232 .. . a
accuracy cross section up from 2 x 0.75 mm 2 , line The indicators can also be supplied in special
lengths up to 100 m will not affect the versions for passive two-terminal use in intrin-
indication. The temperature drift will not sically safe circuits (Ex) i G 5. Explosion protec-
exceed 0.2% for each 100 C change for tion is possible only for indicators having no
temperature. These values conform to classi- scale illumination.
fication YO,2 (VDE 0410).
Temperature Type @ Germanischer Lloyd
range -20 0 bis +45 0 C approval EA 107 . . . 91067 HH 10.75 - 88
Installation If not specified otherwise, indicators are EA 188 . .. 91070 HH 10.75 - 88
position calibrated for vertical mounting (position of the EA232 ... 91071 HH10.75-88
Scale 24, 110 or 220V; EA 106 . .. available without
Mounting inclined . . . deg. illumination scale illumination only, EA 107 .. . can be
To be viewed from below
operated with 24 V only. The dial is transparent.
The illumination can be adjusted or switched
off by means of a dimmer DW 85 e (in separate
.. deg.
box) orWIXG 122/ ... K (without box). The scale
of indicators with clamp fixing can be illumina-
ted indirectly by light slots.
Special versions
Cover glass non-reflecting or safety compound glass Calibration to characteristic curve or table of customers ;
Scale Black dial with white graduations; pointer tip, reading accuracy: ± 1.5% related to full scale
main graduations, figures and measured length
quantity phosphorescent, scale ground after- Adjustment Should a readjustment of the indication be
glowing; graduations, figures, pointer and required , then this can be achieved via a
measured quantity black, scale with precise potentiometer (DW) accessible on the rear of
graduation, single or dual graduation; the casing. The 'potentiometer can be provided
scale stretched in the initial or final range, zero with a locking device (DWf) to prevent a dis-
hushed up to 25% of final value (for 240 0 placement after the adjustment.
needle-deflection); dual or multiple scale by Tropical All indicators can be manufactured in tropica-
special calibration or additional graduation, finish lized execution upon request.
coloured markings at any place of the scale,
coloured sectors or bands, additional captions
on scale. P.T.O.
Dr. E. Horn GmbH

Messgeratefabrik
0-7036 Schonaich
Telefon (07031) 5502-01 . Telefax (07031)
neu: 654588
. Telex 7265659
® 1:[.];l~1
300629
Flush mounting indicators
EA 107 ... e ..
EA106 ... e ..
EA 188 ... e ..
10-.--68 10-.-- b ---~

o
,f
0"
IS
x
....,
.....
\
'0
......,=I=::~ 5.3 --"::::=±::::::::::'~ 5.3
f-----d4-----<l-~1 ~tN574 81.1

Af5
f-----d 4----~ DIN 74 81.1 I
Scale- Weight b Scale- Weight
Type designation od, • o d2 o d3 od, b Type designation od, od 2 o d3 od,
length kg length kg
EA 106 ... e EA 188 ... e

106 140 108 125 157 1 158 188 160 175 124 270 3
EA106 ... eEx EA188 ... eEx
EA 107 ... e 106 140 108 125 91 157 1.3
Surface mounting indicators

EA 160x190 ... a M EA 188 ... a ..
EA232 ... a ..
Dimmer
~;:j:*:;:t:cable glands
M 24 x 1.5
/'
Type designation od, od, a b oc e Scale- Weight Type deSignation od, od, a b oc e Scale- Weight
length kg length kg
EA 160x190 ... aM 220 4 EA232 . .. a

232 250 10 103 10 234 332 5
EA 188 ... a EA 232 ... a Ex
188 192 10 90 8 180 270 3
EA 107 ... a Ex
~ 4.3
Dimmer DW 85 e 'o~ . DIN?4 WIXG 122/ ... K
./
(for adjustment and switch-off k MlOx .75
of scale illumination) ;;-

\
Explanation of EA tacho-indicator I with scale illumination

type designation 188 nominal size (example) (z) pivot bearing
.1 input : AC voltage nl afterglowing
.2 input: DC voltage (zero centre possible) M marine type cable gland M 24x1.5 DIN 89280
a for surface mounting DWf potentiometer -lock type (for adjustment of indication)
e for flush mounting (flange) DW potentiometer for adjustment of indication
Ex ignition protection class (Ex) e G 5 (VDE 0171)
Ordering 1. Type designation 3. Measuring range and measured quantity (rpm, m/min, I/h and others)
Informations 2. Installation position 4. Speed of generator in connection at full scale value and type of generator
Subject to alterations without prior notice 3.91
300629
Diese Zeichnun Ist unser Ei entum. Weiter ebe Ist unzulössi .
---.I- - -
o tO <XJ
- -- 0
~
0
~
- -- -
Q Q
I ~
>(
n
I
I
I
Cable entry
*
Kabelverschraubu ng Pg7
DIN74BI.1
entree de c6ble
Ansicht bei ExeG5-Ausführung
eXl:llosion I:lroof execution ExeG5
.L I--
125
21,S 70 140
I YI:l e an ti d Ei fl a gr..;:o'-'..n"t--===
CAO Nr. EA000054 " 03 Ta Name Z.-Nr. EA 1OlLe Maß stab

Gez. 19.09. HWU.
EA 1OlLe Ex 1: 2
Gepr.
~-r______________. -__- .__~~~N~a~rm
~____- L____-1Benennun9
e Drehzahlanzeiger
d
c
b
o
®
Dr. E. Horn GmbH Ersatz für
Tacho-Indicator
Indicateur tachyrnet'riC1j.IiI.e
Anderung Tag Name 0-71101 Schönaich 1-:[C'r::'s"-etC=z':-t"'d"'u-rc-,h----------------------- - - l

315015
THIS LEAFLET SHOULD BE KEPT IN A SAFE PLACE FOR REFERENCE
DIESES MERKBLATT SOLLTE AN EINER SICHEREN STELLE AUFBEWAHRT WERDEN
CE DOCUMENT DOIT ETRE CONSERVE POUR ETRE UTILISE ULTERIEUREMENT LORS DES ENTRIENS
ESTE FOLLETO DEBE GUARDARSE EN LUGAR SEGURO PARA SER UTILIZADO DURANTE EL SERVICO
Mounting- and operating instructions for directional control valves

Montage- und Betriebsanleitung für Wegeventile
Instruction de montage et de mise en service pour vannes
Instrucciones de montaje y servicio para válvulas de paso
Directional control valves with operating modes
Pneumatically operated - filter; filtration ≤ 50 µm for valves with soft seals
and ≤ 20 µm for valves with metal sealing
Directional control valves are precision-manufactured - pressure control
control units. They must be handled most carefully - valve lubricator; spindle oil 7.4 to 9.6 mm2/s (cSt) at
during transport and assembly. Do not drop them or 20 °C. Recommended oils: Shell Hydrol DO 32,
expose to vibrations. Shell Voltol 46, Esso Febis K 32 or oils of similar
Check before installation if the operating conditions quality
stated on the name plate and/or technical documents - water separator (in case of condensate).
correspond with the existing plant conditions: working
pressure, minimum pilot pressure for pneumatically Items installed in safety controls have to be checked
operated valves. regularly for their general condition and proper
Mount valves carefully and make sure foreign matter functioning. This includes the inspection of all parts
does not get into the piping or valves. which are subject to wear and tear as well as the
Connect the valves in correspondence with their carrying out of operational tests. The time intervals
respective symbol. between each inspection depend on the operating
Pneumatic controls require extreme cleanliness. conditions (contamination of the fluid, switching
Observe the oil content of the air. For the air treatment frequency, pressure and temperature). The extent of
we recommend the installation of an FRL unit these limiting factors determines the interval between
consisting of: the maintenance work.
Directional control valves with operating mode

Solenoid pilot operated scale, sand or chips from damaged threads etc. must
get into the piping or valves. We recommend the
Directional control valves are precision-manufactured installation of a dirt trap upstream of the valves.
control units. They must be handled most carefully Cleanliness and oil content of the air must be assured
during transport and assembly. Do not drop them or when using pneumatic controls. We recommend the
expose to vibrations. installation of an FRL upstream of the valve, if
Check before mounting if the date stated on the name necessary, with additional water separator.
plate (operating pressure, voltage, current and power The solenoid must never be used as lever. As to the
consumptions etc.) corresponds with the existing electrical equipment connection local regulations must
operating conditions. be observed.
For air operated directional valves (pilot exhausting to Protect valves from frost, drain liquid, if necessary.
atmosphere) the static minimum pressure must be Items installed in safety controls have to be checked
available at the supply port P. With valves which can regularly for their general condition and proper
optionally be operated by external pilot source, the functioning. This includes the inspection of all parts
control pressure is supplied via control port Z. which are subject to wear and tear as well as the
On 2-way/2-position valves the flow direction is carrying out of operational tests. The time intervals
indicated by an arrow. On 3-way, 4-way or 5-way between each inspection depend on the operating
valves the connections are marked by symbols. conditions (contamination of the fluid, switching
Connections are to be made according to the respec- frequency, pressure and temperature). The extent of
tive symbols. these limiting factors determines the interval between
Mount valves carefully. No foreign matter such as the maintenance work.
packing residuals, remainders of sealing materials,
1 7500136.99.11.00
Directional control valves with operating modes
1) Direct solenoid operated connections are marked by symbols. Connections are
2) Semi-automatically solenoid operated to be made according to the respective symbols.
Mount valves carefully. No foreign matter such as
Directional control valves are precision-manufactured packing residuals, remainders of sealing materials,
control units. They must be handled most carefully scale or chips from damaged threads etc. must get
during transport and assembly. Do not let them drop into the piping or valves. We recommend the
or expose them to vibrations. installation of a dirt trap upstream of the valves.
Check before mounting if the data stated on the name Cleanliness and oil content of the air must be assured
plate (operating pressure, voltage, current and power when using pneumatic controls. We recommend the
consumption etc.) correspond with the existing installation of an FRL upstream of the valve, if
operating conditions. necessary, with additional water separator.
The solenoid must never be used as lever. As to the
Constructional characteristics: electrical equipment connection local regulations must
be observed.
1) Seal incorporated in plunger or in disc of valve Protect valves from frost, drain liquid, if necessary.
stem which is firmly connected to the plunger. Items installed in safety controls have to be checked
regularly for their general condition and proper
2) Plunger with incorporated seat seal or piston with functioning. This includes the inspection of all parts
valve stem coupled to the plunger. which are subject to wear and tear as well as the
carrying out of operational tests. The time intervals
For switching, a minimum pressure difference be- between each inspection depend on the operating
tween valve inlet and outlet is not necessary. The mini- conditions (contamination of the fluid, switching
mum operating pressure at rest as well as in swit- frequency, pressure and temperature). The extent of
ching position may therefore be 0 bar. these limiting factors determines the interval between
On 2-way/2-position valves the flow direction is the maintenance work
indicated by an arrow. On 3-way or 4-way valves the
2 7500136.99.11.00
3/2 Directional Valves DN 5 to 50
For neutral gaseous and liquid fluids
Solenoid direct operated poppet valves
Connection: Internal thread G 1/4 to G 2
Operating pressure 0 to 100 bar (see table) Catalog Register
A9
Publication 7500537.06.02.93
Description
Solenoid valve for air, water, oil
Flow direction: Optional

Temperature min.: -25 °C, grey cast iron -10°C
Temperature max.: +80 °C (fluid)
+60 °C (ambience)
Mounting position: Optional, preferably vertical
Materials
– Body: Brass (Ms)
Red brass (Rg)
Grey cast iron (GG)
– Seat seal: Perbunan (NBR)
Steel/steel
– Inner parts: Stainless steel, brass
For contaminated fluids, insertion of a dirt trap is recom-

mended (see accessories).
Features
l Working from 0 bar up Switching function:
l Suitable for medium-high vacuum range Pressure connection at port 1, 2 or 3
with sleeves down to 1.33 . 10-2 mbar Multi-purpose valve
without sleeves down to 1.33 . 10-3 mbar
l Approved for installation on board ships
IMI Norgren-Herion Fluidtronic GmbH & Co. KG, D-70731 Fellbach

Stuttgarter Straße 120, D-70736 Fellbach ⋅ Tel.: +49 (0)7 11 / 52 09-0 ⋅ Fax: +49 (0)7 11 / 52 09-6 14
300639
Parameters
DN Line Operating pressure kv-value Switching Material Weight Sec- Dimen- Cat. No. Cat. No.
connection [bar] (Cv (US) ≈ cycles tional sional
min. max. kv x 1.2) with drawing drawing
gaseous
and
gase- liquid liquid
ous fluids fluids up
fluids up to to
40 40 mm2/s
mm2/s Passage Passage Body Seat Valve Solenoid Valve Solenoid
1–2 2–3 [1/min] seal [kg] No. No. DC AC
Switching function: Pressure connection at port 1, 2 or 3
5 G 1/4 0 10 10 0.32 0.38 100 Ms NBR 1.2 – 01 2401103.0801 2401103.08071)

8 G 1/4 0 3 3 0.65 0.92 100 Ms NBR 2.6 01 02 2405650.13002) 2405650.13012)
8 G 1/4 0 15 15 0.65 0.92 100 Ms NBR 2.6 01 02 2401550.13003) 2401550.13013)
8 G 3/8 0 3 3 0.77 1.02 100 Ms NBR 2.6 01 02 2405750.13002) 2405750.13012)
8 G 3/8 0 15 15 0.77 1.02 100 Ms NBR 2.6 01 02 2401650.1300 2401650.1301
8 G 1/2 0 3 3 0.78 1.10 100 Ms NBR 2.6 01 02 2405850.13002) 2405850.13012)
8 G 1/2 0 15 15 0.78 1.10 100 Ms NBR 2.6 01 02 2401750.1300 2401750.1301
12 G 3/8 0 3 3 1.12 1.25 100 Ms NBR 4.2 01 03 2408150.15002) 2408150.15012)
12 G 3/8 0 12 12 1.12 1.25 100 Ms NBR 3.0 01 02 2402450.1300 2402450.1301
12 G 3/8 0 25 25 1.25 1.95 100 Ms NBR 4.2 01 03 2402650.1500 2402650.1501
12 G 3/8 0 40 40 1.12 1.25 100 Ms NBR 4.2 01 03 2406650.1500 2406650.1501
12 G 3/8 0 – 100 1.12 1.25 80 Ms Stahl 4.2 01 03 2407850.1500 2407850.1501
12 G 1/2 0 3 3 1.25 1.69 100 Ms NBR 4.2 01 03 2408250.15002) 2408250.15012)
12 G 1/2 0 12 12 1.25 1.69 100 Ms NBR 3.0 01 02 2402550.13003) 2402550.13013)
12 G 1/2 0 25 25 1.25 1.95 100 Ms NBR 4.2 01 03 2402750.1500 2402750.1501
12 G 1/2 0 40 40 1.25 1.69 100 Ms NBR 4.2 01 03 2406750.15003) 2406750.15013)
12 G 1/2 0 – 100 1.25 1.69 80 Ms Stahl 4.2 01 03 2407950.1500 2407950.1501
15 G 1/2 0 12 12 2.8 2.7 70 Rg NBR 6.2 02 04 2403350.1500 2403350.1501
15 G 3/4 0 12 12 2.8 2.7 70 Rg NBR 6.2 02 04 2403450.1500 2403450.1501
20 G 3/4 0 6 6 5.0 5.5 50 Rg NBR 7.7 02 05 2403510.1500 2403510.1501
20 G1 0 6 6 5.0 5.5 50 Rg NBR 7.7 02 05 2403610.1500 2403610.1501
25 G1 0 8 8 9.0 10.0 30 Rg NBR 22.9 02 06 2403810.1800 2403810.1801
25 G 1 1/4 0 8 8 9.0 10.0 30 Rg NBR 22.9 02 06 2403910.1800 2403910.1801
50 G 1 1/2 0 3 3 25.0 28.5 20 GG NBR 36.3 02 07 2402410.1800 2404010.1801
50 G2 0 3 3 25.0 28.5 20 GG NBR 36.3 02 07 2404110.1800 2404110.1801
Ms - Brass State voltage [V] and frequency [Hz]
Rg - Red brass
GG - Grey cast iron
NBR - Perbunan
1) For alternating-current operation, solenoid is equipped with a DC coil, the appropriate rectifier is installed in the connector.
2) Design not pressure balanced (without sleeves)
3) Equipped with solenoids 1309,1310, 1509 or 1510, these solenoids are approved for marine engineering by: GL Germanischer Lloyd, LR Lloyd’s Register
of Shipping, DNV Det Norske Veritas, PRS Polski Rejestr Statkow, USSR Register of Shipping
Solenoids Current draw:
Standard DCAC Solenoid DC Solenoid AC

voltages 40 to 60 Hz Inrush
Holding
24 V 24 V 0801 16 W 0807 18 VA
18 VA
Other
110 V 1300 20 W 1301 24 VA
24 VA
voltages
220 V 1500 39 W 1501 42 VA
42 VA
on request
230 V 1800 70 W 1801 80 VA
80 VA
Design acc. to VDE 0580 Enclosure to DIN 40050
100 % duty cycle Solenoids 080X, 130X 150X: IP 65
Solenoids 180X: IP 53
For more technical details on solenoids see: Electric connection
Publication 7500784 (solenoids 0801/0807), Solenoids 080X: Connector to DIN 43650
Publication 7500779 (solenoids 1300/1301), Solenoids 130X, 150X, 180X: Cable gland Pg 13,5
Publication 7500778 (solenoids 1500/1501),
Publication 7500773 (solenoids 1800/1801).
2 7500537.06.02.93
300639
Other versions available upon request
l With DVGW-approval to DIN 3394, page 2, Group RM l Switching monitor position:
l Seat seal Viton (FKM), Teflon (PTFE) or Ethylene- Mechanical/electrical
propylene-dien-rubber (EPDM) Inductive/electrical
l With manual override, without detent 360 (push but- l With semi-automatic actuation
ton) or 361 (lever) l With solenoid in protection classes (Ex)s, Ex s IIC T5
l With manual override and detent 350 (lever) or (hand l With solenoid in protection classes (Sch)d (Ex)d, EEx
wheel) d
Sectional drawings
01
1 Body
4 O-ring *
5 Core tube
7 Solenoid
8 Spring *
9 Plunger
14 Grooved ring
15 Spindle assly.
19 O-ring *
Spare parts kits

Cat. No. Cat. No.
Valve Spare parts kit
2401103 0596651
2401550, 2401650, 2401750 0592402
2402450, 2402550 0592713
2402650, 2402750 0592447
2403350, 2403450 0593212
2405650, 2405750, 2405850 0592789
2406650, 2406750 0592790
2407850, 2407950 0592436
2408150, 2408250 0593293
02
2403510, 2403610 0598531
2403810, 2403910 0593270
2404010, 2404110 0598535
1 Body 18 Ring
2 Valve seat 19 O-ring *
4 O-ring * 20 Plug
5 Core tube 21 Union
6 Disk 22 O-ring *
7 Solenoid 23 Flange
8 Spring * 25 Lip ring *
9 Plunger 26 Piston
11 Nut 28 Valve disk *
15 Spindle 29 Bolt
17 Ring 32 Screw
All parts marked with an asterisk are enclosed in spare

part kits.
When ordering spares, please state also valve Cat. No.
7500537.06.02.93 3
300639
Dimensional drawings
01 Dimensional
drawing No.
01
02
03
Dimen- Laid Height

sional length
dra-
wing
No. A B C D E
02 70 234 108 67.5 27.5
03 70 258 115 67.5 27.5
Dimen- Width
sional
dra-
wing
No. F ØG H J
02 47.5 86 59 38
03 47.5 92 62 38
04
05
06
07 Dimensi Laid Height Width
onal length
drawing
No.
A B C D E F G
04 100 269 126 63.5 19.5 92 62
05 120 299 156 80 30 92 62
06 132 370 184 96 36 154 92.5
07 240 425 239 135 45 154 92.5
Dimensi
onal
drawing
No.
H J K L M N O P
04 30 15 13.5 50 M10 12 39 77
05 30 15 15 70 M10 12 42 82
06 40 20 15 100 M12 12 57 102
07 80 40 33 130 M16 21 98 171
Subject to alteration 7500537.06.02.93
300639
20D Pressure Switch
Pressure switch for pneumatic
and allfluid technology
Standard Program
-1 to 100 bar
Microswitch with gold plated contacts (suitable for

intrinsically safe operation)
Field application (microswitch with silver contacts)
Electrical connection: pin-and-socket connector
according to DIN 43650 or clamped connection
Technical Data
Medium:
Neutral, aggressive, non-combustible gases and liquids
Fluid port:
G1/4, G1/2 A
Switching pressure range: Ordering information
-1 ... 100 bar See page 2
Temperature:
Fluid Surrounding
-10°C ... +100°C -25°C... +80°C Alternative variants
-40°C ... +80°C Ex-permission according to ATEX 100a,
(with field application) zone 1 and 2 Ex II 2G EEx de IIC T6)
Operating viscosity: Model testing as per pressure device guideline
1000 mm2/s max. 79/23/EG (DIN 3394-3/DIN EN 1854)*
Reproducibility: on request
±1% from the final value of range (referring to pressure regulation)
Protection Rating:
IP65 (according to DIN 40050)
Mounting Position: 2 3 Switching function:
Optional 1-pin microswitch
p (commutator)
Resistance to shocks and vibrations (if possible avoid them):
4 g max. (sinusoidal)/ 5 Hz max.
1
Terminals 1 – 3:
Impermeability: with rising control value
> 10-7 mbar · l · s-1 contact closing
Pulsations:
Not permitted Terminals 1 – 2:
with rising control value
Switching number:
contact opening
Max. 20/min.
Material:
Housing: die-cast aluminium (standard)
Die-cast aluminium, anodised (field application)
Pressure sensor: brass or stainless steel
Electrical connection/ pressure sensor combination: see page 2
Sealing: stainless steel - bellow
Our policy is one of continued research and development. We therefore reserve the right to amend,
10/03 without notice, the specifications given in this document. N/UK 5.11.024.01
D-300172
20D Pressure Switch
Pressure range for 181 (fixed switching pressure difference)

Model Switching pressure Limit value 2) Switching pressure difference Switching pressure for Switching pressure Drawing
range1) bar for pressure sensor codes 00, pressure sensor difference codes 05, 15 See page
pvu min.to max. 10 and 20 (typ. value) bar codes 21 (typ. value) bar and 25 (typ. value) bar
(VDI 3283 ) bar Range beginning Range end Range beginning Range end Range beginning Range end
181 01 00 -1 ... 0 10 0,06 0,07 0,07 0,08 0,06 0,07 4
181 02 00 -1 ... 1 10 0,06 0,08 0,07 0,10 0,08 0,09 4
181 03 00 -1 ... 1,6 10 0,08 0,09 0,08 0,09 0,08 0,09 4
181 04 00 -1 ... 2,5 10 0,08 0,12 0,09 0,12 0,09 0,12 4
181 11 00 0,05 ... 1 10 0,06 0,08 0,07 0,08 0,07 0,08 4
181 13 00 0,1 – 2,5 10 0,07 0,09 0,09 0,10 0,11 0,15 4
181 14 00 0,5 ... 4 20 0,20 0,25 0,30 0,33 0,30 0,33 4
181 15 00 0,5 ... 6 20 0,20 0,30 0,30 0,35 0,30 0,35 4
181 16 00 0,5 ... 10 20 0,30 0,40 0,30 0,40 0,30 0,40 4
181 17 00 1 ... 16 50 0,60 0,80 0,70 0,80 0,70 0,80 4
181 18 00 1 ... 25 50 0,70 0,90 0,70 0,90 0,70 0,90 4
181 19 00 1) 5 ... 63 85 0,90 1,50 1,00 2,00 1,00 2,00 4
181 10 00 2) 5 ... 100 150 2,50 5,00 3,00 7,00 3,00 7,00 4
Pressure range for 180 (adjustable pressure difference)

Model Switching pressure Limit value 2) Switching pressure difference for variants YY Switching pressure difference for variants YY
range1) bar codes 00, 10, and 20 (typ. value) bar codes 05, 10, 15, 20, 21 and 25 (typ. value) bar
pvu min. to max.
(VDI 3283 ) bar Range Range end Range Range end
beginning Minimum Maximum beginning Minimum Maximum
180 01 00 -1 ... 0 10 0,12 0,13 0,70 0,12 0,13 0,70
180 02 00 -1 ... 1 10 0,13 0,14 1,00 0,19 0,21 1,00
180 03 00 -1 ... 1,6 10 0,17 0,20 2,50 0,22 0,24 2,50
180 04 00 -1 ... 2,5 10 0,17 0,20 2,50 0,22 0,24 2,50
180 11 00 0,05 ... 1 10 0,08 0,11 0,70 0,15 0,16 0,70
180 13 00 0,1 ... 2,5 10 0,11 0,15 2,00 0,34 0,40 2,00
180 14 00 0,5 ... 4 20 0,30 0,40 2,50 0.80 0,80 2,50
180 15 00 0,5 ... 6 20 0,35 0,50 5,00 0,80 0,90 5,00
180 16 00 0,5 ... 10 20 0,40 0,80 8,00 0,90 1,90 8,00
180 17 00 1 ... 16 50 0,80 1,10 12,00 1,70 2,00 12,00
180 18 00 1 ... 25 50 1,00 1,50 20,00 1,80 2,80 20,00
180 19 00 1) 5 ... 63 85 2,00 3,00 20,00 3,50 4,50 20,00
180 10 00 2) 5 ... 100 150 3,50 7,00 55,00 4,00 9,00 55,00
Wire socket is not included in the supply scoe; special versions on request.
1) Short-term pressure peaks are not allowed to exceed this limit value during operation.
Operative utilization of the limit value is not permitted.
The limit value corresponds to the maximum testing pressure
2) Reference pressure is the atmospherical air pressure
Options selector 18˙ ˙˙ ˙˙
Switching pressure difference Substitute Pressure sensor Electrical Material

adjustable 0 connection Substitute
fixed 1 Brass/1.4404 DIN 43650, G1/4 00
Brass/1.4404 M20 x 1,5, G1/4 05
1.4404 DIN 43650, G1/2A 10
1.4404 M20 x 1,5, G1/2A 15
1.4404 M20 x 1,5, G1/2A 5) 21
Switching pressure range (bar) Substitute

-1 ... 0 01
-1 ... 1 02
Ordering information -1 ... 1,6 03
Pressure switch with fixed switching -1 ... 2,5 04
pressure difference with 4 bar. 0,05 ... 1 11
Fluid port G 1/2 A, 0,1 ... 2,5 13
Operating fluid: Water 0,5 ... 4 14
0,5 ... 6 15
Quote: 1811521 3) only for pressure sensor variants 00, 05
0,5 ... 10 16
4) 1 ... 16 17
only for pressure sensor variants 10, 15
5) for field application
1 ... 25 18
5 ... 63 3) 19
5 ... 100 4) 10
N/UK 5.11.024.02 Our policy is one of continued research and development. We therefore reserve the right to amend, 10/03
without notice, the specifications given in this document.
D-300172
20D Pressure Switch
Accessories
Plug facility Plug facility Bracket Surge dampers Pressure port
Reducing nipple
See page 5 See page 5 See page 5 See page 5 See page 5
0585418 (with LED) 0570110 0574772 (steel) 0553258 (stainless steel G1/4 A – G1/4) 0553831 (G1/2 – 1/2 NPT A)
0585419 (with glow lamp) 0553908 (stainless steel) 0574773 (brass/steel G1/4 A – G1/4) 0550083 (G1/4 A – G1/2 A)
0585420 (with glow lamp) 0551894 (stainless steel G1/2 – G1/2 A) 0574764 (G1/4 A – G3/8)
0574765 (G1/4 A – 1/4 NPT)
Switching capacity
For commutator with gilded contacts for pressure tracersubstitute 00, 10 und 20 (values for silver contacts on request)
Load level Current type Load type Umin Max. permitted constant current Imax [A] with U [V] Durability 5)
[V] 30 48 60 125 250 electrical mechanical
with Imax with I Ÿ 0
Normal 3) AC ohmic 12 5 5 5 5 5 5 x 104 ∫107
(f. ex. contactor,
solenoids) AC inductive, 12 3 3 3 3 3
cos Ÿ 0.7
DC ohmic 12 5 1,2 0,8 0,4 -
DC inductive, 12 3 0,5 0,35 0,05 -

L/R Ÿ 10 ms
Minor 4) AC ohmic 5 3) 0,34 0,2 0,17 0,08 0,04 2 x 105 ∫107
(f. ex. electronic
switching circuit) DC inductive, 5 3) 0,1 0,01 - - -
L/R Ÿ 10 ms
Reference number: 30/min, reference temperature: +30°C

In case of spark extinction with diode at I DC and inductive load: 3) Gold layer not required, will be destroyed. Max. permitted current at make (ca. 30 ms)
Imax = 1.5 x Imax table AC on = max. 15A.
Imin = 1 [mA] 4) Gold layer required, continues to remain.
The creep and air distance correspond to VDE 0110 of the insulation group B (with the
5) Bisection of the respective switching current I almost effects a doubling of the contact
exception of the contact distance of the micro switch).
durability. Lower limit of voltage to guarantee sufficient contact safety, smaller voltages
under favourable conditions (contacts free of external layers) are permitted.
Proposal for spark extinction with direct voltage

1. Diode D parallel to the inductive load.
Observe correct polarity with connection
(positive pol at cathode). + (AC)
Dimensioning specificatons for erasing diode: p

Nominal voltage of the diode UD ∫ 1,4 x US.
Nominal current of the diode IN ∫ Iload.
VS
Select fast switching diodes R Last
D R
(blocking recovery time trr √ 200 [ms]). I Last
C
- (AC)
2. RC element parallel to the load
(or parallel to the switching contact).
Suitable for direct voltage and alternating voltage.
Dimensioning principles:
R in [∆] Ÿ 0,2 x Rload in [∆]
C in [µF]Ÿ Rload in [A]
10/03 Our policy is one of continued research and development. We therefore reserve the right to amend, N/UK 5.11.024.03
D-300172
20D Pressure Switch
Basic dimensions (mm) 43,5

22
115,5 19 5,8 104
5
22
C
C
M 4 - 10 tief
50,5
70
81
D D
19
A B A, B
44
47
Electrical connection
Plug according to DIN 43650, Form A Threaded joint M20 x 1,5 as per DIN 46320
D 32,5 22
M 20 x 1,5
30
6 ø 6,5 - 8,8
9,2
21,2
Pressure sensor
Combination possibilites
Pressure sensor dimensions
Switching- Pressure sensor substitue Pressure
pressure sensor Press. sensor H B G Position
range variants on housing
Substiture 00 01 10 15 20 21 25 Variants A 61 47,5 41 G 1/2 A A
01 • • B B 42,5 51 30 G 1/4 A
• • • • • A C 61 40 41 G 1/2 A A
02 • • B D 52 47,5 41 G 1/2 A A
• • • • • A E 47 40 24 G 1/4 A
03 • • B F 43 47,5 41 G 1/4 A
• • • • • C G 43,5 37 32 G 1/2 A A
04 • • B H 53 37 32 G 1/2 A A
• • • • • A I 61,5 37 32 G 1/2 A B
11 • • B
• • • • • A
13 • • B
• • • • • A
14 • • E
Pressure sensor øB
• • • • • D
15 • • E
• • • • • D
16 • • E
H
• • • • • D
17 • • F
• • • • • G
5
18 • • F
ø6
• • • • • G
G 1/2
19 • • • • • H
10 • • • • • I
D-300172
20D Pressure Switch
Accessories Pressure switch with indication - lamp insert

Plug s (black) with luminous indication The lamp insert indicates the switchin condition of the
3-pin + grounded conductor connected pressure switch.
Connector illustration according to DIN 43650
optional direct or alternating voltage
With LED 12 ... 28V Model: 0585418

With glow lamp 90 ... 130V Model: 0585419 1
1
With glow lamp 180 ... 240V Model: 0585419 2 4 4
2
3
3
39 34 4* 4*
Pressure switch Plug Reversible lamp insert

with pin plate optionally pluggable on opener (2)
or closer (3)
* * For contact (4) a separate supply line (Mp or, -) is required

70
3-pin plug with grounded conductor Bracket (2 clamps and 4 screws)

According to DIN 43650 Model: 0570110 Steel Model: 0574772
Stainless steel1.4301 (AISI 304) Model: 0553908
34 141
1,5 27,5 129
104
5,8
12
53
3
14
118
Surge dampers
Stainless steel 1.4301 (AISI 304) Model: 0553258 Stainless steel 1.4301 (AISI 304) Model: 0551894
Brass/Steel Model: 0574773
G 1/4 A G 1/2
45
22 27
46
34
20
G 1/4 ø6
5
ø 21,5 G 1/2 A
10/03 Our policy is one of continued research and development. We therefore reserve the right to amend, N/UK 5.11.024.05
D-300172
20D Pressure Switch
Pressure port reducing nipple

G1/2 ... G1/2 NPT A G1/4 A ... G1/2 A G1/4 A ... G3/8 G1/4 A ... 1/4 NPT
Stainless steel 1.4305 Stainless steel 1.4305 Steel Brass
(AISI 303/304 S) (AISI 303/304 S)
Model: 0553831 Model 0550083 Model: 0574764 Model: 0574765
G 1/2 G1/4 A G 1/4 A G 1/4 A
12
12
12
30
22
36
43,5
22
43,5
27 22
13
22,5
22,5
1/4 NPT
6,5
G 3/8 ø 20
1/2 NPT G 1/2 ø21,5
Warning:
These products are intended for use in industrial compressed The system designers are warned to consider the failure
air or hydraulic systems only. Do not use these products modes of all component parts used in fluid systems and to
where pressures and temperatures can exceed those listed provide adequate safeguards to prevent personal injury or
in “Technical Data”. Please consider the corresponding damage of equipment in the event of such failure.
catalogue sheets. System designers have to provide a warning to end
Before using these products with fluids other than those users in the system instructional manual, if protection
specified, for non-industrial applications, life-support systems, against a failure mode cannot be adequately provided.
or other applications not within published specification,
please consult NORGREN. System designers and end users are cautioned to review
Through misuse, age, or malfunction, components used in warnings found in instruction sheet as packed and shipped
fluid power systems can fall in various modes. with these products.
D-300172
Transfer Gear Pumps
KF 4 ... 80
Transfer Gear Pumps KF 4 ... 80
Contents
Technical Data
Page
Applications / Suitable fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Variants / Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Materials / Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Shaft end seals / Variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 –9
Version noise optimized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Type key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Discharge flow / Input power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 – 14
Input power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Dimension Sheets
Flange-mounting version with pipe thread . . . . . . . . . . . . . . . Nom. displacement 4 – 25 . . . . . 16

Flange-mounting version with SAE 3⁄ 4 and 1-connection . . . . . Nom. displacement 4 – 25 . . . . . 17
Flange-mounting version with SAE 1 1⁄2 -connection . . . . . . . . . Nom. displacement 32 – 80 . . . . . 18
Flange-mounting version with SAE 2-connection . . . . . . . . . . . Nom. displacement 50 – 80 . . . . . 19
Pump with mounting angle, pipe thread . . . . . . . . . . . . . . . . Nom. displacement 4 – 25 . . . . . 20
Pump with mounting angle, SAE 3⁄4 and 1-connection . . . . . . Nom. displacement 4 – 25 . . . . . 21
Pump with mounting angle, SAE 1 1⁄2 -connection . . . . . . . . . . Nom. displacement 32 – 80 . . . . . 22
Pump with mounting angle, SAE 2-connection . . . . . . . . . . . . Nom. displacement 50 – 80 . . . . . 23
Flange-mounting version with universal arrangement . . . . . . . Nom. displacement 4 – 25 . . . . . 24
Flange-mounting version with universal arrangement . . . . . . . Nom. displacement 32 – 80 . . . . . 25
Accessory couplings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Bell housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nom. displacement 4 – 25 . . . . . 27
Bell housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nom. displacement 32 – 80 . . . . . 28
Motor-pump assemblies with pipe thread . . . . . . . . . . . . . . . . Nom. displacement 4 – 25 . . . . . 29 – 30
Motor-pump assemblies with SAE 3⁄4 and 1-connection ......... Nom. displacement 4 – 25 . . . . . 31 – 32
Motor-pump assemblies with SAE 1 1⁄2 -connection .............. Nom. displacement 32 – 80 . . . . . 33 – 34
Motor-pump assemblies with SAE 2-connection ................ Nom. displacement 50 – 80 . . . . . 35 – 36
Threaded flange G-SAE 3⁄4 / Welding flange S-SAE 3⁄4 .......... .......................... 37
Threaded flange G-SAE 1 / Welding flange S-SAE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Threaded flange G-SAE 1 1⁄2 / Welding flange S-SAE 1 1⁄2 . . . . . . . . .......................... 39
Threaded flange G-SAE 2 / Welding flange S-SAE 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Accessory liquid seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
KRACHT GmbH · Gewerbestr. 20 · 58791 Werdohl, Germany · fon +49 (0) 23 92 / 935-0 · fax +49 (0) 23 92 / 935 209 · mail info@kracht.eu · web www.kracht.eu 3
Applications, Suitable Fluids
Applications Suitable fluids
Centrifuge construction, Adhesives, Antifreeze

Coating machines, Compressors Bore oils
Engine construction Cutting oils
Filling stations, Filter systems Diesel oils, Drawing compound
Generator construction Emulsions
Heat transfer systems, Heavy electrical machines Fuel oils, L, EL, H
Lubricant manufacturers, Lubricating oil systems Gear oils, Grease
Machine-building industry, Machine tools, Hardening oils, Heat transfer media,
Manufacture of apparatus, Heavy oils, Hydraulic fluids
Marine engine construction,
Metal-forming machines, Metering systems Isocyanate
Paint industry, Plain metal bearing production, Lubricating oils, Lacquers

Printing machines, PUR machinery Motor oils
Refrigerators, Rubber and tire manufacturing Paint, Paraffins, Plastics, Polyols
Tank plant construction, Printing inks, Processing oils
Transmission building Resins, Rolling oils
Turbine construction Waste oils, Waxes
Vacuum machinery
Waste oil - disposal
- transport
- treatment
4 KRACHT GmbH · Gewerbestr. 20 · 58791 Werdohl, Germany · fon +49 (0) 23 92 / 935-0 · fax +49 (0) 23 92 / 935 209 · mail info@kracht.eu · web www.kracht.eu
Construction
Drive shaft end

Antriebswellenende
Shaft seal
Wellendichtung
Getriebe
Gear unit Housing
Gehäuse
Plain bearing bushes

Lagerbuchse
End cover
Lagerdeckel
Produkt Features Operating Notes
Transfer gear pumps KF gear pumps are used for • The fluids should ensure a certain minimum
pumping a wide variety of fluids. lubricating properties, should not contain solids and
Transfer gear pumps KF gear pumps are distinguished should be chemically compatible.
especially by their wide range of variants which are • Avoid dry operation.
assembled as required on the modular principle and • The pumps may only be operated in the specified
also permit subsequent upgrade. direction of rotation, as otherwise the shaft seal will
The pumps are also suitable for media with low be destroyed.
lubricating properties. • In order to prevent excessive overpressure, a safety
The standard housing sections are of grey cast iron. valve should be provided in the system or on the
The gear units are manufactured from high-strength pump.
case-hardening steel, hardened and mounted in • The pressure relief valve attached to the pump may
special multi-compound plain bearing bushes. only be used as safety valve for short-term operation.
The standard drive shaft is sealed by rotary shaft • To drain off a partial discharge flow over a prolonged
lip-type seal. period, a separate pressure relief valve with return
All pump sizes incorporate helical tooth system. line must be inserted in the reservoir.
This feature, combined with special gear geometry, • A separate pressure relief valve with return line to
results in extremely low noise levels and reduced the reservoir must be foreseen, if a partial discharge
pressure pulsation. flow has to be drained over a prolonged period.
Variants Direction of Rotation
• Sealing of the drive shaft: The following should be note for direction of rotation:
– Rotary shaft lip-type seal • when looking at the • when looking at the
– Double rotary shaft lip-type seal (Quench) pump shaft end, the pump shaft end,
– Mechanical seal direction of pumping is the direction of pum-
• Outboard bearing to take up input drive-side from left to right if the ping is from right to left
radial load shaft rotates clockwise. if the shaft rotates
• Pressure relief valve as safety valve for pump and counterclockwise.
system
• Uniform discharge flow direction with changing Without pressure relief valve
direction of rotation by means of flange-mounting
valve combination (universal device).
Special Design
Various shafts ends and gear units, as well as flange suction side pressure side pressure side suction side
mounted versions, bearing alternatives, multi-stage
pump combinations for your special application are pump running cw pump running ccw
available on request.
Our Sales engineers will be pleased to advise you.
With pressure relief valve
Accessories
• Connecting flanges
• Couplings
• Bell housing
• Tank for liquid seal liquids suction side pressure side pressure side suction side
• Attenuation elements on request pump running cw pump running ccw
ATEX With universal device

Direction of rotation right and left
We offer numerous transfer gear pumps from the
KF 4 ... 80 series in ATEX versions. Please ask for our Direction of rotation consistent,
ATEX product catalogue. see dimension sheets page 23 and 24.
Materials
Housing and cover EN-GJL-250 (GG 25)
EN-GJS-400-15 (GGG 40) on request
Gear Steel 1.7139
Plain bearing bushes DU (multi-layer friction-type bearings P 10, DP 4)

Bearings free of nonferrous metal on request
Shaft end seals NBR, FKM, PTFE, EPDM (other sealing materials on request. E.g. HNBR / CR)
O-ring NBR, FKM, PTFE, EPDM (other sealing materials on request. E.g. HNBR / CR)
Characteristics
Nominal sizes 4…80 cm3 Vg = 4 / 5 / 6 / 8 / 10 / 12 / 16 / 20 / 25 / 32 / 40 / 50 / 63 / 80
Fitting position arbitrary (exception: see universal device)
Direction of rotation right or left

right and left
Fixing type flange (DIN ISO 3019)
Pipe connection KF 4…25 Whitworth pipe thread, SAE flange

KF 32…80 SAE flange
Drive shaft end ISO R 775 short-cylindrical
Operating pressure see chart page 8

suction side
Operating pressure Pn 25 bar (higher pressures on request)

pressure side
Speed KF 4…80 200 … 3 000 1/min
Viscosity mm2/s 12 … 20 000

(dependent on pressure
and rotational speed)
Temperature of pumping media see chart page 8
Ambient temperature Vu = -- 20 °C … 60 °C (-- 4 °F … 140 °F)
Shaft End Seals

Sealing material Pressure Fluid temperature
suction side *
bar °C °F
Pump with single rotary shaft lip NBR -- 0.4...1 -- 10...90 -- 14...194
FKM max. 750 Upm -- 0.4...6
max. 1000 Upm -- 0.4...5
max. 1500 Upm -- 0.4...4 -- 10...150 -- 14...302
max. 2000 Upm -- 0.4...3
max. 3000 Upm -- 0.4...2
FKM (low temperature) -- 0.4...0.5 -- 40...150 -- 40...302
EPDM -- 0.4...0.5 -- 10...120 -- 14...248
PTFE -- 0.4...2 -- 10...200 -- 14...392
Pump with outboard bearing NBR -- 0.4...1 -- 10...90 -- 14...194
and single rotary shaft lip FKM max. 750 Upm -- 0.4...6
max. 1000 Upm -- 0.4...5
max. 1500 Upm -- 0.4...4 -- 10...150 -- 14...302
max. 2000 Upm -- 0.4...3
max. 3000 Upm -- 0.4...2
PTFE -- 0.4...2 -- 10...200 -- 14...392
Pump with double rotary shaft seal NBR -- 0.4...1 -- 10...90 -- 14...194
with connection borehole FKM max. 750 Upm -- 0.4...6
for liquid seal (quench) max. 1000 Upm -- 0.4...5
max. 1500 Upm -- 0.4...4 -- 10...150 -- 14...302
max. 2000 Upm -- 0.4...3
max. 3000 Upm -- 0.4...2
PTFE -- 0.4...2 -- 10...200 -- 14...392
Pump with double rotary shaft seal NBR -- 0.9...0.2 -- 10...90 -- 14...194
for vacuum operation with FKM -- 0.9...0.2 -- 10...150 -- 14...302
connection borehole for liquid seal
(quench) PTFE -- 0.9...0.2 -- 10...200 -- 14...392
Pump with triple rotary shaft seal NBR -- 0.9...1 -- 10...90 -- 14...194
for vacuum and normal operation FKM max. 750 Upm -- 0.9...6
with connection borehole for fluid max. 1000 Upm -- 0.9...5
liquid seal (quench) max. 1500 Upm -- 0.9...4 -- 10...150 -- 14...302
max. 2000 Upm -- 0.9...3
max. 3000 Upm -- 0.9...2
Pump with mechanical seal FKM -- 0.4...10 -- 10...150 -- 14...302
PTFE -- 0.4...10 -- 10...200 -- 14...392
EPDM -- 0.4...10 -- 10...120 -- 14...248
Pump with mechanical seal and FKM -- 0.4...10 -- 10...150 -- 14...302
connection borehole for liquid seal
* short term during start-up status: -- 0.6 bar

Speed: 200 – 3 000 1/min
The indicated maximum values are dependent
upon the remaining operating conditions.
In case of universal devices, pay attention to limitation of Pe min.
Other sealing materials on request.
Variants
Pump with single Pump with outboard Pump with double rotary Pump with double rotary
rotary shaft lip bearing and single shaft seal with connection shaft seal for vacuum
Fixing type: F / W rotary shaft lip borehole for liquid seal operation with connection
Fixing type: G / X (quench) borehole for liquid seal
Sealing materials:
Fixing type: F / W (quench)
NBR = sealing type 1 Sealing materials:
FKM = sealing type 2 NBR = sealing type 1 Sealing materials: Fixing type: F / W
PTFE = sealing type 3 FKM = sealing type 2 NBR = sealing type 19 Sealing materials:
EPDM = sealing type 9 PTFE = sealing type 3 FKM = sealing type 7 NBR = sealing type 19
PTFE = sealing type 4 FKM = sealing type 7
PTFE = sealing type 4
Special number: 74
Pump with triple rotary Pump with Pump with mechanical seal
shaft seal for vacuum mechanical seal and connection borehole
and normal operation Fixing type: F / W for liquid seal
with connection borehole Fixing type: F / W
Sealing materials:
for fluid liquid seal
FKM = sealing type 5 Sealing materials:
Fixing type: F / W PTFE = sealing type 6 FKM = sealing type 5
Sealing materials: EPDM = sealing type 20 Special number: 198
NBR = on request
FKM = on request
KF 4 ... 80 noise optimized
The noise optimized pumps in the KF series are designed The noise optimized version of the KF pump is marked
for conveying media with higher proportions of air, with the special number 197 at the end of the rating
predominantly for use as lubricating oil pumps in trans- plate.
missions. Special measures prevent the otherwise pumps with the special number 197 are built as pumps
normally increased noise present in auriferous transmission in combination with an electric motor or as mounted
oil. The noise levels do not exceed or only barely pumps. The pump in combination with an electric
exceed the measurements with non-auriferous oils. motor (Fig. 1) does not have an outboard bearing, so it
Also, there is no noise spectrum shift to higher, unplea- has to be driven via an elastic coupling. The mounted
sant frequencies. In applications without auriferous pump (Fig. 2) comes equipped with an outboard bearing
portions in the media, it is not recommended to use to absorb the centrifugal forces such as those which
this version as it will not bring about noise reduction arise when using a flying pinion. Pumps for electric
effects there. motor drives and mounted pumps are sealed at the
shaft end using a lip-type shaft seal.
Fig. 1 Fig. 2
Pump with Pump with outboard bearing

single rotary shaft lip and single rotary shaft lip
Fixing type: F / W Fixing type: G / X
Sealing materials: Sealing materials:
NBR = sealing type 1 NBR = sealing type 1
FKM = sealing type 2 FKM = sealing type 2
Special number: 197 Special number: 197
The noise optimized version is also available in a ductile

cast iron version. We can supply these pumps in the
ATEX version also.
Note
Dimensions conformable Standard

KF transfer gear pump
Type Key
Ordering example
KF 40 R F 1 - D 15 - /... ·
Housing and cover material

not specified EN-GJL-250 (GG 25)
GJS EN-GJS-400 (GGG 40)
Special No.
158 KF 4...25 SAE-connection
197 KF 4...80 noise optimized with
shaft seal
232 KF 50...80 SAE 2-connection
Valve type D 15 adjustable from 0 – 15 bar

D 25 adjustable from 15 – 25 bar
(only for one direction of rotation)
Seal type 1 Single rotary shaft lip NBR

2 Single rotary shaft lip FKM
3 Single rotary shaft lip PTFE
4 Double rotary shaft seal PTFE
5 GLRD with FKM secondary seals
6 GLRD with PTFE secondary seals
7 Double rotary shaft seal FKM
9 Single rotary shaft lip EPDM
19 Double rotary shaft seal NBR
20 GLRD with EPDM secondary seals
23 Single rotary shaft lip FKM for low temperature
Mounting F DIN flange without outboard bearing

G DIN flange with outboard bearing
W Mounting angle without outboard bearing
X Mounting angle with outboard bearing
Direction of rotation R right

L left
B right and left
U universal Note
direction of rotation right and left,
Nominal size 4 ... 80 direction of discharge consistent
Product name
Technical Data
Nominal geometrical Operating Maximum Speed range Permissible

size displacement pressure * pressure load **
(pressure peaks) (n =1500 1/min)
Vg pb pmax nmin nmax Fradial

cm3/r bar bar 1/min 1/min N
4 4.03
5 5.05
6 6.38
8 8.05
10 10.11 700
12 12.58
16 16.09
25 40 200 3000
20 20.1
25 25.1
32 32.12
40 40.21
50 50.2 1500
63 63.18
80 80.5
Remark
** Operating pressure pb = perm. sustained pressure
** Permissible load only for version with outboard
bearing. Fradial at centre of shaft end.
For certain operating conditions, the minimum or

maximum characteristics should not be used.
For example, the max. operating pressure is not
permissible in combination with low speed and
low viscosity.
In such limit ranges, please consult us.
Power Consumption
Speed n = 950 1/min

Pressure pb in bar Nominal size Pressure pb in bar
2 4 6 8 10 15 20 25 2 4 6 8 10 15 20 25
3.7 3.6 3.6 3.5 3.4 3.3 3.1 2.9 4 0.04 0.05 0.07 0.08 0.09 0.13 0.16 0.20
4.6 4.5 4.5 4.4 4.3 4.1 3.8 3.6 5 0.04 0.06 0.08 0.10 0.11 0.16 0.20 0.25
Power consumption P in KW
5.8 5.7 5.6 5.5 5.4 5.1 4.9 4.6 6 0.05 0.07 0.09 0.12 0.14 0.19 0.25 0.30
7.3 7.2 7.1 7.0 6.8 6.5 6.2 5.8 8 0.06 0.09 0.11 0.14 0.17 0.24 0.31 0.38
Discharge Q in l/min
9.2 9.0 8.9 8.7 8.6 8.2 7.7 7.3 10 0.07 0.10 0.14 0.17 0.21 0.29 0.38 0.47
11.4 11.3 11.1 10.9 10.7 10.2 9.6 9.1 12 0.08 0.12 0.16 0.21 0.25 0.36 0.47 0.58
14.6 14.4 14.2 13.9 13.7 13.1 12.4 11.7 16 0.09 0.15 0.20 0.26 0.31 0.45 0.60 0.74
18.2 18.0 17.7 17.4 17.1 16.3 15.5 14.7 20 0.10 0.18 0.25 0.32 0.39 0.56 0.74 0.92
22.8 22.4 22.1 21.7 21.3 20.4 19.4 18.3 25 0.12 0.21 0.30 0.39 0.48 0.70 0.92 1.14
29 29 28 28 27 26 25 23 32 0.2 0.3 0.4 0.5 0.6 0.9 1.2 1.5
37 36 36 35 34 33 31 29 40 0.2 0.4 0.5 0.6 0.8 1.1 1.5 1.8
46 45 44 43 43 41 38 36 50 0.3 0.5 0.6 0.8 1.0 1.4 1.9 2.3
58 57 56 55 54 51 48 45 63 0.4 0.6 0.8 1.0 1.2 1.8 2.4 2.9
73 72 71 69 68 65 61 58 80 0.4 0.7 1.0 1.3 1.6 2.3 3.0 3.7
Speed n = 1450 1/min

Pressure pb in bar Nominal size Pressure pb in bar
2 4 6 8 10 15 20 25 2 4 6 8 10 15 20 25
5.7 5.6 5.6 5.5 5.4 5.3 5.1 4.9 4 0.06 0.08 0.10 0.12 0.15 0.20 0.25 0.30
7.1 7.1 7.0 6.9 6.8 6.6 6.4 6.1 5 0.07 0.10 0.12 0.15 0.18 0.24 0.31 0.38
Power consumption P in KW
9.0 8.9 8.8 8.7 8.6 8.3 8.0 7.8 6 0.08 0.11 0.15 0.18 0.21 0.30 0.38 0.47
11.3 11.2 11.1 11.0 10.9 10.5 10.2 9.8 8 0.09 0.14 0.18 0.22 0.26 0.37 0.47 0.58
Discharge Q in l/min
14.2 14.1 14.0 13.8 13.6 13.2 12.8 12.4 10 0.11 0.16 0.21 0.27 0.32 0.45 0.58 0.72
17.7 17.6 17.4 17.2 17.0 16.5 15.9 15.4 12 0.12 0.19 0.26 0.32 0.39 0.55 0.72 0.89
22.6 22.4 22.2 22.0 21.7 21.1 20.5 19.8 16 0.16 0.26 0.37 0.47 0.57 0.82 1.08 1.33
28.3 28.0 27.7 27.4 27.1 26.4 25.6 24.7 20 0.17 0.28 0.39 0.49 0.60 0.87 1.14 1.41
35.3 35.0 34.6 34.3 33.9 32.9 31.9 30.9 25 0.20 0.34 0.47 0.61 0.74 1.08 1.41 1.75
45 45 44 44 43 42 40 39 32 0.3 0.5 0.7 0.8 1.0 1.4 1.9 2.3
56 56 55 55 54 52 50 49 40 0.4 0.6 0.9 1.1 1.3 1.8 2.3 2.9
70 70 69 68 67 65 63 61 50 0.5 0.8 1.1 1.3 1.6 2.3 2.9 3.6
89 88 87 86 85 82 79 77 63 0.7 1.0 1.3 1.7 2.0 2.9 3.7 4.5
113 112 111 109 108 105 101 98 80 0.8 1.2 1.7 2.1 2.5 3.6 4.7 5.8
The ratings refer to a mineral oil with a viscosity The output of the drive motor should be selected 20 %
of 34 mm2/s. higher than tabular value P.
Margin of error for the flow Q + 2.5 % ... -- 5 % of the For viscosity > 100 mm2/s, an increase in the required
tabular value. For viscosity < 30 mm2/s, take a reduction power is necessary, in this case proceed as per description
of the rated flow Q into account. on page 14 /15.
Discharge Flow / Input Power
Calculation Example: Pump type KF 80
n Viscosity ν = 3000 mm2/s

P1Pu = Ptab · + fν · Q
1450
Operating pressure p = 15 bar
P1Pu = pump power consumption (kW) at Ptab = 3.6 kW
Ptab = power consumption per table (kW) at 1450 1/min n = 500 1/min
n = speed (1/min) kW
f ν = 0.017
dependent on viscosity! l/min
(see speed recommendation) 80.5 · 500
Q= = 40 l/min
1000
fν = viscosity factor kW
see diagram page 14 [ l/min ] becomes
500
Q = discharge flow (l/min) with Q =
Vg · n
P1Pu = 3.6 ·( 1450
+ 0.017 · 40 kW )
1000 P1Pu = 1.92 kW
Vg = geometrical
3 Motor
displacement (cm /r) power output: P2Mot = 1.2 · P1Pu = 2.3 kW
Select helical
geared motor with P = 3.0 kW
n = 500 1/min
Conversion factors Speed recommendation

lb
1 bar ^
= 14.5
in2
= 14.5 psi Kinematic viscosity ν mm2/s
< 300 300 500 1000 2000 3000 6000 10000 20000 30000
l gal
1 ^
= 0.220 = [U.K.] ≥ 1500 1250 1000 750 600 500 400 300 200 100
min min
l gal Speed nmax 1/min

1 ^
= 0.264 = [US]
min min
Input Power
1400 0.07
n 1/min kW fν
l/min
1200 0.06
Speed
Viscosity
Drehzahl
Viskositätsfaktor
1000 0.05
800 0.04
n fν
600 0.03
400 0.02
200 0.01
0
2 3 4 5 6 78 9 2 3 4 5 6 78 9 2 3 4 5 6 78 9
102 103 104 105
kinematische Viskosität mm2/s
Kinematic viscosity
ν
Diagramm: n, f ν = f (ν)
Note:
To determine the power consumption,
always take the max. operating viscosity at
starting state into consideration.
The power of the drive motor should be
selected 20 % higher than the value determined.
Flange-Mounting Version with Pipe Thread
KF 4 ... 25
J 33
80 F
ø 10 9
16 7
5
ø8
ø14 j6
14,2
5
ø63 h8
80
4
95 a 16
b 25
KF 4 ... 25 with pressure reliev valve
95 J1 33
80 F
ø 10 9
16 7
ø14 j6
5
ø8
14,2
5
ø 63 h8
80
4
100 a 16
b 25
Nominal Suction and Weight in kg

size pressure connection
without with
a b F J J1
valve valve
G 3⁄ 4
4...12 Ø 36 54 109 140 2.9 3.7
17 deep
G1
16...25 Ø 42 63 131 161 3.5 4.3
19 deep
Flange-Mounting Version with SAE 3⁄4 and 1-Connection (Special No. 158)
KF 4 ... 25
Nominal
Suction and pressure connection Weight in kg
size
without with
A B E M F J J1
valve valve
M10
4...12 SAE 3⁄4 47.6 22.2 19.5 54 109 140 4.2 5.0
15 deep
M10
16...25 SAE 1 52.4 26.2 25 63 131 162 4.8 5.6
17 deep
Flange-Mounting with SAE 1 1⁄2 -Connection
KF 32 ... 80
J 44
100 F
ø 10 13
27 7
M 12
03 20 deep
20 tief
ø1
ø24 j6
8
ø80 h8
20
ø 38
69,9
110
4
110 35,7 28
36
110 J1 44
100 F
ø10 13
27 7
M 12
20deep
20 tief ø24 j6
3
ø10
8
ø80 h8
20
ø 38
69,9
110
4
153
35,7 28
36
Nominal Weight in kg
size
without with
F J J1
valve valve
32...50 SAE 11/2 84 173 212 7.7 9.5
63 / 80 SAE 11/2 100 208 247 9.4 11.2
Flange-Mounting Version with SAE 2-Connection (Special No. 232)
KF 50 ... 80
M 12 –
20 deep
M 12 –
20 deep
size
without with
F J J1
valve valve
50 SAE 2 84 121 212 7.7 9.5
63 / 80 SAE 2 100 206 217 9.4 11.2
Pump with Mounting Angle, Pipe Thread
KF 4 ... 25
J 33
F 95
5
R5
b
a
16
ø14 j6
14,2
ø63 h8
5
135
80
80
4
12
16 ø11
25
16 90 90
85 120
J1 33 100
F 95
5
R5
b
a
ø14 j6
14,2
ø63 h8
135
80
80
12
ø11
90
16 90
85 120
Nominal Suction and Weight in kg

without with
a b F J J1
valve valve
G 3⁄ 4
4...12 Ø 36 54 109 140 4.2 5.0
17 deep
G1
16...25 Ø 42 63 131 161 4.8 5.6
19 deep
Pump with Mounting Angle, SAE 3⁄4 and 1-Connection (Special No. 158)
KF 4 ... 25
Nominal
size
without with
A B E M F J J1
valve valve
M10
4...12 SAE 3⁄4 47.6 22.2 19.5 54 109 140 4.2 5.0
15 deep
M10
16...25 SAE 1 52.4 26.2 25 63 131 162 4.8 5.6
17 deep
Pump with Mounting Angle, SAE 1 1⁄2 -Connection
KF 32 ... 80
J 44
F
110
7
5
R6
35,7
ø24 j 6
27
ø80 h 8
20
69,9
165
110
38
8
100
4
ø11
28 M 12-20 deep
tief
12
36
18 94 120
80 150
J1 44
F 153
110
5
R6
35,7
ø24 j 6
ø80 h 8
20
69,9
110
38
165
100
ø11
M 12-20 deep
tief
12
18 94 120
80 150
size
without with
F J J1
valve valve
32...50 SAE 11/2 84 173 212 9.5 11.3
63 / 80 SAE 11/2 100 208 247 11.2 13,0
Pump with Mounting Angle, SAE 2-Connection (Special No. 232)
KF 50 ... 80
M 12 –
20 deep
KF 50 ... 80 with pressure relief valve
M 12 –
20 deep
size
without with
F J J1
valve valve
50 SAE 2 84 121 212 9.5 11.3
63 / 80 SAE 2 106 206 217 11.2 13.0
Flange-Mounting Version with Universal Arrangement
KF 4 ... 25
A 33
80 F
16 16
Ø 10 4
20.8
5
Ø8
5
h8
Ø 63
102
60.2
9
157 7 deep
G 3/4-17 tief
B
1/2-15deep
tief
25
GG1/2-15
j6
Ø 14
Ordering code
KF UF . .
Seals 12
Nominal Weight Perm. manometr. low pressure

size in kg at the pump suction connection
A B F p e bar
4
5
6
174.5 166.5 135.5 6.9
8
10 0.35
12
16
20 196.5 188.5 157.5 7.5
25
Flange-Mounting Version with Universal Arrangement
KF 32 ... 80
B 44 77,8
F Ø 50
298
42,9
28 M 12-18 tief
deep
4
50
133
Ø1
8
03
h8
Ø 10 13
Ø 80
7
27
A
100
42,9
36
Ø 50
77,8
j6
deep
Ø 24
M 12 -18 tief
Ordering code
KF UF. .
Seals 12
Nominal Weight Perm. manometr. low pressure

size in kg at the pump suction connection
A B F p e bar
32
40 173 159 69 27.5
50
0.35
63
208 175 85 29.5
80
Accessory Couplings
Version A Version B
L L
Part
Teil 11 Part
Teil 11 Part
Teil 11 Part
Teil 22
DH
DH
D1
D
D
dH
dH
M s b s M M s b s M
l1 E l2 Gear rim l1 E l2
Ordering code Coupling Hub material Pre- Finished Dimensions

size (AL) bore bore
Weight Moment min. max.
of inertia
kg kgm2 part part part part part part
1 2 1 2 1 2 l1/l2 E s b L M DH D D1 dh
RA 19-Z 25/..-Z 25/.. 19 0.117 0.00003 4 – 6 – 19 – 25 16 2 12 66 20 40 32 – 18

Version A
RA 24-Z 30/..-Z 30/.. 24 0.24 0.00008 6 – 8 – 24 – 30 18 2 14 78 24 55 40 – 27
RA 28-Z 35/..-Z 35/.. 28 0.39 0.0002 8 – 10 – 28 – 35 20 2.5 15 90 28 65 48 – 30
RA 38-Z 45/..-Z 45/.. 38 0.82 0.0007 10 – 12 – 38 – 45 24 3 18 114 37 80 66 – 38
RA 19/24-Z 25/..-Z 25/.. 19/24 0.129 0.00004 4 17 6 19 19 24 25 16 2 12 66 20 40 32 40 18

Version B
RA 24/28-Z 30/..-Z 30/.. 24/28 0.26 0.0001 6 22 8 24 24 28 30 18 2 14 78 24 55 40 48 27
RA 28/38-Z 35/..-Z 35/.. 28/38 0.46 0.0003 8 26 10 28 28 38 35 20 2.5 15 90 28 65 48 65 30
RA 38/45-Z 45/..-Z 45/.. 38/45 0.89 0.0008 10 36 12 38 38 45 45 24 3 18 114 37 80 66 76 38
Type Code KF Coupling
Ordering code
RA 38 - Z 45/38 - Z 45/38
Coupling size pump side motor side

cylindrical cylindrical
coupling hub lengt and hub bore
Operating temperature: Weights and mass moments of inertia refer

-- 20 °C to + 80 °C (-- 4 °F to 176 °F) to max. finish machined bore without slot.
(short duration temperature peaks Finish-machined bores to ISO Fit H7,
up to 120 °C / 248 °F are permissible). parallel key slots in accordance with DIN 6886 Sh.1.
Bell Housing
KF 4 ... 25 Aluminum bell housing
Size Bell housing Coupling Mass Weight
A B C D F K L N P kg
71 S
PT160-A-063-80 RA19-Z25/14-Z25/14 160 110 130 110 7 7 80 9 M8 1.01
71
80 S
PT200-A-063-100 RA19-Z25/14-Z25/19 200 130 165 145 7 7 100 11 M10 1.06
80
90 S
PT200-A-063-100 RA19/24-Z25/14-Z25/24 200 130 165 145 7 7 100 11 M10 1.06
90 L
100 LS
100 L PT250-A-063-120 RA24/28-Z30/14-Z30/28 250 180 215 190 7 7 120 14 M12 1.75
112 M
Bell Housing
KF 32 ... 80 Aluminum bell housing
Size Bell housing Coupling Mass Weight
A B C D F K L N P kg
80 S
PT200-A-080-100 RA19/24-Z25/24-Z25/19 200 130 165 145 7 11 100 11 M10 1.41
80
90 S
PT200-A-080-110 RA24-Z30/24-Z30/24 200 130 165 145 7 11 110 11 M10 1.19
90 L
100 LS
100 L PT250-A-080-124 RA24/28-Z30/24-Z30/28 250 180 215 190 7 14 124 14 M12 1.42
112 M
132 S
PT300-A-080-144 RA28/38-Z35/24-Z35/38 300 230 265 234 7 14 144 14 M12 2.10
132 M
160 M
PT350-A-080-188 RA38/45-Z45/24-Z45/42 350 250 300 260 7 18 188 18 M16 3.05
160 L
Motor-Pump Assemblies with Pipe Thread
KF 4 ... 25
with pressure relief valve
KF 4 ... 25 Pump sizes
Nominal Suction and

A B F J J1
G 3⁄ 4
4...12 Ø 36 54 109 140
17 deep
G1
16...25 Ø 42 63 131 162
19 deep
Motor-Pump Assemblies with Pipe Thread
KF 4 ... 25
Frame Power Speed Power Speed Bell housing Coupling Total weight *
size Motor 6 pole Motor 4 pole kg
Nominal size
kW 1/min kW 1/min 4...12 16...25
71 S 0.18 920 0.25 1400 10 10.5
PT160-A-063-80 RA19-Z25/14-Z25/14
71 0.25 920 0.37 1410 11 11.5
80 S 0.37 920 0.55 1420 13.5 14
PT200-A-063-100 RA19-Z25/14-Z25/19
80 0.55 930 0.75 1420 14.5 15
90 S 0.75 930 1.1 1410 17.5 18
PT200-A-063-100 RA19/24-Z25/14-Z25/24
90 L 1.1 930 1.5 1420 20.5 21
100 LS – – 2.2 1430 26.5 27
100 L 1.5 950 3 1430 PT250-A-063-120 RA24/28-Z30/14-Z30/28 29.5 30
112 M 2.2 940 4 1435 32.5 33
* with pressure relief valve add, weight 0.8 kg
KF 4 ... 25 Dimensions
Frame Dimensions
size
4...12 16...25 4...12 16...25 4 ... 25
L 1* L 1* L 2* L 2* L a1 a b c* e* f* g* h o* p* q* ø s* w1
71 S 397 419 428 450 80 160 90 112 9 112 136 130 71 127 176 81 7 45
71 397 419 428 450 80 160 90 112 9 112 136 130 71 127 176 81 7 45
80 S 434 456 465 487 100 200 100 125 10 125 154 150 80 138 190 87 10 50
80 434 456 465 487 100 200 100 125 10 125 154 150 80 138 190 87 10 50
90 S 466 488 472 494 100 200 100 140 10 125 170 177 90 134 217 99 10 56
90 L 466 488 497 519 100 200 125 140 10 150 170 177 90 159 217 99 10 56
100 LS 518 540 549 571 120 250 140 160 12 172 197 197 100 187 237 102 12 63
100 L 518 540 549 571 120 250 140 160 12 172 197 197 100 187 237 102 12 63
112 M 530 552 561 583 120 250 140 190 12 168 222 221 112 161 258 140 12 70
Note
* Dimensions dependent on motor typ All pump and motor sizes can be combined.
(drawing: manufacture ABB).
Other manufactures motors can be supplied on request.
Motor frame sizes are based on DIN 42673 / 677.
Motor-Pump Assemblies with SAE 3⁄4 bzw. 1-Connection (Special No. 158)
KF 4 ... 25
Nominal
size
without with
A B E M F J J1
valve valve
M10
4...12 SAE 3⁄4 47.6 22.2 19.5 54 109 140 4.2 5.0
15 deep
M10
16...25 SAE 1 52.4 26.2 25 63 131 162 4.8 5.6
17 deep
Motor-Pump Assemblies with SAE 3⁄4 bzw. 1-Connection (Special No. 158)
KF 4 ... 25
Nominal size
kW 1/min kW 1/min 4...12 16...25
71 S 0.18 920 0.25 1400 10 10.5
PT160-A-063-80 RA19-Z25/14-Z25/14
71 0.25 920 0.37 1410 11 11.5
80 S 0.37 920 0.55 1420 13.5 14
PT200-A-063-100 RA19-Z25/14-Z25/19
80 0.55 930 0.75 1420 14.5 15
90 S 0.75 930 1.1 1410 17.5 18
PT200-A-063-100 RA19/24-Z25/14-Z25/24
90 L 1.1 930 1.5 1420 20.5 21
100 LS – – 2.2 1430 26.5 27
100 L 1.5 950 3 1430 PT250-A-063-120 RA24/28-Z30/14-Z30/28 29.5 30
112 M 2.2 940 4 1435 32.5 33
Bau- Dimensions
größe
4...12 16...25 4...12 16...25 4 ... 25
71 S 397 419 428 450 80 160 90 112 9 112 136 130 71 127 176 81 7 45
71 397 419 428 450 80 160 90 112 9 112 136 130 71 127 176 81 7 45
80 S 434 456 465 487 100 200 100 125 10 125 154 150 80 138 190 87 10 50
80 434 456 465 487 100 200 100 125 10 125 154 150 80 138 190 87 10 50
90 S 466 488 472 494 100 200 100 140 10 125 170 177 90 134 217 99 10 56
90 L 466 488 497 519 100 200 125 140 10 150 170 177 90 159 217 99 10 56
100 LS 518 540 549 571 120 250 140 160 12 172 197 197 100 187 237 102 12 63
100 L 518 540 549 571 120 250 140 160 12 172 197 197 100 187 237 102 12 63
112 M 530 552 561 583 120 250 140 190 12 168 222 221 112 161 258 140 12 70
Note
Motor-Pump Assemblies with SAE 1 1⁄2 -Connection
KF 32 ... 80
M 12 –
20 deep
M 12 –
20 deep
Nominal
size
F J J1
32...50 84 173 212
63 / 80 100 208 247
Motor-Pump Assemblies with SAE 1 1⁄2 -Connection
KF 32 ... 80
Nominal size
kW 1/min kW 1/min 32...50 63...80
80 S 0.37 920 0.55 1420 18.4 20.1
PT200-A-080-100 RA19/24-Z25/24-Z25/19
80 0.55 930 0.75 1420 19.4 21.1
90 S 0.75 930 1.1 1410 22.3 24
PT200-A-080-110 RA24-Z30/24-Z30/24
90 L 1.1 930 1.5 1420 25.3 27
100 LS – – 2.2 1430 31.3 33
100 L 1.5 950 3 1430 PT250-A-080-124 RA24/28-Z30/24-Z30/28 34.3 36
112 M 2.2 940 4 1435 37.3 39
132 S 3 960 5.5 1450 50 52
132 M 4 960 7.5 1450 PT300-A-080-144 RA28/38-Z35/24-Z35/38 58 60
132 M 5.5 955 – – 64 66
160 M 7.5 975 11 1455 91 93
PT350-A-080-188 RA38/45-Z45/24-Z45/42
160 L 11 970 15 1460 105 107
Frame Dimensions
size
32...50 63...80 32...50 63...80 32 - 80
80 S 498 533 537 572 100 200 100 125 10 125 154 150 80 138 190 87 10 50
80 498 533 537 572 100 200 100 125 10 125 154 150 80 138 190 87 10 50
90 S 515 550 554 589 110 200 100 140 10 125 170 177 90 134 217 99 10 56
90 L 540 575 579 614 110 200 125 140 10 150 170 177 90 159 217 99 10 56
100 LS 586 621 625 660 124 250 140 160 12 172 197 197 100 187 237 102 12 63
100 L 586 621 625 660 124 250 140 160 12 172 197 197 100 187 237 102 12 63
112 M 598 633 637 672 124 250 140 190 12 168 222 221 112 161 258 140 12 70
132 S 684 719 723 758 144 300 140 216 14 212 262 261 132 216 296 151 12 89
132 M 684 719 723 758 144 300 178 216 14 212 262 261 132 216 296 151 12 89
160 M 854 889 893 928 188 350 210 254 20 288 310 310 160 299 370 194 15 108
160 L 854 889 893 928 188 350 254 254 20 288 310 310 160 299 370 194 15 108
Note
Motor-Pump Assemblies with SAE 2-Connection (Special No. 232)
KF 50 ... 80
M 12 –
20 deep
M 12 –
20 deep
Nominal
size
F J J1
50...80 84 173 212
63 / 80 100 208 247
Motor-Pump Assemblies with SAE 2-Connection (Special No. 232)
KF 50 ... 80
Nominal size
kW 1/min kW 1/min 32...50 63...80
80 S 0.37 920 0.55 1420 18.4 20.1
PT200-A-080-100 RA19/24-Z25/24-Z25/19
80 0.55 930 0.75 1420 19.4 21.1
90 S 0.75 930 1.1 1410 22.3 24
PT200-A-080-110 RA24-Z30/24-Z30/24
90 L 1.1 930 1.5 1420 25.3 27
100 LS – – 2.2 1430 31.3 33
100 L 1.5 950 3 1430 PT250-A-080-124 RA24/28-Z30/24-Z30/28 34.3 36
112 M 2.2 940 4 1435 37.3 39
132 S 3 960 5.5 1450 50 52
132 M 4 960 7.5 1450 PT300-A-080-144 RA28/38-Z35/24-Z35/38 58 60
132 M 5.5 955 – – 64 66
160 M 7.5 975 11 1455 91 93
PT350-A-080-188 RA38/45-Z45/24-Z45/42
160 L 11 970 15 1460 105 107
Frame Dimensions
size
50...80 63...80 50...80 63...80 50 - 80
80 S 498 533 537 572 100 200 100 125 10 125 154 150 80 138 190 87 10 50
80 498 533 537 572 100 200 100 125 10 125 154 150 80 138 190 87 10 50
90 S 515 550 554 589 110 200 100 140 10 125 170 177 90 134 217 99 10 56
90 L 540 575 579 614 110 200 125 140 10 150 170 177 90 159 217 99 10 56
100 LS 586 621 625 660 124 250 140 160 12 172 197 197 100 187 237 102 12 63
100 L 586 621 625 660 124 250 140 160 12 172 197 197 100 187 237 102 12 63
112 M 598 633 637 672 124 250 140 190 12 168 222 221 112 161 258 140 12 70
132 S 684 719 723 758 144 300 140 216 14 212 262 261 132 216 296 151 12 89
132 M 684 719 723 758 144 300 178 216 14 212 262 261 132 216 296 151 12 89
160 M 854 889 893 928 188 350 210 254 20 288 310 310 160 299 370 194 15 108
160 L 854 889 893 928 188 350 254 254 20 288 310 310 160 299 370 194 15 108
Note
Accessory Connections
Threaded Flange G-SAE 3⁄4
Weight 0.39 kg – N
–F
–P
Welding Flange S-SAE 3⁄4
–F
–P
N = NBR O-Ring
F = FKM O-Ring
P = PTFE O-Ring
Threaded Flange G-SAE 1
–F
–P
Welding Flange S-SAE 1
–F
–P
N = NBR O-Ring
F = FKM O-Ring
P = PTFE O-Ring
Threaded Flange G-SAE 1 1⁄2
–F
–P 44 O-Ring 47,22x3,52 94
24 69,9
G 1 1/2"
ø38
35,7
77
M12
Zylinderschraube
Cheesehead screwM12x45
M 12 x 45DIN
DIN912
912
25 18
Welding Flange S-SAE 1 1⁄2
–F
–P O-Ring 47,22x3,52 94
44 69,9
ø38
ø48,6
35,7
77
M12
Zylinderschraube
Cheesehead screwM12x45
M 12 x 45DIN
DIN912
912
25 18
N = NBR O-Ring
F = FKM O-Ring
P = PTFE O-Ring
Threaded Flange G-SAE 2
–F
–P
Welding Flange S-SAE 2
–F
–P
N = NBR O-Ring
F = FKM O-Ring
P = PTFE O-Ring
Accessory Liquid Seal
Tank for liquid seal liquids Adapter for screw size tap G 1⁄8
Note
Note
Product Portfolio
Transfer Pumps Flow Measurement

Transfer pumps for lubricating oil Gear and turbine flow meters and electronics
supply equipment, low pressure for volume and flow metering technology in
filling and feed systems, dosing and hydraulics, processing and laquering technology.
mixing systems.
Industrial Hydraulics /
Mobile Hydraulics Test Bench Construction
Single and multistage high pressure Cetop directional control and proportional
gear pumps, hydraulic motors and valves, hydraulic cylinders, pressure, quantity
valves for construction machinery, and stop valves for pipe and slab construction,
vehicle-mounted machines. hydraulic accessories for industrial hydraulics
(mobile and stationary use).
Technology Test benches / Fluid Test benches.
KF 4...80 / GB / 05.08
KRACHT GmbH · Gewerbestraße 20 · 58791 Werdohl, Germany · fon +49 (0) 23 92 / 935-0 · fax +49 (0) 23 92 / 935 209
mail info@kracht.eu · web www.kracht.eu
23.04.2009
Datenblatt
ERSTELLT MIT VEM-KATALOG, VERSION 6.02
Hersteller Kunde
VEM motors Thurm GmbH
Äußere Dresdener Str. 35
D-08066 Zwickau
Drehstrommotoren mit Käfigläufer, Normmotoren

Graugussgehäuse
Typ K21R 100 LX4
Betriebsart S1
Bemessungsleistung [kW] 3
Polzahl (-) 4
Bemessungsfrequenz [Hz] 50
Bemessungsdrehzahl [min-1] 1430
Bemessungsspannung [V] 230/400
Schaltung (-) D Y
Bemessungsstrom [A ] 11.6 6.7
rel. Anzugsstrom (-) 6,5
rel. Anlaufmoment (-) 2,5
rel. Sattelmoment (-) 2,2
rel. Kippmoment (-) 2,9
Lastzustand (%) 100 75 50 25
Leistungsfaktor (-) 0,79 0,7 0,56 0,36
Wirkungsgrad (%) 82,6 82,3 81 70
Th. Kl. 155(F/B)
Kühlmitteltemperatur [°C] 40°C
Aufstellungshöhe [m] 1000m
Schutzart IP55
2
Trägheitsmoment [kgm ] 0,00725
Masse [kg] 30
Lager DS 6206 2Z C3
Lager NS 6206 2Z C3
Nachschmierfrist [h]
Fett Asonic GLY 32
Fettmenge [g]
A-Schalldruckpegel [ dB ] 50
Sonderangaben zur Lagerung 1 ohne
Sonderangaben zur Lagerung 2 ohne
Lagerüberwachung ohne
Wicklungsschutz ohne
Wicklungsschutz 2 ohne
Stillstandsheizung ohne
Sonderausführungen 1 ohne
Schwinggrößenstufe Stufe A
Wuchtung mit halber Paßfeder
Farbsystem moderate
Farbton RAL 7031 blaugrau
Schichtdicke 60 µm
Lieferbedingungen und/oder amtliche Vorschriften: DIN EN 60034-1

Dieses Dokument wurde elektronisch hergestellt, alle Angaben sind nur nach Bestätigung durch den Hersteller
verbindlich.
Seite 1/2
VEM motors GmbH Telefon: 0 39 43 / 68-0 Geschäftsführer: Rechtsform: GmbH Commerzbank AG Dresdner Bank AG Deutsche Bank AG
Carl-Friedrich-Gauß-Straße 1 Telefax: 0 39 43 / 68 21 20 Sitz: Wernigerode Dresden Wernigerode Wernigerode
D-38855 Wernigerode Jürgen Sander Amtsgericht
Postfach-Nr. 101252 E-Mail: motors@vem-group.com Dr. Dietmar Puschkeit Stendal HRB 112964 BLZ 850 400 00 BLZ 800 800 00 BLZ 810 700 00
D-38842 Wernigerode www.vem-group.com Dr. Susanne Frieß Ust.-Id. Nr. DE 212 649 455 Kto.-Nr. 800 15 88 Kto.-Nr. 350 50 30 00 Kto.-Nr. 250 04 03
23.04.2009
Datenblatt
ERSTELLT MIT VEM-KATALOG, VERSION 6.02
Drehstrommotoren mit Käfigläufer, Normmotoren

Graugussgehäuse
K21R 100 LX4
Einbaulage Bauform: IM B3 Klemmenkasten: KA 05
Flansch: - Kabelverschraubung O: 1 xVerschlussstopfen
Klemmkastenlage: oben
Motor
A AA AB AC AD B B' BA BA' BB C CA K K'
160 32 188 196 - 140 140 - - 171 63 - 12 12
Anschlußkasten
L LC H HA HD HH Bl AG LL BE AH
357 - 100 11 237 77 20 92 92 - -
Flansch Toleranzen
P N LA M T S H N D DA
- - - - - - -0,5 j6 k6 k6
Welle-DS Welle-NS
D E GA F DB DA EA GC FA
28 60 31 8 DIN 332-DS M10 - - - -
DB...Zentrierbohrung
Lieferbedingungen und/oder amtliche Vorschriften: DIN EN 60034-1

Dieses Dokument wurde elektronisch hergestellt, alle Angaben sind nur nach Bestätigung durch den Hersteller verbindlich.
Seite 2/2
VEM motors GmbH Telefon: 0 39 43 / 68-0 Geschäftsführer: Rechtsform: GmbH Commerzbank AG Dresdner Bank AG Deutsche Bank AG
Carl-Friedrich-Gauß-Straße 1 Telefax: 0 39 43 / 68 21 20 Sitz: Wernigerode Dresden Wernigerode Wernigerode
D-38855 Wernigerode Jürgen Sander Amtsgericht
Postfach-Nr. 101252 E-Mail: motors@vem-group.com Dr. Dietmar Puschkeit Stendal HRB 112964 BLZ 850 400 00 BLZ 800 800 00 BLZ 810 700 00
D-38842 Wernigerode www.vem-group.com Dr. Susanne Frieß Ust.-Id. Nr. DE 212 649 455 Kto.-Nr. 800 15 88 Kto.-Nr. 350 50 30 00 Kto.-Nr. 250 04 03
Transfer Gear Pumps
Operating and Maintenance Instructions
KF 4 - 80
D-300435
Content
Symbols for safety instructions 3
General safety instructions 3
Manufacturer's address 3
The documentation 4
Description of equipment 4
General 4
Specified use 5
Construction 5
Explanation of the type code 6
General data 7
Overview of nominal sizes 7
Overview of materials 8
Overview of operating pressures 8
Pump installation and removal 8

Mechanical installation 8
Alignment of the coupling 9
Determination of the direction of rotation 10
Selection of the suction line 10
Selection of the suction line 11
Sizing of the pressure line 11
Pump removal 13
Commissioning 13
Particularity of sealing variants 4 and 7 (double radial shaft sealing ring) 14
Pressure setting of the pressure relief valve 14
Maintenance 15
Seals 15
Changing the pump's direction of rotation 16
Tightening torque for cover fixing screws 16
Change of direction of rotation at sealing variant 5 (Slip-ring sealing) 16
Repairs 17
Elimination of damages 17
Error diagnostics 17
Return of pumps 17
Recognise and avoid errors 17
2 BKF-0004-05.03-GB
D-300435
Safety
Symbols for safety instructions

The safety instruction embodied in these operating instructions are identified with the attention!-
symbol.
If these instructions are not heeded, hazards to personnel and damage to equipment may result.
Further notes which do not have a warning character but provide tips for optimum operation are
symbolised by a hand:
General safety instructions
The operating safety of the pump supplied is only guaranteed if the pump is used as
specified (see "Description of equipment"). The stated limiting values (see also
"Technical data") must not be exceeded under any circumstances.
Personnel having the responsibility for installing, operating or repairing the pump need to
have the appropriate qualifications; these may have been obtained through training or
appropriate instruction. Such personnel must be familiar with the content of these operating
instructions.
During the execution of all work, the prevailing national rules for accident prevention and
safety at the work place and where appropriate the internal regulation of the operator must
be observed, even if the latter are not named in these operating instructions.
Leakages of dangerous substances handled by the pump must be contained and disposed in
such a way that there is no danger to personnel or the environment. The relevant statutory
regulations must be observed.
During all work on the pump and prior to installation, the connecting pipeline must be
depressurised and the motor isolated!
The operator has to ensure that these operating instructions are accessible at all times to
personnel in charge.
Manufacturer's address
Kracht GmbH
Gewerbestraße 20
D- 58791 Werdohl
Germany
Tel.: 00 49 / 23 92 / 935-0
Fax: 00 49 / 23 92 / 935-209
e-mail: info@kracht-hydraulik.de
Internet: www.kracht-hydraulik.de
BKF-0004-05.03-GB 3
D-300435
The documentation
The present operating instructions describe the installation, the operation and the repair of the
KRACHT transfer pumps KF 4…80.
The device is manufactured in different versions. The specific version can be identified from the
type label affixed to the pump. The structure of the type designation and a detailed description of
the individual versions and nominal sizes can be found in the "Technical data" section (see
"Description of equipment").
Description of equipment
General
KRACHT pumps out of the KF series are external gear pumps which operate according to the
displacement principle. Two gear wheels which are rotating in mesh with each other cause an
increase in volume to occur as the spaces between the gear wheels are exposed at the pump inlet
(suction side), so that the medium can flow into the pump. Simultaneously, a corresponding
volume is displaced at the pump outlet (pressure side) through rotation of the gear teeth into the
filled area vacated by the preceding teeth. The transport of fluid is achieved through the
entrainment along the cavities between the gear teeth and the walls of the gear chambers. The so
called geometric delivery volume Vg is displaced per revolution of the gear wheels. A value Vgn
referred to as the nominal volume is used in technical documentation to identify the pump size.
Gear pumps are self-priming in wide confines. The described displacement process is initially
achieved without noticeable pressure rise. It is only after the burden of external loading is applied,
for example if a delivery head is imposed, there is resistance at the pump outlet, pipeline
components, etc. that a working pressure must be generated to overcome these resistances.
Displacement pumps must never be operated against "closed valves", since the
uncontrollable pressure heads which occur in this case could damage the pump
and the associated plant elements.
As usual in the case of so called rigid pumps, i.e. pumps without compensation for axial play, the
lateral play between the gear wheel contact surfaces is set such that the permissible operating
pressure is safely controlled. The directions of rotation and supply of external gear pumps when
viewed on the end of the driving shaft are given as in the following figures:
pd ps ps pd
Pressure side Suction side Suction side Pressure side
Fig. 1 Fig. 2
Shaft rotating counterclockwise Shaft rotating clockwise
Delivery from right to left Delivery from left to right
4 BKF-0004-05.03-GB
D-300435
Specified use
The KF is a pump for the continuous delivery of fluids. The different sealing variants enable the
pump to be used for various media.
It has to be ensured that the medium to be delivered is compatible with the materials used in the
construction of the pump (see "Technical data").
The maximum permissible operating data mentioned in the "Technical data" must be observed
unconditionally.
Construction
The basic construction of the KF is shown in the figure below:
Fig. 3
1 Driving shaft
2 Driven shaft
3 Housing
4 Cover
5 Plain bearing bush
6 Radial shaft sealing ring
(Shaft seal varies to suit sealing requirements)
7 Retaining ring
BKF-0004-05.03-GB 5
D-300435
Technical data
Explanation of the type code
Product name
Nom. size Vg 4, 5, 6, 8, 10, 12, 16, 20, 25 cm³

Vg 32, 40, 50, 63, 80 cm³
Direction of R clockwise (cw)

rotation L counterclockwise (ccw)
B clockwise and counterclockwise
U universal
(Direction of flow delivery remains the
same as the angle of rotation changes)
KF 40 R F 1 - D 15 /... - ...
Ordering example
Mounting
F DIN flange without support bearing
G DIN flange with support bearing
W mounting angle without support bearing
X mounting angle with support bearing
Seal type
1 radial shaft sealing ring NBR
2 radial shaft sealing ring FPM
3 radial shaft sealing ring PTFE
4 double radial shaft sealing ring PTFE
5 GLRD with FPM-secondary seals
6 GLRD with PTFE-secondary seals
7 double radial shaft sealing ring FPM
9 radial shaft sealing ring EPDM
(sealing not resistant to mineral oil)
Pressure relief valve

D 15 adjustable over 0-15 bar
D 25 adjustable over 15-25 bar
Special code no.
Code no. for special design
Codification for material
Codification for special material

GJS EN-GJS-400-15
6 BKF-0004-05.03-GB
D-300435
General data
Type of construction External gear pump

Materials See overview "Materials"
Type of mounting Flange DIN ISO 3019
Driving shaft end ISO R 775 short/cylindrical
Pipeline connection KF 4 up to 25 Whitworth-pipe thread
KF 32 up to 80 SAE-flange connection
Installation attitude Any*
Viscosity νmin 12 mm²/s
νmax 20000 mm²/s
Surrounding temperature ϑu min -20 °C
ϑu max 60 °C
Filtering Filter fineness ≤ 60 µm
* Exception: universal version (KF ...U...)
Overview of nominal sizes

geom. delivery volume RPM range perm. Radial Sound
force** level
Vg nmin nmax Fradial L
Nom. size cm³ 1/min 1/min N db(A)
4 4.03 64
5 5.05 64
6 6.38 64
8 8.05 65
10 10.11 200 3000 700 65
12 12.58 65
16 16.09 64
20 20.10 64
25 25.10 64
32 32.12 68
40 40.21 68
50 50.20 200 3000 1500 68
63 63.18 68
80 80.50 68
* See type label at pump: KF...

** Radial forces only at version with support bearing. Fradial on central shaft journal.
BKF-0004-05.03-GB 7
D-300435
Overview of materials
Sealing Housing/
Gear Bearing Shaft seals O-Ring
type* Cover
1 NBR NBR
2 FPM FPM
3 PTFE FEP
4 Carburising PTFE FEP
EN-GJL-250
5 steel P 10 Carbon (in synthetic resin), FP
EN-GJS-400-15**
(1.7139) CrMo-Casting, FKM, 1.4571
6 SiC-SiC, FFKM, 1.4571 FEP
7 FPM FPM
9 EPDM EPDM
** At version in EN-GJS-400-15 type code KF ... - GJS
Overview of operating pressures

Operating pressure Temperature of
Sealing Suction side Pressure side delivered medium
type*
p**e min bar pe max bar pb bar pb max bar ϑ min °C ϑ max °C
1 1 90
2 150
3 10 200
4 -0.4 1 25 40 -10
5 10 150
6 200
7 1 150
9 0.4 100
** At universal version (KF…U…) please note restriction of pmin
For certain operating conditions, the stated minimum and maximum values are not
valid! Thus, for example, the maximum operating pressure is not permissible in
conjunction with low rpm and minimum viscosity.
Pump installation and removal

Mechanical installation
Only pipelines and connections compatible with the anticipated operating pressure
range can be used.
The relevant manufacturer's specifications should be considered!
• Before installation the pump has to be checked for possible damage and contamination during
transport.
• The corresponding coupling hub has to be mounted on the motor- and pump shaft.
When installing the coupling, the hub should be heated up and slid onto the shaft in the heated
condition.
8 BKF-0004-05.03-GB
D-300435
• The shaft must not be struck during the mounting operation!
Each coupling hub has to be secured on the respective shaft against axial
displacement by means of the threaded pin which presses on the adjusting spring!
Alignment of the coupling

When installing the coupling it has to be assured that the "E" dimension is precisely kept so that
the coupling can move freely in the axial way during operation. In order that the elastic toothed rim
is not exposed to pressure on its face, for axial movement, the dimension "E" is to be taken as a
minimum.
Shaft separation "E" Shaft with adjuster spring

sits in toothed rim (dw)
Careful and exact alignment of the shafts prolongs the durability of the coupling!
Type of coupling 19 24 28 38 42 48 55 65 75
19/24 24/28 28/38 38/45 42/55 48/60 55/70 65/75 75/90
Separation E 16 18 20 24 26 28 30 35 40
dimension*
Dimension* s 2 2 2,5 3 3 3,5 4 4,5 5
Dimension * dH 18 27 30 38 46 51 60 68 80
Dimension * dW 12 20 22 28 36 40 48 55 65
Max. axial ∆Ka 1.2 1.4 1.5 1.8 2.0 2.1 2.2 2.6 3.0
movement*
Max. radial ∆Kr 0.20 0.22 0.25 0.28 0.32 0.36 0.38 0.42 0.48
offset*
n=1500 1/min
Max. angle 1.2° 0.9° 0.9° 1.0° 1.0° 1.1° 1.1° 1.2° 1.2°
offset ∆K
n=1500 1/min w
* Dimensions in mm
BKF-0004-05.03-GB 9
D-300435
The given permissible misalignment values for the couplings represent general guidelines which
take the loading of the coupling into consideration up to the nominal torque TKN and an operating
rpm n = 1500 as well as an ambient temperature of +30° C. For operating conditions outside these
limits, the KRACHT GmbH should be consulted. The misalignment values are individually
applicable, in the case of a simultaneous occurrence they should be applied proportionately.
The couplings can either take up a radial- or an angular misalignment.
If the shaft clearance dimension is less than the coupling dimension "E", then one of the shaft ends
can extend into the toothed rim section. The dimension "dw" corresponds to the maximum shaft
diameter which, with the adjuster spring, is allowed to penetrate into the toothed rim, dimension
"dH". If it is possible to remove the adjuster spring, i.e., only the shaft penetrates into the toothed
rim section, then the shaft dimension can be increased to up to 2 mm less than the given
dimension "dH", so that the axial freedom of movement of the toothed rim is not restricted.
Rotating parts must be protected by the customer against unintentional contact!
• Mount the pump on the pump supports or foot.

• Before installing the pump clean the pipeline system, remove dirt, sand, swarf etc. Welded
pipes, in particular, must be scoured or scavenged. Do not use cotton waste/rags for cleaning
purposes.
• Remove the protective stoppers in the pump's suction and pressure connections.
Determination of the direction of rotation

The pump's direction of rotation is determined as follows:
• When viewing on the end of the pump • When viewing on the end of the pump
shaft, the direction of supply is from left shaft, the direction of supply is from right
to right when the shaft rotates clockwise to left when the shaft rotates
counterclockwise
Without pressure relief valve
Suction side Pressure side Pressure side Suction side
Rotation clockwise Rotation counterclockwise
With pressure relief valve
Suction side Pressure side Pressure side Suction side
Rotation clockwise Rotation counterclockwise
10 BKF-0004-05.03-GB
D-300435
Selection of the suction line
Provision of the suction line should be carried out with great care, since the operational behaviour
of the pump is greatly affected by this factor.
The suction line should be as short and straight as possible. Additional sources of pipeline
resistance, such as formed parts and valves, should be avoided.
The depression in the suction line depends on the sum of all the resistances at the suction side
and the suction head, taking account of the specific data to the medium in the line.
The depression can be checked by installing a vacuum meter on the pump/suction
connection.
The permissible pressure at the pump inlet must not fall below the mentioned value pe min in the
"Technical data" section.
The only exception to this is the start-up condition of the pump when a pressure of –0.6 bar
(depression) is tolerable for up to max. 30 minutes.
The nominal diameter of the suction line can be chosen to be considerably larger than that
of the pump connection.
In case of exceeding the permissible values (see "Technical data"), the result would
be a reduction of the delivery volume (due to the reduced filling of the pump), a
higher sound level and cavitation.
If hosing is used on the suction side of the pump, then it must be of adequate stability such that the
hose does not deform and constrict the flow under the suction effect.
The provision of a funnel-shaped suction opening or an oblique intersection at the end of
the suction pipe are recommended for increasing the cross-section on the suction side.
When laying out the suction line in the medium container, attention
should be paid to the achievement of unimpaired suction.
There should be no partition walls adjacent to the opening of the
suction line.
The laying out of the suction line as a syphon, whereby the pump is
continually full after start-up, is a possible way of avoiding suction
problems (see Fig. 6).
Sizing of the pressure line

The nominal diameter of the pressure line should be selected in a
way that the flow velocity does not exceed the values given in the
following table.
Pressure ≤ 10 bar ≤ 25 bar Fig. 6
Flow velocity ≤ 3 m/s ≤ 3,5 m/s
The pump pressure should be checked by a gauge installed as close as possible to the pump
connection.
KRACHT pumps are displacement pumps (see "Description of equipment"). This

means that the use of a pressure relief valve or some other means of restricting
pressure in the system is essential!
In order to avoid overloading the pump due to pressure above the permissible value, a pressure-
limiting valve, incorporating return flow to the reservoir, must be installed as close as possible to
the pump pressure connection.
An alternative method of limiting the pressure on KRACHT transfer pumps is to install a pressure-
limiting valve directly onto the pump.
BKF-0004-05.03-GB 11
D-300435
When operating a pump which has to deliver via a check valve into an under-pressure circuit (e.g.
reserve pump in a lubrication circuit), suction difficulties can occur if the suction line is filled with
air. In these cases, the pressure line should be vented directly before the check valve.
This, for example, can be achieved by fitting a venting jet in the circuit (Fig. 7) or by providing a
restricted bypass (Fig. 8).
Fig. 7 Fig. 8
The volume of the pressure line between pump and check valve has to be at lest 75% of the
volume of the suction line.
• Connect the pipelines of both suction and pressure side of the pump and pay attention to the
instructions of the relevant manufacturer.
Neither the suction nor the pressure side pipelines should transfer loads to the
pump!
The pipelines have to be connected absolutely stress-free to the pump supports.
The pipelines are to be constructed in such a way that even during operation, no stresses can be
transferred through the pipelines, for example through changes in length due to temperature
fluctuations.
Damaged pipes and hoses must be replaced immediately!
• When installing it has to be assured that no sealing material an enter the pipeline. Sealing
materials such as hemp and mastic are not permissible since they an lead to contamination
and hence to operating failures.
• Fill the medium container with the prescribed fluid.
The best possible cleanliness has to be assured when filling the fluid container!
Clean filler plugs and caps on fluid transport and storage containers before opening. Check fluid
containers and clean if necessary. The filter gauze on filling tubes and filter inserts on fitted filters
must not be removed under any circumstances.
Attention should be paid to adequate filling of the fluid container!
12 BKF-0004-05.03-GB
D-300435
In order to achieve optimum noise protection, it is recommended that an anti-vibration
flange is fitted between the pump and the pump supports and that damping elements are
inserted between the electric motor and the installation.
Likewise, the use of suction and pressure hoses reduces the noise level of an hydraulic
installation.
Pump removal
During all work the best possible cleanliness should be assured. Before loosening screwed
connections, the external surrounding should be cleaned.
During all work at the pump and before the removal, the connection lines have to
be depressurised and the motor isolated!
In addition, precautions must be taken to ensure that the motor can not run-up
during work on the pump.
• Remove the depressurised pipelines from the pump.
Leakages of dangerous media must be collected and disposed of in such a way

that no danger results to personnel or the environment. The statutory regulations
have to be observed.
• Secure the pump connections and pipelines against the ingress of dirt.
Commissioning
The commissioning is only to be carried out by appropriately trained and qualified
personnel. Before starting-up a plant it has to be ensured that an adequate
quantity of the operating medium is available in order to avoid dry-run.
• Check the permissible operating values against the anticipated operating conditions.
• Check all fixing bolts on the pump.
• Check the direction of rotation. If the direction of rotation has to be changed, refer to the
section "Maintenance".
The pumps are only designed for running in the direction of rotation indicated by
the arrow resp. indicated by the symbol on the type label.
An operation of the pump in the not permissible direction of rotation will lead to failure of
the slip-ring sealing in the case of sealing version 5!
Before start up the pump has to be filled with the fluid medium.
BKF-0004-05.03-GB 13
D-300435
Particularity of sealing variants 4 and 7 (double radial shaft sealing ring)
The sealing chamber (see Fig. 9) has to be filled with a suitable
inhibiting medium before the initial operation of the pump (e.g.
Mezamol or similar).
Before initiation the sealing chamber has to be filled Sealing chamber

with an inhibiting medium.
• The pumps should be started up at either very low or zero

pressure loading. The existing shut-off devices should be fully
opened and the pressure relief valve, installed in the pressure
line, should be adjusted to the lowest opening pressure setting.
Pressure setting of the pressure relief valve Fig. 9
Only valid for pumps with a built-in pressure relief valve
(pump type code: KF … -D15 resp. KF … -D25)
Response pressure lower Response pressure higher
Fig. 10
1 lock nut
2 adjuster screw
3 securing screw (do not loosen!)
CAUTION: The pressure relief valves of the series DKF are only designed as safety
valves!
These valves should only respond briefly!
A permanent drawing off of the conveyed fluid medium via the DKF valve will result
in the destruction of the pump due to over-heating!
To adjust the pressure setting at pressure relief valve (see Fig. 10):
• loose the lock nut (1),
• set the adjuster screw (2):
rotation cw = response pressure higher
rotation ccw = response pressure lower
• when the required pressure has been set, re-lock the adjuster screw (2) with the lock nut (1).
The securing screw (3) must not be loosened!
14 BKF-0004-05.03-GB
D-300435
The start-up is achieved by repeated rapid switching on and off of the drive motor (inching mode)
without reaching the full rpm, until it is apparent that the pump is operating satisfactorily. The
satisfactory operation being detectable either from manometer reading, or from the noise
generated by the pump, and being achieved over a period of not longer than 30 seconds. This
particularly applies when a cold pump must be started-up with a fluid medium that has already
been warmed, in order to achieve a slow heating up of the pump and to prevent jamming of the
pump due to heat shock. After switching on the motor, it is then allowed to run for a few minutes,
under zero or low pressure. The pressure loading can then be increased in stages until the desired
operating pressure is reached.
• On attaining the required operating values, the temperature of the medium and of the pump
should be checked. The control points on the pump are the shaft bearing positions and the shaft
seals. The temperatures reached on the surface of the pump housing should be approx. 10°C
above the temperature of the medium.
• After several hours of running, the final operating temperature should be checked (for maximum
permissible temperatures see section "Technical data").
Maintenance
Assuming correct installation in accordance with the conditions of use and correct operation,
KRACHT gear pumps are of such a construction that a long and trouble-free operational life
should be obtained. They only require a minimum of maintenance which, however, is necessary
for reliable operation, since experience has shown that a high percentage of the failures and
damages which can occur are attributable to the ingress of dirt and inadequate maintenance. The
extent of servicing required and the service and inspection intervals are, in general, laid down by
the manufacturer in an appropriate plan.
A regular check-up of all operating data as there are pressure, temperature, current
consumption, degree of filter contamination etc. contributes to the early detection of
potential failures.
The best possible cleanliness should be ensured during all work. Before loosening screwed
connections, the surrounding areas are to be cleaned. All openings are to be sealed with protective
covers so that there is no ingress of dirt into the system.
Leakages of dangerous media must be collected and disposed in such a way that
no danger results to personnel or to the environment. The stationary regulations
have to be observed.
Seals
• Static seals at the joint of the suctions resp. pressure connection and the pump should be
checked on a regular base.
• Maintenance of the sealing variant 4 and 7 (double radial shaft sealing ring)
The filling level of the sealing chamber should be inspected regularly and the inhibiting medium
replenished if necessary.
• Maintenance of the sealing variant 5 and 6 (slip-ring seals)
The slip-ring seal is particularly subject to wear, depending on the application and accordingly,
must be carefully checked. A too high primary pressure, incorrect direction of rotation or soiling,
lead to increased wear and greater leakage.
Low leakage rates are essential to the functioning of the slip-ring sealing. The slip-ring sealing
should be renewed if the leakage rate increases.
The installation instructions of the manufacturer of the slip-ring sealing are to be considered.
BKF-0004-05.03-GB 15
D-300435
Changing the pump's direction of rotation
On pump types KF…R… and KF…L… , i.e. pure left or right rotating pumps, a change of the
direction of rotation is only possible by re-building the pump.
Cover fixing screws Cover fixing screws
Tightening torque for cover fixing screws

Nominal size* 4 … 25 32 … 80
Tightening torque 25 Nm 49 Nm
* see type code on device: KF …
If the direction of rotation of a pump is required to be changed, the cover and the pressure relief
valve on the pump housing must be freed, in order that they can be rotated through 180° and
refitted.
On pumps without pressure relief valve, the leakage oil bore on the inside of the cover must be on
the suction side of the pump.
On pumps with pressure relief valve, the relief valve adjuster screw must point towards the
pressure side of the pump (see section "Mechanical installation" page 10).
This conversion of the pump is only to be done by appropriately trained and

experienced personnel!
Change of direction of rotation at sealing variant 5 (Slip-ring sealing)

A change of the direction of rotation on sealing variant 5 cannot be done immediately!
In this case, in order to carry out the rotation of the cover and the relief valve, as detailed above, in
addition the slip-ring seal has to be exchanged (note the direction of coiling of the spring).
When exchanging the slip-ring seal, the installation instructions of the seal manufacturer should be
consulted.
16 BKF-0004-05.03-GB
D-300435
Repairs
A repair comprises:
• Error diagnostics, i.e. isolation of the error. Determining and localising the cause of the
error.
• Elimination of damages, i.e. replacement or repair of defective components and elimination of
the primary cause.
Elimination of damages
The elimination of the damage takes place on site, predominantly through exchange of the
defective component/s. Their repair is generally done by the manufacturer.
Repairs are only to be done by trained specialist personnel.
Given the appropriate know-how and adequate equipment, the repair may also be done by the end
user or the initial equipper. Assistance on this is available in form of spare lists and repair
instructions.
Error diagnostics
Lack of adequate sealing is a frequent source of failure. If this occurs at the pipeline connections, it
may be eliminated by simply tightening the screwed fittings.
In case of a lack sealing on the pump, the respective seals must be replaced (see spare lists).
Return of pumps
In case of a repair or check in the manufacturer's plant, the device has to be packed appropriately.
Furthermore, a safety data sheet of the used medium has to be added to the device. For known
minerals oils, the exact type designation is necessary at least.
For hardening or sticking media the device has to be cleaned before being returned to Kracht.
Recognise and avoid errors

The following list gives the causes of errors which are most frequently encountered during
operational failures together with an indication of the problem areas to be rectified.
In the event of the occurrence of an errors which can not be identified, please ask for assistance
from KRACHT GmbH.
Error Possible cause

Increased sound Pump cavitation • Suction level too high
• Suction filter blocked or too small
• Internal diameter of the suction line too small
• Suction line too long
• Too many curves in the suction line
• Too many local constrictions in the suction line
• Suction line blocked or not sealed
• Viscosity too high
• Temperature too low
BKF-0004-05.03-GB 17
D-300435
Formation of foam or • Suction line not sealed
air inclusion in the
• Fluid reservoir level too low
medium
• Tank return line not sealed
• Incorrect container layout
• Lack of sealing, suction side or shaft seal
• Return line ends above level of fluid in reservoir
• Inadequate venting
Mechanical vibrations • Faulty aligned or loose coupling
• Faulty or inadequate pipeline fixing
• Flittering pressure relief valve
• Construction not noise-optimised (lack of damping
elements)
• Unfavourable installation location of the pump
• Pump worn out, tooth flank wear
Pump does not • Fluid reservoir level too low

suck • Wrong direction of rotation
• Throttling element in the suction line
• Suction line too long
• Contaminant in the suction line
• Volume of the pressure line between pump and
check valve too small, pump can not compress the
air in the suction line into the pressure line
• Check valve in the pressure line not vented
Insufficient • Throttling element in the suction line
supply flow
• Fluid reservoir level too low
• Suction filter blocked or too small
• Viscosity too low
• Rpm too high
• Pressure too high
• Pressure relief valve set too low
• Pump sucks air
• Pump worn out
Insufficient Supply flow too low • Viscosity too low
pressure • Pressure relief valve set too low or does not lock
• Rpm too low
• Drive power too low
Pressure drop of the • Pump worn out
pressure line too low
18 BKF-0004-05.03-GB
D-300435
Power • Pressure too high
consumption too
• Viscosity too high
high
• Drive power too low
• Motor winding defective
Operating • Insufficient cooling and heating dissipation
temperature too
• Fluid supply too low
high
• Fluid conveyed under load into the reservoir via
pressure relief valve
Pump heat-up • Built-in pressure relief valve set too low
above • Pressure too high
permissible level
• Viscosity too low
• Spectacle gland tightened excessively
• Pump worn out
Leakage at the • Inlet pressure above permissible value
shaft sealing
• Wrong direction of rotation
• Shat radial load too high
• Seal wear
• Seal temperature too high
• Wrong seal material
Coupling wear • Faulty aligned or loose coupling
• Inadequate axial play in coupling
• Coupling overloaded
• Temperature too high
BKF-0004-05.03-GB 19
D-300435
Rotary Gear Pumps 51-551
Operating Instructions
Rotary Gear Pumps
Models:
51, 76, 101, 151, 251, 351, 451, 551
date of issue: 04.07.00 release:2 written by: King checked by:
D-300413
Seite 1 / 1 Pumpenfabrik Ernst Scherzinger GmbH & Co. KG • Bregstr. 23-25 • 78120 Furtwangen/ Germany
Tel.: +49 (0) 77 23 – 65 06-0 • Fax: 65 06-40 • E-Mail: info@scherzinger.de
0. Contents
0. Contents ................................................................................................................................................................................. 2
1. General ................................................................................................................................................................................... 3
1.1. Usage ............................................................................................................................................................................. 3
1.2. Pump Model Designation ................................................................................................................................................ 3
1.3. Pump Data ...................................................................................................................................................................... 3
1.4. Representatives .............................................................................................................................................................. 4
2. Safety...................................................................................................................................................................................... 4
2.1. Symbols Used In These Operating Instructions .............................................................................................................. 4
2.2. Personnel Qualification ................................................................................................................................................... 5
2.3. Possible Dangers If Safety Warnings Are Not Observed ................................................................................................ 5
2.4. Local Safety Regulations ................................................................................................................................................ 5
2.5. Safety Guidelines For The Operator ............................................................................................................................... 5
2.6. Safety Guidelines For Maintenance, Assembly and Disassembly................................................................................... 5
2.7. Technical Changes And Manufacturing Of Spare Parts.................................................................................................. 5
2.8. Inadmissible Operation ................................................................................................................................................... 5
3. Transportation And Storage .................................................................................................................................................... 6

3.1. Shipping .......................................................................................................................................................................... 6
3.2. Transportation................................................................................................................................................................. 6
3.3. Storage ........................................................................................................................................................................... 6
3.4. Preparation For Storage After Use.................................................................................................................................. 6
4. The Pump ............................................................................................................................................................................... 6

4.1. Principle Of A Gear Pump............................................................................................................................................... 6
4.2. Design of the Lubrication Pumps .................................................................................................................................... 7
4.2.1. General Design ....................................................................................................................................................... 7
4.2.2. Directions of Flow.................................................................................................................................................... 9
4.2.3. Internal Relief Valve ................................................................................................................................................ 9
4.2.4. Shaft Seals And Bearings ....................................................................................................................................... 9
4.3. Dimensions ................................................................................................................................................................... 10
5. Installation............................................................................................................................................................................. 10
5.1. Place Of Installation ...................................................................................................................................................... 10
5.2. Tools ............................................................................................................................................................................. 10
5.3. Initial Installation ........................................................................................................................................................... 10
5.3.1. Check Before Installation ...................................................................................................................................... 10
5.3.2. Pump With Motor .................................................................................................................................................. 11
5.3.3. Pumps For Foot Mounting..................................................................................................................................... 11
5.3.4. Mounting C - Face Pumps (F - Version)................................................................................................................ 12
5.3.5. Motor Assembly Of C – Face Pumps (ZK - Version)............................................................................................. 12
5.3.6. Electric Connection ............................................................................................................................................... 14
5.3.7. Piping .................................................................................................................................................................... 14
6. Start UP / Shut Down............................................................................................................................................................ 14

6.1. Prepare For Operation .................................................................................................................................................. 14
6.2. Start Up......................................................................................................................................................................... 15
6.3. Relief Valve................................................................................................................................................................... 15
6.4. Monitoring ..................................................................................................................................................................... 16
6.5. Shut – Down ................................................................................................................................................................. 16
6.6. Dismounting .................................................................................................................................................................. 16
7. Maintenance ......................................................................................................................................................................... 17
7.1. General Information ...................................................................................................................................................... 17
7.2. Inspection...................................................................................................................................................................... 17
7.3. Repair Work .................................................................................................................................................................. 17
7.4. Tools ............................................................................................................................................................................. 17
D-300413
1. General
This manual includes all necessary information required during installation, operation and maintenance. It Should
be read prior to commencing installation and operation. It is absolutely necessary to store the manual within reach
of the pump.
In additional to this manual, the operating instructions of the motor should be read and always be kept within reach
of the pump.
1.1. Usage
Pumps described in these operating instructions are capable of pumping lubricating liquids. All liquids must be non
- corrosive for the used materials (see section 1.3).
Should you require any additional information regarding the pump, contact Scherzinger Pumpen GmbH & Co. KG,
Scherzinger Pump Technology Inc. or their local authorized distributor. Please state the pump model and the date
of manufacture in your correspondence.
1.2. Pump Model Designation

This manual is valid for the lubrication pumps 51, 76 102, 151, 251, 351, 451 and 551 beginning with the year
1998, manufactured by Ernst Scherzinger GmbH & Co KG, 78120 Furtwangen, Germany.
The date of manufacture is stamped on the casing. The first letter marks the year of manufacturing, the following
number the month of manufacturing. To determine the year, we started in 1997 with the letter F was used (G:1998,
H:1999, I:2000, etc.).
The bottom line of this manual shows the issue and date of issue of this operating instruction.
All the described motor pumps in these operating instructions conform with valid EG - laws and are allowed to
carry the CE symbol.
1.3. Pump Data

Max. Operating Pressure (outlet side) 30 Bar (435 psi)
Max. System Pressure (inlet side) 0,2 Bar (3 psi) (with Lip Seal Ring)
20 Bar (290 psi) (with Magnetic Drive)
25 Bar (363 psi) (with Packing)
Max. Suction -0,4 Bar (-6 psi) (with Lip Seal Ring)
-0,8 Bar (-11,5 psi) (with Magnetic Drive)
Max. Pressure Rise 30 Bar (435 psi) (with Lip Seal Ring)
10 Bar (145 psi) (with Magnetic Drive)
30 Bar (425 psi) (with Packing)
Flow Rate at 1400 RPM, 50mm²/s Size 51 2,8 l/min (0,73 GPM)
and 2 Bar Pressure Rise Size 76 3,7 l/min (0,96 GPM)
Size 101 5,2 l/min (1,35 GPM)
Size 151 7,6 l/min (1,97 GPM)
Size 251 16 l/min (4,16 GPM)
Size 351 26 l/min (6,75 GPM)
Size 451 43 l/min (10,9 GPM)
Size 551 69 l/min (17,9 GPM)
Storage Temperature +10 to +50°C (50 to 122°F)
Operating Temperature -20 to +80°C (-8 to 176°F) (Seals Buna N)
-10 to +160°C (-8 to 320°F) (Seals Viton)
-20 to +100°C (-8 to 212°F) (Seals PTFE)
-20 to +60°C (-8 to 140°F) (Seals EPDM)
Viscosity Range 2 to 3000 mm2/s
Speed Range 100 to 1800 RPMn
D-300413
Noise < 70 dB(A), Ground Gears, speed 1400

RPMn Pressure Rise 20 Bar,
Operating Temperature 20°C,
Liquid 200 mm²/s, Lubricant
Dimensions see data sheets
Materials in Contact With Liquid Casing Cast Iron GG-25
Cover Cast Iron GG-25
Shafts Case Hardened Steel
Gears Case Hardened Steel
Seals Buna N (standard)
PTFE (if requested)
Viton (if requested)
EPDM (if requested)
Liquids See Quotation
Motors C-Face or bare shaft pumps are delivered without electric motor.
For motor pumps see specification of drive manufacturer or
distributor
If you intend to operate the pump outside of the above given parameters, please consult the manufacturer of the
WARNING pump. Modifications may be necessary to ensure successful operation. Otherwise the pump or your system may
be damaged.
1.4. Representatives
Please contact Scherzinger Pump Technology Inc. for the representative in your area.
2. Safety
Equipment that is incorrectly installed, operated in a dangerous manner, or poorly maintained, is a potential safety
hazard. If all reasonable precautions are not taken, the result may be personal injury or damage to equipment.
2.1. Symbols Used In These Operating Instructions

These operating instructions contain safety regulations. If these regulations are ignored, the result may cause
injury or death. Warnings are noted with the following symbols:
danger symbol high voltage symbol
symbol referred to DIN 4844 - W9 symbol referred to DIN 4844 – W8
Please pay close attention to items marked with the following symbol. Pump or system damage is possible if these
warnings are ignored.
WARNING
Information plates attached directly to the pump:
Sign with direction of rotation

Declaration of fluid connections
Date of manufacture
Name plate
This information must be observed and preserved.
D-300413
2.2. Personnel Qualification

Individuals responsible for operation, maintenance and assembly of this equipment require proper training. It is
essential the operator is aware of proper operational methods. This operating manual must be read and
understood before installing and operating the pump.
2.3. Possible Dangers If Safety Warnings Are Not Observed

Failure to observe safety warnings may cause danger to the personnel, environment and the pump. Liability claims
are also possible.
Examples of such dangers are:
Malfunction of the pump

Electrical shock
Mechanical failure
Danger to the environment by leakage
2.4. Local Safety Regulations

The installation and operation of the pump must comply with national and local health, legislation, and safety
regulations.
2.5. Safety Guidelines For The Operator

Protect hot or cold machine parts against touching.
Leaking dangerous liquids (e.g. explosive, poisonous, hot) must be drained, to ensure they do not cause
danger to personnel and the environment. Laws must be obeyed.
Electrical dangers must be avoided.
2.6. Safety Guidelines For Maintenance, Assembly and Disassembly

Maintenance, assembly and disassembly must be performed by skilled technicians, who have read these
operating instructions.
Perform all work while the pump is not in operation.
If you are pumping noxious liquids, the pump must be decontaminated prior to performing maintenance.
After completion of maintenance, all safety devices must be reinstalled.
Prior to start up, all guidelines must be followed.
2.7. Technical Changes And Manufacturing Of Spare Parts

It is necessary to consult the manufacturer prior to make modifications and technical changes to the pump. We
recommend the use of spare parts produced by the manufacturer. The use of other parts will void your warranty.
2.8. Inadmissible Operation

The safe operation of the pump model is only possible if the pump is operated in a correct manner according to
section 1 - General – of this operating manual. The pump data in the data sheet must also be observed.
D-300413
3. Transportation And Storage
3.1. Shipping
The pumps are packaged to prevent corrosion (painted / if the pumps are not painted, they are oiled) and damage
during shipment. Additionally, the inlet and outlet ports are plugged to prevent leakage of retained test liquid,
protect the threads, and to prevent particles from reaching the internals of the pump.
3.2. Transportation
To avoid shipping damage, protect the transportation box against impact.
We guarantee that the pump at time of delivery was working well. The pump was packaged in a suitable
transportation box. After receipt, inspect pump immediately for shipping damage. If you discover damage
immediately contact the forwarder agent and/or supplier.
3.3. Storage
If the pump is stored and will be used later heed to following points:
Do not store the pump in wet or humid rooms

Do not put mechanical load on the shaft end
Let inlet and outlet ports plugged
Storage temperature to section 1.3.
If pumps should be stored than 6 months, metallic parts must be specially protected against corrosion.
3.4. Preparation For Storage After Use

For shut-down and dismount see sections 6 and section 7.
Depending on the liquid pumped, there are different methods for preparing the pump for storage. If liquids without
poisonous or aggressive additives were pumped, flush the pump for one minute with at operating speed with new
lubricating oil.
If toxic or aggressive liquids were pumped, be sure to follow all safety precautions. First, flush the pump with a
neutralizing liquid at operating speed. Parts such as the relief valve (section 6.3), magnetic coupling (section 4.2.4)
and packing box (section 4.2.4), which cannot be cleaned completely by flushing the pump need to be
disassembled and cleaned by hand.
If liquids that solidify have been pumped (e.g. paint), completely disassemble the pump (section 7.3). Clean all
WARNING parts by hand to guarantee a successful start up. Clean the pump with normal detergent (see resistance of pump
materials). After assembly the pump should be flushed with a preserving oil at operating speed.
When handling noxious liquids, adhere to all safety regulations!
4. The Pump
4.1. Principle Of A Gear Pump

Gear pumps are rotary displacement pumps in which two gears engage with each other. The transfer of fluid is
caused by counter rotation of two gears in a gear chamber. The gears are fixed on two shafts, which are running in
bearings in the casing and the cover. The shaft drives one gear. The other is driven by the first gear. The opening
teeth create a suction, which draws the liquid into the pump (figure 4.1). The liquid is transported between the teeth
and the gear chamber to the pressure side (figure 4.2, figure 4.3). When the gear teeth mesh, the liquid is
squeezed out and pressed into the discharge port (figure 4.4). In this way liquid can be pumped against pressure.
D-300413
→ → → →
→ → → → →
→ → → →
figure 4.1 figure 4.2 figure 4.3 figure 4.4
4.2. Design of the Lubrication Pumps
4.2.1. General Design

The robust body consists of two parts: Casing 1 and cover 2. The pump design lends itself to easy, fast and
economic maintenance. The cover is screwed with either four or six screws to the casing. The two parts are sealed
an O - ring 3. The gears and the shafts are pressed together and run in sleeve bearings – the casing and the
cover itself are the bearings. The torque is transmitted from the drive shaft with drive gear 4 to the idler shaft with
idler gear 5. The standard shaft is a lip seal ring 6.
Scherzinger lubrication pumps are available in eight different pump sizes (size 50 to size 550, flow rates see Pump
Data, section 1.3) and four different mounting variations (
figure 4.5 to figure 4.8).
The shown cut away drawings are valid for the pump sizes 151 and 251 and may vary in details for the other sizes.
2 3 1 4
5 Å 6
figure 4.5 – foot mounted pump with lip seal ring – e.g. to screw to a base plate
D-300413
2 3 1 4
5 6 7
figure 4.6 – C-face pump with lip seal ring – to mount e.g. directly to a gear box
2 3 1 4
5 6 7 8
figure 4.7 – C-face pump with lip seal ring to mount directly to a DIN – motor
2 3 2 4 9
5 6 7 8
figure 4.8 – Pump with lip seal ring mounted to an electric motor
D-300413
4.2.2. Directions of Flow

Additional to the basic models of the pumps described in section 4.2.1, each pump is available with different
directions of flow.
If you look at the shaft end:

Clockwise Rotation - Inlet Port to the Left þ discharge port to the right
Counter Clockwise Rotation - Inlet Port to the Right þ discharge port to the left
If direction of rotation changes and inlet port to the left þ discharge port to the right
If direction of rotation changes and inlet port to the right þ discharge port to the left
4.2.3. Internal Relief Valve

The optional available internal relief valve protects your system
against inadmissible high pressures. Depending on the needed
cracking pressure, it can be set with different springs to
pressures between 0 to 30 Bar (figure 4.9).
While cracking, the valve relieves internally from pressure to

suction side to protect the system and pump from damage.
Refer to section 6.3 for Relief Valve adjustment.
figure 4.9
4.2.4. Shaft Seals And Bearings
The drive shaft can be sealed in different ways. In standard design the
shaft is sealed by a lip seal ring (figure 4.10). This kind of sealing mostly
is used for pumps with a low inlet pressure (-0,4 to 0,2 bar) and low
viscous liquids (up to 700mm²/s).
figure 4.10
If suction height reaches more than 4m up to 7m (-0,7 bar), often two Lip
Seals are used. If the liquids to be pumped have poor lubrication qualities
or is a highly viscous liquid, two lip seal rings are recommended. In this
case the space between the two lip seals are filled with grease (figure
4.11).
figure 4.11
A Packing Box (figure 4.12) should be selected when the pump has to
handle inlet pressure (up to 25 bar) or the liquids to be pumped are highly
viscous (more than 1000mm²/s). If using high viscous liquids, reduced
pump speeds are recommended.
Advantages of Packing: It is easy to maintain. If it wears out and starts
leaking, it easily can be tightened.
figure 4.12
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Absolute leak free operation only can be guaranteed if no rotating parts

(e.g. shafts) have to be sealed. The Magnetic Coupled Pump (figure 4.13)
is hermetically sealed. Pumps with a magnetic coupling transmit the
torque from the driving motor to the pump by magnetic forces without
contact. Magnetically coupled Rotary Gear Pumps can handle a system
pressure up to 20 bar (inlet pressure) and a differential pressure of -0,8 to
10 bar.
Operation of the magnetic coupling is only allowed up to the operating
temperature of the used magnets (150°C).
figure 4.13
In some applications, the pumps must be driven e.g. with a belt drive.
This creates an additional radial force to the shaft bearings. For Belt Drive
applications, the pumps can be ordered with an additional Ball Bearing
(figure 4.14).
Allowed radial forces at a speed of 1450 RPM and a lifetime of 10.000h,
force points to the middle of the feather key:
51: 250 N 251: 400 N

figure 4.14 76: 250 N 351: 450 N
101: 400 N 451: 450 N
151: 400 N 551: 500 N
4.3. Dimensions
All relevant pump dimensions can be seen in the dimension sheets of the pumps.
5. Installation
5.1. Place Of Installation

When choosing the place of installation make sure there is enough space around the pump for easy maintaining.
The place of installation must be dry. Do not mount in aggressive environment.
5.2. Tools
For mounting our gear pumps you need:
A wrench for the piping
A wrench or ring wrench for the mounting screws
Allan key for the coupling
5.3. Initial Installation
5.3.1. Check Before Installation

First check the pump for transportation damages (se section 3.2).
Verify the following information, some items may not pertain to your pump model:
Liquid to be pumped
Pump data (flow rate, pressure rise, motor performance)
Pump model and type
Direction of rotation and position of inlet and outlet ports
Type of Shaft Seal
Additional Ball Bearing for shaft
WARNING If there are differences between the pump required and the pump received please contact the manufacturer prior
to starting the pump.
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5.3.2. Pump With Motor

When choosing a place for installation, be sure the motor-pump unit is mounted on an even surface. If necessary,
use spacers near the mounting bolts 1 to ensure the unit is level.
If you do not level the pump, mechanical stress may damage the motor or the pump or at least cause
WARNING
malfunctions. Tighten the mounting screws carefully 2 after having leveled the pump.
WARNING Make sure the unit is proper ventilated to avoid overheating of the motor.
WARNING Avoid mounting the pump with the pump head down. In this case the lip seal is bad lubricated and may fail.
1 2
figure 5.1
The four mounting screws 2 are not in the scope of supply.
5.3.3. Pumps For Foot Mounting

a) Pump with coupling on base plate
While assembling pump and motor make sure pump shaft and motor shaft are aligned well. There must be no
radial or axial forces on both shafts. This can be avoided by using a flexible shaft coupling. Couplings of this type
are available at Scherzinger.
Aligning of pump and motor has to be done before connecting the piping (figure 5.2). The mounting bases of pump
and motor must be parallel. For adjusting the height of the shaft, see dimension sheets of pump and motor.
1. Bolt down the motor (usually the more weighty component) with all four screws 1.
2. Fix the coupling parts with the stud screws to the shafts.
3. Align the pump roughly.
4. Screw in the fixing screws 2 for the pump. Pump must be easily to move.
5. Turn drive shaft slowly (through fan shroud 3 or by turning the coupling on motor shaft 4) pump aligns now.
6. Tighten screws 2. Make sure the pump does not move while doing this.
The axial clearance between the shaft ends must be determined by the supplier of the coupling.
To guarantee both units are aligned properly some experience is required. Is the alignment is done badly, the force
WARNING on the shaft ends and the wear will be increased. The pump may fail.
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5 4 3
2 1
figure 5.2
After assembly of the coupling, it is requested to protect the coupling e.g. by a coupling guard - see figure 5.2 - 5 -
against touching.
b) Mounting a pump driven by a belt drive
Driving pumps with a V-Belt Drive, Flat Belt Drive or multiple belt
drive is only possible with pumps with an additional Ball Bearing
for the shaft end (see section 4.2.4 - figure 4.14 and additional
explanation). When calculating and choosing the belt drive,
check the max. shaft end load of the used pump model.
The pulley must be centered on the feather key (figure 5.3) and
fixed safely. The more the pulley is shifted to the shaft end, the
higher the bearing load and the less is the possible radial
bearing load.
figure 5.3
After assembly, protecting the belt drive by a guard against touching is absolutely necessary.
5.3.4. Mounting C - Face Pumps (F - Version)

The way of mounting of c-face pumps differs with the application. A description how this pump has to be installed
cannot be made. If you need help in your special case of installation, do not hesitate to contact Scherzinger
Pumps.
5.3.5. Motor Assembly Of C – Face Pumps (ZK - Version)

The delivered shaft coupling can be either consisting of two parts (see figure 5.4) that will be fixed to the shaft
ends or three parts (see figure 5.5) with a flexible compensating element.
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figure 5.4
figure 5.5
The coupling including the set screws are included. The coupling part of the pump is mounted in the correct
position (figure 5.6 - length a). To mount the motor to the pump do as follows:
1. Attach motor coupling 1 in distance b to the drive shaft.

2. Fix coupling part with set screw 2 to shaft.
3. Put motor 3 on fan shroud (shaft side up).
4. If needed, put flexible compensating element to the coupling part.
5. Attach pump with c-face flange 4 to the motor 3 (It may be helpful to turn the pump slightly).
6. Fix pump with Screws 5 (not in scope of delivery) to the motor.
4 6 2 5 3
figure 5.6
Please use the following table to determine the dimensions of a and b in mm. All measures are valid for ISO
motors, IMB 34 (tolerances due to ISO 7168):
Motor Motor
Pump Size a b Pump Size a b
Size Size
51 63 *) *) 151 71 6 -4
51 71 *) *) 151 80 5,5 -3,5
51 0,25 *) *) 251 71 1 0
76 63 *) *) 251 80 5 3
76 71 *) *) 251 90 2 -2
101 63 *) *) 351 80 2 3
101 71 6 -4 351 90 2 3
101 80 5,5 -3,5 351 100 *) *)
451 80 2 0 551 90 *) *)
451 90 3 3 551 100 *) *)
451 100 *) *) 551 112 *) *)
*) upon request
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5.3.6. Electric Connection

Motor connections should be done in accordance with local laws and legislation. Also pay attention to the
operating instructions of the motor.
To receive the maximum motor torque, always use a delta connection.
5.3.7. Piping
It is very important to install correct fittings to the pump. All fittings should screw together easily, use force only for
final seat.
WARNING Avoid pipe connections that place any external strains or loads on the pump.
The piping must have a suitable inner diameter. The minimum diameter is the nominal widthof the pump
connections. On the suction side of the pump, we recommend piping one size larger than the nominal width of the
pressure side. As directional quantity we recommend following maximum flow velocities in the piping.
Up to 200 mm²/s Up to 600 mm²/s Up to 2000 mm²/s

Suction Piping 1,5m/s 1,0m/s 0,5m/s
Discharge Piping 3,0m/s 2,0m/s 1,0m/s
To protect the pump from damage caused by solids in the liquid, we recommend a 50-micron filter in the suction
WARNING
piping. Be sure the filter does not cause a serious pressure drop.
Suction piping should be as straight and direct as possible to the pump with a minimum number of elbows. We
recommend using long radius elbow type.
The suction pipe should have a continuous rise to the pump. If it is necessary to install the piping rising and
descending, there must be a provision to purge air at the highest points of the piping.
WARNING After installing the piping, be sure it is free of sediments and chips. Otherwise the pump may be damaged.
If the suction head will be greater than 4 meters, we recommend installing a check valve in the suction piping.
Please contact the manufacturer for suction strainers with an integrated check valve in various sizes.
Gear pumps must not operate against closed valves or a system closed to its discharge side. The pump can
create a hazardous pressure rise, which can system environmental damage. We recommend a pump with an
integrated relief valve, or a relief valve installed directly in the discharge pipe of the pump.
In situations where de-aerating is a critical process, the installation of isolating valves, located directly before the
inlet port and directly after discharge port is recommended. This allows for removal of the pump without draining
the complete system.
Pipes should be screwed together and not leak, otherwise air may penetrate into the pump, which will prevent the
pump from sucking, or on the discharge side the liquid could drop out.
It may be necessary to integrate silencers in the piping.
6. Start Up / Shut Down
6.1. Prepare For Operation

After complete installation, before start up check the pump and the environment by following questions:
Is it possible to turn the pump by hand (small pumps) or with a tool (big pump)?
Are suction and pressure piping connected correctly?
Do pump and drive have the same direction of rotation?
Is the time of dry running restricted to a minimum?
Are the pump internals wetted with the liquid to be pumped if the pump has to prime (max. dry running time 20
sec.)?
are check valves, valves in right position? D-300413
Are the pipes checked for leakage?

Is it possible to stop the pump by an emergency switch in case of malfunction?
Is enough liquid in the reservoir?
If temperature of pumps and liquid differ more than 50°C the pump has to be adapted in temperature!
Are all rotating parts protected against touching?
6.2. Start Up
Flush the system and the pump head with the liquid to be pumped.
Adjust relief valve to wanted pressure according to section 6.3.
WARNING Dry running time should not extend 20 seconds.
6.3. Relief Valve

With the integrated relief valve it is possible to determine the relative pressure rise to exact value (see section
4.2.3).
All relief valves are tested to ensure they are in good working condition. Relief valves are not set at a specific
value, unless requested by the customer.
The relief valve should be set while the pump is operating. Measure the pressure on the outlet side of the pump.
Pay attention to do the adjustment with the correct operating conditions:
Flow Rate
Temperature
System Pressure
Speed of Rotation
Correct Valve Spring
Two different valve types are available: (figure 6.1 and figure 6.2)
1 2 3 4 5 6 7 8 9
figure 6.1 – relief valves of pump types 101, 151 and 251
Adjusting Valves of the Types 101, 151 and 251

1. Unscrew plug screw 1 and remove seal 2
2. Adjust the relief valve by turning the adjusting screw 2 with an Allan key
• To the left (counter clockwise) => decreasing the crack pressure
• To the right (clockwise) => increasing the crack pressure
• Scherzinger recommends to set the crack pressure about 20% higher than the needed pressure rise
3. Replace plug screw 1 and seal 2 and tighten both
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1 2 3 4 5 6 7 8 9
figure 6.2 - relief valves of pump types 51, 76, 351, 451 and 551
Adjusting Valves of the Types 51, 76, 351, 451 and 551
1. Unscrew and remove cap screw 1 and open counter nut 5
2. Adjust the relief valve by turning the adjusting screw 2 with a screw driver
• To the left (counter clockwise) => decreasing the crack pressure
• To the right (clockwise) => increasing the crack pressure
• Scherzinger recommends to set the crack pressure about 20% higher than the needed pressure rise
3. Tighten counter nut 5 to fix the adjusting screw
4. Replace and tighten cap screw 1
5. Make sure all seals 4 are rearranged correctly
While cap screw (plug screw) 1 is opened, a small amount of leakage is possible.
The relief valve is designed for a short-term overload protection. Pumping liquid through a relief valve will generate
heat in the liquid. For application at ambient operating temperatures, if the relief valve is opened more than 3
WARNING
minutes, damage to the pump head could occur. The higher the operating temperature, the shorter the possible
relief valve opening time.
WARNING: do not remove adjusting screw while pump is in operation or the system is under pressure. Liquid can
spurt out and cause personal injuries!!
6.4. Monitoring
We recommend installing a manometer on the outlet side of the pump to check the operating pressure. If the
operating temperature is greater than 80°C we recommend installing a temperature gauge. Temperatures greater
WARNING
than 80°C (Buna N) or 160°C (Viton) may destroy the seals or damage the magnets (with magnetic coupling).
6.5. Shut – Down

Reduce the speed of rotation, if possible, to half operating speed.
Drain the pump head by reducing the outlet pressure to atmospheric pressure and remove the suction piping
out of the liquid tank so that the pump sucks air (not if the system is under pressure).
Be sure the pump does not run dry for more than 30 seconds.
If you are pumping noxious liquids, flush the pump with a neutralizing liquid.
Flush the pump with lubrication oil (e.g. Shell GF68).
6.6. Dismounting
Switch off drive motor and remove electric connections. Make sure all steps in section 6.5 have been
completed.
Remove the pump
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7. Maintenance
7.1. General Information
Be sure that the pump head is cleaned with a non-toxic liquid. In the event the pump head was operating with
dangerous or noxious liquids, use necessary safety precautions.
7.2. Inspection
All internal bushings are sleeve bearings, lubricated by the pumped liquid. Only one pump version (see section
4.2.4 - figure 4.14) is equipped with an additional ball bearing at the shaft end. Also for this type no maintenance is
necessary.
7.3. Repair Work

WARNING If the pump head has been disassembled, it is necessary to replace all O–rings to ensure a proper seal.
An exact description of the maintenance steps can, due to the various pump types, not be supplied.
Please consult the matching spare part list.
7.4. Tools
For maintenance you will need:
Allan key 2 to 10mm
Wrench 8 to 40 mm
Dynamometric key (3 to 40 Nm)
pliers for retaining rings for shafts and bores (DIN471 / 472)
pincers to remove the feather keys
tool to press in the lip seal rings
D-300413
Ernst Scherzinger GmbH & Co. KG

Bregstrasse 23
78120 Furtwangen
PO Box 11 54
78113 Furtwangen
Telephone +49 / 0 77 23 / 65 06 –0
Telefax +49 / 0 77 23 / 65 06 – 40
Internet: http://www.scherzinger.de
E-Mail: info@scherzinger.de
D-300413
Compact Heat Exchanger
Product Line K
INSTALLATION AND OPERATING MANUAL

Type :
Order No. :
Serial No. :
Customer :
CustomerNo. :
Project :
311548
Table of Contents
GENERAL 4
Operational Range 4
Service 4
Guarantee 4
Conservation 4
Transportation 4
STRUCTURAL BUILD-UP 5
Tube bundle 5
Shell 5
Bonnets 5
Seals 5
Accessories/spare parts 5
SERVICE 6
Installation 6
Screw fasteners 6
Type plate 6
Starting up 7
Operating instructions 7
Switching off/standstill of the unit 7
MAINTENANCE 7
Periodic inspections 7
Dismounting 7
Assembly 8
Cleaning 8
Installation and Operating Manual for Compact Heat Exchangers of Product Line K Page 2 of 10
Stand: 23.08.2004 Instruction Manual-English.doc
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TROUBLESHOOTING 9
To low performance!/outlet temperature to high! 9
Leaky tubes! 9
Leaky rolling connection! 9
Leaky O-ring! 9
CONTACTS 9
Cleaning 9
Repair/spare parts 10
APPENDIX
Type plate
Data sheet
Drawings
Parts list
311548
INSTALLATION AND OPERATING MANUAL
FOR COMPACT HEAT EXCHANGERS OF PRODUCT LINE K
General
Operational Range
Heat exchanger of product line K were developed in particular for application in the field of the
industrial and maritime cooling. The present device is a high efficient heat exchanger on the principle
of shell and tube, in compact and lightweight design. The apparatus of this product line can be
adapted to different conditions of use by particular combination of material and components. The field
of application include all possible uses of cooling, in particular turbines, compressors, refrigeration
units, hydraulic plants, in the range of engines, gears etc. Service life of the devices is essentially
influenced by proper maintenance and operation. For this reason, observe strictly these instructions.
Service
For all service inquiries, please contact directly our factory, our sales force or your contracting party.
In the case of spare part orders, please indicate always the designation of the device and/or the spare
part. The necessary specifications can be taken from the enclosed drawings and from parts lists.
Guarantee
Warranty claims are to be taken from our general supply and payment terms, providing no other
individual agreements were made.
Repairs of defective parts at a later stage may only be carried out with our approval. If circumstances
should not permit asking our approval, you can ignore it. In this case you must inform us immediately
at the nearest occasion.
In principal any changed service conditions must be approved by us in writing.
Conservation
Under normal conditions are internal surfaces of the devices protected for a duration of 6 months. A
post-preserving is necessary after 6 months. The preserving liquid and the note on safety can be
provided by us. The used preservative is well compatible with all mineral lubricants. The removal of
these substances can be done by using any known solvent (check material compatibility!). The
devices should only be stored in closed rooms. Condensation through strong variation of temperature
must be avoided.
Transportation
A damage of the device must be by all means avoided. The transportation of the unpacked device
when using lifting systems has to be carried out with sufficient number of transportation straps set
around the casing. Please note the dead weight of the device indicated on the current data sheet or
the type plate.
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Structural build-up
Tube bundle
The tube bundle consists of two opposite identical tube plates with three grooves. The tubes are rolled
into the tube plate wholes. Between the tube plates at the outer side of the tubes, the surface is
enlarged forming fins which are in connection with the tubes. The result is a compact finned bundle. At
the outer side of the finned bundle, there are grooves across the whole length which are used to take
up sealing straps. In the finned bundle, a different number of baffles can be installed. A groove is
milled in the top of the baffle which contains a spring and a sealing plate. The interior O-ring grooves
in the tube plates seal against the casing in assembled state. The external seals are used for sealing
the bonnet. In this way, a intermixing of the media is avoided if a seal becomes defective and a
leakage localization is simplified. In the central groove, sheets are positioned which fix the tube plate
in assembled state and allow a thermal expansion for the opposite tube plate. With two path devices,
the fixation must be at the side of the connections. In any case, the side of fixation is marked by an
imprinted 'F' at the flange of the casing in the area of the flanges M1 or M2. The fixation must be
positioned at this side when in working condition.
Shell
The shell is used for taking up the tube bundle and forms the shell side casing. It consists of end
pieces which are circular-welded with the shell tube. The end pieces can be placed in such a way
that the connections are positioned at one side or rotated by 180°. The shell tube is a
precision tube with restricted allowances. ! Changes must not be carried out on the casing.
At the starting area of the end pieces, the interior groove of the tube plates seals by
means of an O-ring. This area must be treated carefully in order to guarantee a sealing effect.
The mounting brackets grip around the shell tube. These allow an optional assembly position of the
device.
Casings of model KK are cast casings in standardized, fixed version.
Bonnets
The bonnets consist of different materials (see part list), depending on version of the device. The
bonnet forms together with the tube bundle the chamber of the cooling medium and is fixed to the
casing by screws. At one side of the device, sheets are inserted between bonnet and casing which fix
the tube plate. At the other side, washers form a spacer.
The one path version has two identical bonnets positioned opposite each other. With the two path
version, one bonnet with two connections is mounted at one side of the device, at the other side there
is a reversing cover. To seperate the two chambers in the bonnet, a plastic or aluminium path partition
is inserted into the tube plate at the connection side. In assembled state, the path partition seals
bonnet and tube plate, i.e. it splits the flow of tubeside medium through the device.
Seawater resistant versions contains sacrificial anodes.
Seals
All tube plate seals consist of O-rings.
All pipe threads are sealed by copper or aluminum rings.
The tube bundle is sealed at the side along its length with a sealing strip against the casing. The
sealing strips consist of the same material as the O-rings. All seals are available from our factory with
indication of the drawing number.
Accessories/spare parts
Accessories and spare parts can be taken from the enclosed drawings and part lists. Drawing and
identification numbers of components which are necessary for ordering, are also listed there. Price
lists for the spare parts and not listed accessories can be requested via our marketing department or
directly from factory.
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Service
Installation
The following items must be considered during the installation of the device:
• Protective caps fitted to connections must be removed. If there is no protective cap on a
connection, check whether it has been pushed into the connection or foreign parts have
penetrated the device.
• Foreign bodies must not penetrate the openings of the connections.
• The connection of the pipes must be tension-free to ensure that no inadmissibly
high thermal or mechanical tensions affect the device in service.
!
• All circuits must be designed to avoid penetration of dirt and dust. We recommend
the assembly of dirt traps and suitable filters.
• Tubes must be correctly installed so that air locks cannot built up.
• The assembly can be horizontal or vertical.
• Sufficient space should be available to ensure easy accessibility to all screw connections. Take
particular care for providing enough space for remove the tube bundle. You can take the
necessary space dimensions for remove the tube bundle from the sketch. It is possible to remove
the tube bundle from both sides of the device.
• . The direction of flow is to be taken from the enclosed sketch and from the datatsheet
• Before startup, the device must be completely bled.
• Never weld or modify the cooler.
• In case of using the device as oilcooler before startup, clean/flush the oil circuit but not the
lubricated points.
• Orifice plates must only be installed at the outlet side of the device.
Screw fasteners
To ensure a safe operation and a long service of fastening elements, the screw fastenings should be
only torqued. The table below lists the torque figures for used screws. Through influence of various
factors, the specified values may show a deviation which in individual cases require lower or higher
values.
Connection shell/bonnet Connection flanges
type screw/ torque [Nm] screw/ material of torque [Nm]

strength strength thread
K12 M12 5.6 38 M12 5.6 aluminium 30
M12 8.8 80 red bronze 30

K20 M16 5.6 95 M16 5.6 aluminium 75
M16 8.8 200 red bronze 75
K25 M20 5.6 180 cast steel 100
M20 8.8 400 M24 5.6 cast steel 300
Type plate
The type plate is at the side of the device and is permanently fixed. You can find a copy of the type
plate in the appendix.
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Starting up
At first the apparatus must be filled up with the intended medium, then the entire system must be
checked for leakage. For watercooled devices use only clean water at the tube side. Before
the actual starting up of the system, make sure that the cooling medium is circulated.
Operating the device without flow of
! cooling medium is not permissible.
Only for watercooled units:
If the flow adjustment is carried out by a control, we recommend a oil-sided control, especially when
operating with river or sea water.
Discuss the control of cooling water with our factory, because factors like material and quality of
cooling water are very important to avoid later problems.
The use of additives in the cooling water has to be confirmed through HS-Cooler GmbH.
Operating instructions
During the operation, make sure by suitable means that pre-set parameters for which the
devices are designed are kept. !
If reserve devices with switch- over valves are present, switch these devices periodically on
(all 2-3 days) or load the reserve device daily for some time with the full water volume.
Switching off/standstill of the unit for watercooled units

With a short-term standstill (<4 days) of the unit, the apparatus can remain filled.
When switching off the unit, the water must be removed. In the case of operating the device with sea
water or aggressive water, flush the unit additionally with clean water. The tube bundle should as far
as possible be dried inside with compressed air. Further, if a drainage is not possible, then a flow of
the correct amount of cooling water must be maintained.
Maintenance
Periodic inspections
Devices of product line K are normally reliable and easy to maintain. However, some periodic
inspections of the device are necessary to provide a safe, continuous operation. Normally inspections
on the tubeside (waterside) predominate. The shellside is less inclined to pollution so that an
inspection can be carried out based on the experience of the operator.
The following inspections should be practiced:
• When operating with sea water, sacrificial anodes are installed in the
bonnets/covers. These should be checked in the initial phase all 3 months. If the
anodes are used up, they must be ! replaced by new ones. In the case of
excessively fast consumption of the anodes, water quality and the electrical potential of the
system must be checked.
• The device should be cleaned at the water side at least once a year. An excessive pollution of the
tubes must by all means be avoided. The bonnets can be removed without depressurerizing the
shell side. The intervals are to be shortened during long ship operation in harbors or in other
polluted waters and depending on the experience of the operator.
• At shorter intervals the device must be subject to an externally visual inspection, in order to
identify leakage or other problems early. Through the double O-ring sealing, leakages can be
precisely located and the relevant expenditure can be estimated.
Dismounting
Proceed as follows when dismounting the apparatus:
• Lock-up any pipelines
• Empty the apparatus at the tube side, if a removal of the tube bundle is necessary, empty also the
shell side.
• Remove the pipelines at the tube side.
• Remove the bonnets/covers. For this purpose, the screws at the bonnet/casing connection must
be loosened. Between the bonnet/cover there are 4 fixing plates or washers. These must be
311548
replaced at the same side again during re-assembly. The marking on the casing flange must be
here observed.
• If you want to dismount without remove the tube bundle, the bonnet/cover without
fixing plates must be disassembled first in order to protect the tube bundle against
displacement, before you remove the ! fixing plates. This can be done with
another set of fixing plates or with similar aids.
Dismounting without remove the tube bundle:
• Remove the O-rings from the external groove of the tube plates and secure the tube bundle to the
casing with four screws and the four fixing plates in the middle groove of the tube plates. The tube
side can now be inspected and cleaned mechanically. The shell side can remain under pressure.
Dismounting with remove the tube bundle:
• Remove the O-rings from the external groove of the tube plates. At one tube plate, a marking of
the fixed position in relation to the casing is attached. A half of a ‘X’ is stamped at the front of the
tube plate and the adjacent casing flange. Check the position of the marking. Push the tube
bundle (where appropriate with auxiliary tools) so far sideways until the O-ring of the interior
groove becomes visible. Remove the O-ring from the interior groove. Pull out the tube bundle in
the opposite direction. Remove the tube bundle carefully from the casing without damaging the
fins. As far as possible suspend the tube bundle with the help of large-surface
transportation straps. The grooves taking the O-rings must not be damaged. During
dismounting of the tube bundle the ! sealing plate and the spring can drop out of the
baffle groove. The spring and the sealing plate have to be installed during
assembly of the bundle by pressing them into the groove whilst the baffle passes the inlet of the
shell.
• When dismounting vertically fixed devices, make sure in any case that the tube bundle
does not slips down after removal of the fixing plates. We recommend to provide an
additional set of fixing plates and to start the removal at the side where no fixing
plates are mounted. There the bundle must be
! secured first. After
dismounting the second bonnet, the bundle can be removed carefully. While assembling, only one
set of fixing plates is permittedat the side of the marking.
Assembly
The assembly is carried out in reversed order as dismounting. The following must also be considered:
• Generally use new O-rings and clean O-ring grooves.
• Note the marking for proper assembly of the tube bundle (X).
• Note the marking for correct assembly of the fixing plates (F).
• At the side of the tube bundle there are sealing straps. These should only be
replaced when damaged. When pushing-in the tube bundle take care that the sealing
straps are not displaced ! or twisted. Before assembling the tube bundle, the sealing
straps should be greased. You can use the operating medium. The sealing
straps must be effective along the entire length of the tube bundle.
• Insert the sealing plate and the spring into the baffle groove and press down during insertion of the
tube bundle
• Lubricate O-rings with suitable O-ring grease.
• During insertion of the tube plate into the sealing faces, make sure that the O-rings do not shear.
The bonnets/covers must be set up in parallel onto the tube plate and must be pushed evenly onto
the O-ring; ensure also that the O-ring does not shear.
• With two path devices, a path partition must be fitted at the side of the bonnet with the two
connections. At this side, the fixing sheets must also be installed later.
• When assembling the two path bonnet, make sure that the path partition is correctly placed.
• Then continue as described under 'Operation'.
Cleaning
In the case of only small amount of fouling, the tube side can be mechanically cleaned. Disassemble
the device as described under 'dismounting without remove the tube bundle' and clean with
a suitable nylon brush (do not use metal brushes) each tube inside, then clean with water.
Never remove stuck deposits or ! coarse dirt by force.
311548
In the case of stuck deposits, the tube bundle must be cleaned chemically. This can be carried out by
rinsing the tube in the assembled state or submerging in disassembled state. Such a cleaning must
only be practiced by specialists. Only suitable solvents must be used. To select a suitable agent, refer
to the added part list. Take the materials of the plastic separator strip and O-rings in the assembled
state into consideration. Under 'Contacts' you find some companies offering respective agents or
carrying out a complete cleaning.
Provided that the type designation gets a C at the 11th position (example: KS12-BCN-821C L1000),
then it is a coated tube bundle. To prevent a damage caused by corrosion this bundle is coated on the
inside of the tubes and on the tubesheets. When dismounting the bundle and during cleaning make
sure that the coating will not be damaged or destroyed. Use only nylon cleaning brushes and
approved cleaning agents. If there are any doubts about suitability of an agent, please contact our
service department.
Troubleshooting
To low performance!/outlet temperature to high!

• Check all temperatures and material flows in accordance with the design data?
• Are foreign bodies in pipe or in device causing obstruction?
• Is the tube bundle correctly assembled, check marking?
• Are the path partition and the fixing plates correctly assembled in the two path bonnet?
• Are all pressure rooms vented?
• Are tube side or shell side too dirty (too thick deposits)?
• Are more than 10% of the tubes plugged?
Leaky tubes!
If the presumption exists that tubes have become leaky, proceed as with 'dismounting without remove
the tube bundle'. The shell side can remain under pressure. After cleaning the tube plates, you can
identify the defective tube by the state of the emerging medium. Lock the leaky tube at both ends with
our ‘Tubelock’-Repairset. Alternative you can use a conical copper or aluminium plug or a conical hard
wood plug. The plug must not be pushed too strong since otherwise adjacent rolling connections can
be damaged. You can lock 10% of the tubes at the most without noticeable reduction in performance.
Dismounting the defective tube is not possible.
Leaky rolling connection!

If it is found during the check for leaky tubes that a rolling connection is leaky, it can be rolled again
with a specific rolling tool. This work however is only to be carried out by specially trained personnel.
Since defects of this type are uncommon, a check of the complete bundle in our factory is
recommended.
Leaky O-ring!
If a leakage is found between bonnet/cover and casing, an O-ring of the tube plate is defective. The
kind of the emerging medium defines at which groove of the tube plate the defect developed. In the
case of a defect on the tube side, proceed as described under 'dismounting without remove the tube
bundle'. In the case of a defect at the shell side, proceed as described under 'dismounting with
withdrawing the tube bundle'. In this case the tube bundle does not need to be removed completely
from the casing. Assemble the O-ring as described in 'Assembly'.
Contacts
Cleaning
Suppliers for cleaning agents:
• Ashland Chemicals – www.ashchem.com
311548
• Henkel Oberflächentechnik- www.henkel.com
• Ondeo Nalco – www.ondeo-nalco.com
Contractors for complete cleaning

• Vecom – www.vecom.nl
• - Ondeo Nalco – www.ondeo-nalco.com
Repair/spare parts
Repairs must only be carried out by specially trained personnel. However we recommend to carry out
any repair in our factory.
You can purchase spare parts directly from us with indicating the sketch and serial number. Please
contact our head offices or our sales office.
HS-Cooler GmbH Wittenburg is not liable for any defect resulting from any adverse use
of the product.
We reserve the right to adapt this operating manual at any time without prior notice
to include the latest developments.
311548
- Ergänzung zu Kapitel ‚Wartung/Demontage/Demontage ohne Herausziehen des - Aanvulling bij het hoofdstuk
Rohrbündels‘. Bei Zusammenbau müssen die Fixierplatten wieder an der richtigen ’Onderhoud/demontage/
Seite des Wärmetauschers eingebaut werden - siehe dazu die Bedieungsanleitung! demontage zonder uittrekken van
de buizenbundel‘. Bij de montage
- Addition to chapter ’Maintenance/Dismounting/Dismounting without moeten de fixeerplaten opnieuw aan de
remove the test bundle‘. During assembly the fixing plates have to be correcte zijde van de warmtewisselaar
assembled to the correct side of the heat exchanger – see the instruction manual! worden ingebouwd – zie ook de
gebruiksaanwijzing!
- En complément du chapitre « maintenance/démontage/démontage sans
tirer vers l‘extérieur le faisceau tubulaire ». Lors de l’assemblage les dalles de - Komplettering av kapitel
fixation doivent être encastrées dans le côté exact de l’échangeur de chaleur - voir à cet ’Skötsel/demontage/
effet l’instruction d’exploitation. demontage utan att dra ut rörpaketet‘.
Vid sammansättningen måste
- Complemento al capítulo “Mantenimiento/Desmontaje/Desmontaje sin fixerplattorna åter monteras på rätt sida
extraer el haz de tubos”. Al realizar el montaje, las placas fijadoras se han av värmeväxlaren - se bruksanvisningen
de volver a colocar en el lado correcto del intercambiador de calor - ver para ello las om detta!
instrucciones de servicio.
- Supplement til kapittel
- Completamento del capitolo ’Manutenzione/Smontaggio/Smontaggio senza Vedlikehold/demontering/
estrazione del fascio tubolare‘. Nella fase di assemblaggio, le piastre di fissaggio demontering uten uttrekking av
devono essere rimontate sul corretto lato dello scambiatore di calore – vedi a questo rørbunt. Ved sammensetting må
proposito le istruzioni per l’uso! posisjoneringsplatene monteres på
korrekt side av varmeveksleren - se
- Suplemento do capítulo „Manutenção/Desmontagem/Desmontagem sem bruksveiledningen!
extracção do feixe de tubos“. No momento da montagem, as placas de fixação
deverão ser outra vez aplicadas no lado correcto do permutador térmico -- consulte o - Täydennys lukuun ’Huolto/
manual de instruções! Purkaminen/purkaminen ilman
putkinipun ulosvetämistä’. Koottaessa
on kiinnityslevyt asennettava taas
oikein lämmönvaihtimen sivulle – katso
käyttöohje!
A - Дополнение к главе
´Техобслуживание/демонтаж/
демонтаж без выдергивания пучка
труб´ - При сборке все фиксирующие
пластины должны монтироваться в
правильной стороне теплообменника
– смотри касательно этого инструкцию
по эксплуатации!
- Uzupełnienie do rozdziału
‘Konserwacja/Demontaż/
Demontaż bez wyciągania wiązki rurowej’.
Przy montażu, płyty ustalające muszą zostać
znowu wbudowane po właściwej stronie
wymiennika ciepła – patrz: Instrukcja obsługi!
- Dodatek k poglavju
- Vzdrževanje/Demontaža/
demontaža brez izvleka snopa cevi. Pri
sestavi je potrebno fiksirne ploščice spet
vgraditi nazaj na pravilni strani toplotnega
izmenjevalnika – glejte k temu navodila
za upravljanje!
- Dodatok ku kapitole
„Údržba/demontáž/demontáž
bez vyťahovania zväzku trubiek“.
Pri montáži je potrebné fixačné dosky
znovu namontovať na správnu stranu
B
výmenníka tepla – pozri v tejto súvislosti
návod na obsluhu!
1. 2.
Stand: 01.11.2006
311548
3. 4.
5. 6.
7. 8.
9. 10.
Stand: 01.11.2006
311548
- Ergänzung zu Kapitel ‚Wartung/Demontage/Demontage - Komplettering av kapitel ’Skötsel/demontage/
ohne Herausziehen des Rohrbündels‘. Konstruktiver demontage utan att dra ut rörpaketet‘.
Aufbau der Wärmetauscher KS## - F## - #2# abweichend von Den konstruktiva uppbyggnaden av värmeväxlare KS## - F## - #2#
der Standard Ausführung. Vor dem Öffnen des Wärmetauschers avviker från standardutförandet. Innan värmeväxlaren öppnas,
unbedingt beide Druckräume komplett entleeren! måste ovillkorligen de båda tryckkammarna tömmas komplett!
- Addition to chapter ’Maintenance/Dismounting/ - Supplement til kapittel Vedlikehold/demontering/

Dismounting without remove the test bundle‘. The demontering uten uttrekking av rørbunt. Konstruktiv
constructive design of the heat exchangers KS## - F## - #2# is oppbygging av varmeutveksleren KS## - F## - #2# avvikende
different from the standard version. Always completely drain both fra standard-utførelsen. Før varmeveksleren åpnes må begge
pressure chambers prior to opening the heat exchanger. trykkrommene tømmes helt!
- En complément du chapitre « maintenance/démontage/ - Täydennys lukuun ’Huolto/Purkaminen/purkaminen

démontage sans tirer vers l‘extérieur le faisceau ilman putkinipun ulosvetämistä’.
tubulaire ». Montage constructif des échangeurs de chaleur Lämmönvaihtimien KS## - F##-#2# rakenne vakiomallista poikkeava.
KS ## - F## - #2# divergent par rapport à la version standard. Ennen lämmönvaihtimen avaamista on kumpikin painekammio
Avant l‘ouverture de l‘échangeur de chaleur, il est obligatoire ehdottomasti tyhjennettävä täydellisesti!
de vider complètement les deux chambres de compression!
- Дополнение к главе ´Техобслуживание/демонтаж/
- Complemento al capítulo “Mantenimiento/Desmontaje/ демонтаж без выдергивания пучка труб´ - Конструктивное
Desmontaje sin extraer el haz de tubos”. La estructura устройство теплообменника KS## – F## - #2# отклоняется
constructiva del intercambiador de calor KS## - F## - #2# difiere del от стандартного исполнения. Перед тем, как открывать
modelo estándar. Antes de abrir el intercambiador de calor, es теплообменник, обязательно полностью опорожнить обе
imprescindible vaciar completamente los dos compartimentos de камеры нагнетания!
presión.
- Uzupełnienie do rozdziału ‘Konserwacja/Demontaż/
- Completamento del capitolo ’Manutenzione/ Demontaż bez wyciągania wiązki rurowej’. Konstrukcja
Smontaggio/Smontaggio senza estrazione del fascio wymienników ciepla KS ## -F## -#2# rózniaca sie od wykonania
tubolare‘. Struttura dello scambiatore di calore KS## - F## - #2# standardowego. Przed otwarciem wymiennika ciepla bezwarunkowo
differente dal modello standard. Prima di aprire lo scambiatore di opróznic calkowicie obydwie komory cisnieniowe!
calore, svuotare assolutamente in modo completo entrambe le
camere di pressione! - Dodatek k poglavju - Vzdrževanje/Demontaža/
demontaža brez izvleka snopa cevi. Konstruktivna
„
- Suplemento do capítulo Manutenção/Desmontagem/ izgradnja toplotnih izmenjevalnikov KS## - F## - #2# ni enaka
Desmontagem sem extracção do feixe de tubos“. standardni izvedbi. Preden boste toplotni izmenjevalnik odprli,
Disposição construtiva do permutador de calor KS## - F## - #2# obvezno izpraznite oba tlacna prostora!
diferente do modelo standard. Antes de se abrir o permutador de
calor as duas câmaras de pressão devem ser completamente - Dodatok ku kapitole „Údržba/demontáž/demontáž
esvaziadas! bez vyťahovania zväzku trubiek“. Konštrukcná stavba
výmenníka tepla KS## - F## - #2# je odlišná od štandardného
- Aanvulling bij het hoofdstuk ’Onderhoud/demontage/ prevedenia. Pred otvorením výmenníka tepla bezpodmienecne
demontage zonder uittrekken van de buizenbundel‘. vyprázdnite obidva tlakové priestory!
Constructie van de warmtewisselaar KS## - F## - #2# afwijkend van
de standaarduitvoering. Voor het openen van de warmtewisselaar in
ieder geval beide drukkamers compleet leegmaken!
Stand: 01.02.2007
311548
311617
Pos. Quantity Unit Description Part/Standard Number Remark
1 1 pc. Shell GS12 - 1

2 1 pc. Tube Bundle RL12 - C N - 1 2 1
G-CuSn5PbZn
3 1 pc. Waterbox 1 1/2" SAE KL12-B-002 (3.1B)
4 2 pc. Anode 3/8" KL-1021

G-CuSn5PbZn
5 1 pc. Cover KL12-B-003 (3.1B)
6 1 pc. Anode 3/8" KL-1021
7 2 pc. Sealing Plug DIN 910 - G 1/8" A Brass
8 2 pc. Sealing Ring DIN 7603 - A 10 x 13.5 x 1 Copper
9 4 pc. Fixation Plate KL12-0-108 Steel galv.
10 2 pc. Clamp Bracket KL12-0-109 Steel
11 4 pc. Hex Bolt ISO 4017 - M12 x 40 - 8.8 Steel galv.
12 4 pc. Hex Nut ISO 4032 - M12 - 8 Steel galv.
13 4 pc. Washer DIN 125 - A 13 Steel galv.

Steel galv.
14 8 pc. Hex Bolt ISO 4014 - M12 x 60 - 5.6 AD-W7 (Stamped)
Steel galv.
15 8 pc. Hex Nut ISO 4032 - M12 - 5-2 AD-W7 (Stamped)
16 12 pc. Washer DIN 125 - A 13 Steel galv.
17 1 pc. Type Plate Aluminium
DATE NAME
DRAW 29.11.99 Garbe
CHECK 29.11.99 Graulich

Parts List
NORM
K S 1 2 - BCN - 1 2 1
Sheet
SYM REVISION DATE NAME FILE: Parts List KS12.doc
1 of 1
311617
311617
311617
Pos. Quantity Unit Description Part/Standard Number Remark
CuZn38Sn1 F34
AD-W6/2 (3.1)
1 2 pc. Tubesheet KL12 - C - 052 CuAl10Fe5Ni5-C
DIN EN 1982 (3.1)
CuNi10Fe1Mn F29
2 72 pc. Tube LR = L + 28mm 7.5mm x 0.5mm AD-W6/2 (3.1)
3 L/1.1 pc. Fin 1.1 KL12-0-104 Aluminium
4 4 pc. O-Ring KL-1510 NBR
5 2 pc. Sealing Strip L x 13 x 3 NBR
6 1 pc. Baffle KL12-0-106 Aluminium
7 1 pc. Water Partition KL12-0-107 Polypropylen
DATE NAME
DRAW 02.11.99 Garbe
CHECK 02.11.99 Graulich

PARTS LIST
NORM
R L 1 2 - CN - 1 2 1 Sheet
1 of 1
SYM REVISION DATE NAME FILE: Parts List RL12-C#-###.doc
311617
PRESSURE FILTER Sheet No.
Series LF 101 DN 25 PN 25 1125
1. Type index:
1.1. Complete filter: (ordering example)
LF. 101. 10VG. 16. E. P. -. G. 5. -. AE
1 2 3 4 5 6 7 8 9 10 11
1 series:
LF = in-line filter
2 nominal size: 101
3 filter-material and filter-fineness:
80 G = 80 µm, 40 G = 40 µm, 25 G = 25µm
stainless steel wire mesh
25 VG = 20 µm(c), 16 VG = 15 µm(c), 10 VG = 10 µm(c),
6 VG = 7 µm(c), 3 VG = 5 µm(c) Interpor fleece (glass fibre)
4 resistance of pressure difference for filter element:
16 = ∆p 16 bar
5 filter element design:
E = single-end open
S = with by-pass valve ∆p 2,0 bar
S1 = with by-pass valve ∆p 3,5 bar
6 sealing material:
P = Nitrile (NBR)
V = Viton (FPM)
7 filter element specification: (see catalog)
- = standard
VA = stainless steel
IS06 = see sheet-no. 31601
8 connection:
G = thread connection according to ISO 228
9 connection size:
5 = G1
10 filter housing specification: (see catalog)
- = standard
11 clogging indicator or clogging sensor :
- = without
AE = visual-electrical, see sheet-no. 1609
OP = visual, see sheet-no. 1628
OE = visual-electrical, see sheet-no. 1628
VS1 = electronical, see sheet-no. 1607
1.2. Filter element: (ordering example)

01N. 100. 10VG. 16. E. P. -
1 2 3 4 5 6 7
1 series:
01N. = filter element according to
INTERNORMEN factory specification
2 nominal size: 100
3 - 7 see type index-complete filter
weight: 8,5 kg
Changes of measures and design are subject to alteration!
EDV 03/03
Friedensstrasse 41, 68804 Altlussheim, Germany

phone +49 - (0)6205 - 2094-0 e-mail sales@internormen.com
fax +49 - (0)6205 - 2094-40 url www.internormen.com
300685
2. Spare parts:
item qty. designation dimension article-no.
1 1 filter element 01N. 100
2 1 O-ring 22 x 3,5 304341 (NBR) 304392 (FPM)
3 1 O-ring 76 x 4 305599 (NBR) 310291 (FPM)
4 2 screw plug G¼ 305003
5 2 screw plug G½ 304678
6 1 clogging indicator, visual OP see sheet-no. 1628
7 1 clogging indicator, visual-electrical OE see sheet-no. 1628
8 1 clogging indicator, visual-electrical AE see sheet-no. 1609
9 1 clogging sensor, electronical VS1 see sheet-no. 1607
10 1 clogging sensor, electronical VS2 see sheet-no. 1608
11 2 O-ring 14 x 2 304342 (NBR) 304722 (FPM)
12 2 screw plug G¼ 305003
item 12 execution only without clogging indicator or clogging sensor
3. Description:
In-line filters of the type LF 101 are suitable for a working pressure up to 25 bar.
Pressure peaks are absorbed with a sufficient margin of safety.
The filter is mounted in such a way that inlet and outlet are on the same level. It can be used as suction filter, pressure filter and
return-line filter. The filter element consist of star-shaped, pleated filter material which is supported on the inside by a perforated core
tube and is bonded to the end caps with a high-quality adhesive. The flow direction is from outside to the inside.
To clean (see special leaflet 21070-4) and change respectively the filter element, the filter cover will be removed and the filter
element can be taken out.
Filter finer than 40 µm should use throw-away elements made of Interpor fleece (glass fibre). Filter elements as fine as 5 µm(c) are
available; finer filter elements on request.
INTERNORMEN-Filter elements are known as elements with a high intrinsic stability and an excellent filtration capability, a high dirt-
retaining capacity and a long service life.
INTERNORMEN-Filter are suitable for all petroleum based fluids, HW-emulsions, most synthetic hydraulic fluids and lubrication oils
Approvals according to TÜV, and the major „Shipyard Classification Societies“ D.N.V.; B.V.; G.L.; L.R.S.; R.I.N.A.; A.B.S. and others
are possible.
4. Technical data:
temperature range: -10°C to +80°C (for a short time +100°C)
operating medium: mineral oil, other media on request
max. operating pressure: 25 bar
test pressure: 33 bar
connection system: thread connection according to ISO 228
housing material: aluminium-cast
sealing material: Nitrile (NBR) or Viton (FPM), other materials on request
installation position: vertical
mini-measuring connection: G¼
evacuation-or bleeder-connection: G½
volume tank: 1,0 l
Classified under the Pressure Vessel Directive 97/23/EC for mineral oil (fluid group 2), Article 3, Para. 3.
Classified under ATEX Directive 94/9/EC according to specific application (see questionnaire sheet-no. 34279-4).
5. Symbols:
without indicator with electrical with visual-electrical with visual-electrical with visual with visual-electrical with electronical with electronical
indicator indicator indicator indicator indicator clogging sensor clogging sensor
AE 30 and AE 40 AE 50 and AE 60 AE 70 and AE 80 OP OE VS1 VS2
6. Pressure drop flow curves: Precise flow rates see ‘INF-Expert-System Filter’, respectively ∆p-curves ; depending
on filter fineness and viscosity.
7. Test methods: Filter elements are tested according to the following ISO standards:
ISO 2941 Verification of collapse/burst resistance

ISO 2942 Verification of fabrication integrity
ISO 2943 Verification of material compatibility with fluids
ISO 3723 Method for end load test
ISO 3724 Verification of flow fatigue characteristics
ISO 3968 Evaluation of pressure drop versus flow characteristics
ISO 16889 Multi-pass method for evaluating filtration performance
E 1125
300685
Manual and maintenance instructions Sheet No.
for INTERNORMEN-line filters 21143-4C
LF 101, 251, 401, 631, 1001, 1950, 2200, related specifications Page 1/2
This manual is effective for all filters of the type series LF 101/251/401/631/1001/1100/1950/2200 and related specifications. It contains
certain requirements and instructions which ensure unobjectionable operation of the filter. It can be completed with specific additional
instructions by the operator himself if necessary.
1. Safety instructions
- Prior to operating the filter, manual and maintenance instructions have to be read carefully.
- Follow the instructions of this manual under any circumstances!
- The manufacturer does not assume liability for any damage, which occurs due to the disregarding of these instructions.
- If operations are carried out differently, the safety of the pressurized device can not be assured!
- Operating conditions given in the data sheet, especially excess pressure and temperature range, have to be followed unconditionally.
Variation of these parameters can cause damage to important pressure holding parts and sealing. Also take in consideration the
compatibility of filter components with the operating fluid.
- Under working conditions the filter housing is pressurized. Do not try to loosen or remove any part of the filter or the filter housing
during operation. The operating fluid could escape at high pressure and high temperatures.
- Leaking operating fluid always brings a danger of injuries and burns!
- Do not open the filter housing until you made sure that it is not pressurized any more!
- Touching parts of the filter may cause burning, depending on the operating temperature.
- When exchanging the filter keep in mind that it might have operating temperature. Danger of burning!
- Always wear safety goggles and gloves when working on the filter!
- If you come into contact with the operating fluid please follow the instructions of the fluid manufacturer!
- Only use original spare parts.
For filters being used in hazardous locations the INTERNORMEN documentation N° 41269 "Supplementation of the Operating Manual
for the use of filters in potential explosive areas.
2. Installation of the filter

Note the safety instructions!
The filter has to be installed without any potential in an upright position using the fixing installations intended for these purposes.
Also make sure, that
- sufficient fixation of the element is ensured.
- the clogging indicator is accessible and can be checked easily.
- the drain valve (G ½ A, bottom), air bleeding valve (2x G ½ A, top) and pressure measuring connections (2x G¼ A) can be
accessed easily.
- there is enough room above the filter to remove and replace elements (also check the data sheet).
- sufficient measures were taken to prevent corrosion
- the filter is protected from other mechanical influences (such as impacts and hits).
Counterflanges of the pipe-system have to be connected properly to the „In“ and the “Out” flanges of the filter, in order to prevent any
force to be applied onto the filter from the pipes. When performing these steps make sure no contamination or other particles enter the
filter.
Following fastening torques are suggested for the counterflanges:

LF 101/251/401/631 LF 1001/1100/1950/2200
60 Nm 130 Nm
Appropriate pipework (pipes, hoses) ensures that drain and air-bleed valves are connected to proper containers. For these purposes
original INTERNORMEN-Technology drain and air-bleed valves can be used.
Filters with electric or electronic clogging indicators require the connection of these devices to suitable power supply. Please note the
data sheet and the instructions of the clogging indicators.
3. Initial operation
Note the safety instructions!
3.1 Prior to initial operation

Prior to the initial operation of the system or the machine, which means prior to filling in any fluid, check the internal condition of the
filter. Proceed as follows:
- Open the filter housing by removing the lit. Check the cleanness of the housing, the presence of an element, the sealing, etc..
- Close the housing tight.
3.2 Filling and bleeding

- Open the air-bleed valve
- Fill the filter until the operating fluid leaks from the air-bleed valve free of bubbles.
- Close the air-bleed valve
Afterwards the filter is ready for operation.
EDV 10/04 - Englisch

306165
for INTERNORMEN-line filters 21143-4C
LF 101, 251, 401, 631, 1001, 1950, 2200, related specifications Page 2/2
4. Maintenance and inspection

Also please note all particular site-related instructions for inspection.
Using filters equipped with clogging indicators it is necessary to exchange or clean the element if the signal “Clogged filter” is emitted
(also note the data sheet or the instructions of the clogging indicators).
Contaminated elements have to be replaced as soon as possible! If a clogged element is not removed it may cause severe damage to
the entire system!
Caution!
Always exchange elements with sealing. If a cleaned metal mesh element type „G“ is reused replace its sealing. The exact
markings can be found in spare part lists for each element.
4.1 Installing the filter element
Note safety instructions!
Maintenance or the exchange of contaminated filter elements has to be performed as follows:
- Shut down the entire machine and relieve the system pressure from the filter. Equalize the pressure with the surrounding atmosphere.
- Open the drain valve,
- Remove the lit of the filter and lead off the escaping operating fluid into qualified containers.
- Remove the element by light swaying and pulling.
- Cover or close the adaptor end inside the housing and clean the entire inside.
- Close the drain valve and remove the cover of the adaptor end.
- Check the sealing of the filter lit and replace the O-ring if necessary.
- Take the replacing element, make sure the serial number matches the number of the old element, and insert it into the housing (prior
check if the elements sealing are undamaged and tighten them)
- close the filter with it’s lit,
- finally perform the steps described in 3.2 “Filling and bleeding”
4.2 Cleaning the filter element
Metal mesh filter elements can be recycled after cleaning. This cleaning procedure can be performed based on the cleaning instructions
for INTERNORMEN metal mesh filter elements on sheets no. 21070-4 and 39448-4.
When removing and reinserting the element please proceed as described in 4.1 “Installing the filter element”.
Caution!
When using a filter with single-service elements always keep enough replacing elements in stock!
5. Measuring pressure difference

Note safety instructions!
The pressure drop on the filter, which indicates the contamination of the element, is measured using the installed clogging indicator. If a
certain limit value (also see specification of the element) is reached, a signal (visual or electrical) will be emitted.
In addition to that, the pressure loss can be determined externally using the measuring connections G ¼ A based on DIN 3852 T2 on
both inlet and outlet of the filter. Miniature measuring connections EMA 3/R ¼ Ermeto are preferred as the connecting elements for
pressure difference detection.
6. Service
The service will be performed by
INTERNORMEN Technology GmbH phone: +49(0)6205-2094-0

Friedensstr. 41 fax: +49(0)6205-2094-40
D-68804 Altlussheim e-mail: info@internormen.com
Germany url: www.internormen.com
Special questions about the operation of the filter will also be answered within this area.
Spare parts respectively wearing parts have to be ordered according to the spare part list of the filter-data-sheet.

306165
300682
300682
PRESSURE FILTER Sheet No.
Series MNL 40 - 100 DN 15 - 25 PN 160 1427 D
1. Type index:
1.1. Complete filter: (ordering example)
MNL. 63. 10VG. HR. E. P. -. G. 4. -. -. AE
1 2 3 4 5 6 7 8 9 10 11 12
1 series:
MNL = standard in-line filter-medium pressure range
according to DIN 24550 T1, T2
2 nominal size: 40, 63, 100
3 filter-material and filter-fineness:
25 VG = 20 µm(c), 16 VG = 15 µm(c), 10 VG = 10 µm(c),
6 VG = 7 µm(c), 3 VG = 5 µm(c) Interpor fleece (glass fibre)
4 resistance of pressure difference for filter element:
30 = ∆p 30 bar
HR = ∆p 160 bar (rupture strength ∆p 250 bar)
5 filter element design:
E = single-end open
6 sealing material:
P = Nitrile (NBR)
V = Viton (FPM)
7 filter element specification: (see catalog)
- = standard
VA = stainless steel
8 connection:
G = thread connection according to ISO 228
9 connection size:
3 = G½
4 = G¾
5 = G1
10 filter housing specification: (see catalog)
- = standard
11 internal valve:
- = without
R = reversing valve, Q ≤ 70,06 l/min
12 clogging indicator or clogging sensor:
- = without
AOR = visual, see sheet-no. 1606
AOC = visual, see sheet-no. 1606
AE = visual-electrical, see sheet-no. 1615
1.2. Filter element: (ordering example)

2. Dimensions: 01NL. 63. 10VG. HR. E. P. -
type MNL 40 MNL 63 MNL100
1 2 3 4 5 6 7
connection G½ G¾ G1
A 182 242 332 1 series:
B 210 270 360 01NL. = standard filter element according to DIN 24550, T3
C 30 36,5 46
2 nominal size: 40, 63, 100
weight kg 2,0 2,5 3,3
volume tank 0,25 l 0,35 l 0,55 l 3 - 7 see type index-complete filter
Connection assignments as shown in the table are standard according to
DIN 24 550 T1. Are the connection assignments against DIN 24 550 T1,
see item 9 of the type code.
Changes of measures and design are subject to alteration!

EDV 07/03

300686
3. Spare parts:
item qty. designation dimension article-no.
MNL 40 MNL 63 MNL 100
1 1 filter element 01NL.40 01NL.63 01NL.100
2 1 O-ring 22 x 3,5 304341 (NBR) 304392 (FPM)
3 1 O-ring 54 x 3 304657 (NBR) 304720 (FPM)
4 1 support ring 60 x 2,6 x 1 311779
5 1 clogging indicator visual AOR or AOC see sheet-no. 1606
6 1 clogging indicator visual-electrical AE see sheet-no. 1615
7 1 clogging sensor electronical VS1 see sheet-no. 1617
8 1 clogging sensor electronical VS2 see sheet-no. 1618
9 1 O-ring 15 x 1,5 315357 (NBR) 315427 (FPM)
10 1 O-ring 22 x 2 304708 (NBR) 304721 (FPM)
11 1 O-ring 14 x 2 304342 (NBR) 304722 (FPM)
12 1 screw plug 20913-4 309817
item 12 execution only without clogging indicator or clogging sensor
4. Description:
The pressure filters of the series MNL 40-100 are suitable for a working pressure up to 160 bar and equiped with elements
according to DIN 24 550 T3.
The pressure peaks are absorbed by a sufficient margin of safety. The MNL-filter is in-line mounted.
The filter element consists of star-shaped, pleated filter material which is supported on the inside by a perforated core tube and is
bonded to the end caps with a high-quality adhesive. The flow direction is from outside to the inside. Filter elements are available
down to 4µm(c).
INTERNORMEN-Filter elements are known as elements with a high intrinsic stability and an excellent filtration capability, a high dirt-
retaining capacity and a long service life.
INTERNORMEN-Filter are suitable for all petroleum based fluids, HW-emulsions, most synthetic hydraulic fluids and lubrication oils.
INTERNORMEN-Filter elements are available up to a pressure difference resistance of ∆p 160 bar and a rupture strength of ∆p 250 bar.
The internal valves are integrated into the centering pivot for the filter element.
After reaching the opening pressure the by-pass valve causes that an unfiltered partial flow passes the filter. With the reverse valve
a protection of the filter element is given when having a reverse flow inside the filter. The reverse flow will not be filtered.
5. Technical data:
temperature range: -10°C to + 80°C (for a short time + 100°C)
operating medium: mineral oil, other media on request
max. operating pressure: 160 bar
test pressure: 208 bar
connection system: thread connection according to ISO 228
housing material: aluminium forging alloy; C-steel
sealing material: Nitrile (NBR) or Viton (FPM), other materials on request
installation position: vertical
Classified under the Pressure Vessel Directive 97/23/EC for mineral oil (fluid group 2), Article 3, Para. 3.
Classified under ATEX Directive 94/9/EC according to specific application (see questionnaire sheet-no. 34279-4).
6. Symbols:
without indicator with electrical with visual-electrical with visual-electrical with visual with electronical with electronical
indicator indicator indicator indicator clogging sensor clogging sensor
AE 30 and AE 40 AE 50 and AE 60 AE 70 and AE 80 AOR/AOC VS1 VS2
filter without
internal valve
filter with
by-pass valve
filter with
reversing valve
7. Pressure drop flow curves: Precise flow rates see ‘INF-Expert-System Filter’ respectively ∆p-curves ; depending
on filter fineness and viscosity.
8. Test methods: Filter elements are tested according to the following ISO standards:
ISO 2941 Verification of collapse/burst resistance

ISO 2942 Verification of fabrication integrity
ISO 2943 Verification of material compatibility with fluids
ISO 3723 Method for end load test
ISO 3724 Verification of flow fatigue characteristics
ISO 3968 Evaluation of pressure drop versus flow characteristics
ISO 16889 Multi-pass method for evaluating filtration performance
E 1427 D
300686
for clogging indicator type AO-AE 20084-4B
These instructions refer to data sheet 1613.
1. Functioning
The clogging indicator with the designation AE is a combined optical and electrical pressure difference
indicator.
This type of pressure difference indicator can be mounted on all pressure filters p ó 420 bar. With
growing contamination of the filter element the difference between the supply pressure and the output
pressure of the filter is increasing. Depending on this pressure difference - but independent of the
operating pressure - optical and electrical signals are released.
The difference between the clogging indicators AE and AO is that the type AO indicates only optically.
Depending on pressure difference, a measuring piston, charged with supply pressure and output
pressure, moves towards a measuring spring.
Depending on the length gauge a permanent magnet which is integrated in the measuring piston
switches a Reed-contact (magnetic-switch) and releases the electrical control signal.
The optical control signal is indicated by a red indicator pin which is connected to the magnetic
measuring piston. Depending on the length gauge of the measuring piston the red indicator pin appears
and is visible inside the transparent plastic cap.
The electrical indication appears - at a given switching pressure - as a digital signal, and the optical
indication appears as an analogous signal which starts at 75% of the stated switching pressure (the red
pin enters the transparent cap) and ends at 150% of the switching pressure (red pin is touching the end
of the cap).
Clogging indicators of the variaties 5 to 8 are equiped with additional light indicators. According to the
chosen design the optical light signal will be visible at the transparent cover of the line adapter at the
clogging indicator.With light signals LG the glow lamp indicates the necessity change of the filter
element. The light signal LED indicates normal operation with a green light diode and with the yellow light
diode the necessity of the filter element change.
2. Operating instruction
Normally filters are supplied with mounted clogging indicator. When retrofitting - the filter is to be
discharged of the operating pressure.
- dismantling the screw plug out of the bare hole which is foreseen for the clogging indicator
- screw in the clogging inidcator into the bare hole (starting torque 150 Nm)
It is necessary to make sure the availability and the right positioning of sealing parts
- O-ring 22 x 2 and
- O-ring 14 x 2
as well as a dirt-free mounting. The electrical contacts are to be connected according to the graphical
symbol shown on the type plate of the clogging indicator. For the directional adjustment of the connector
plug it is necessary to release the socket screw M3 on the retaining block of the plug, to adjust the
desired direction and to tighten again the socket screw.
Note: When changing the direction please take care of the contact of the adjusting screw on the
stopping face (front of the hexagon width across 30).
3. Maintenance
The device is maintenance-free, however, note that no cleaning fluids and solvents get on the
transparent cap of the optical indicator.

306169
Accessories
Electrical Alarm Contacts

T Model 821, Magnetic Snap-Action Contacts
T Model 831, Inductive Alarm Sensors
T Model 830 E, Electronic Contacts
WIKA Data Sheet AC 08.01
Applications
T Control and regulation of industrial processes

T Monitoring of plants and switching of electric circuits
T Indication of limit values
T Inductive alarm contacts for safe switching, even in
explosion hazardous areas
T Process industry applications: in machine and plant
construction, chemical and petrochemical industry,
power plants, mining, onshore and offshore and
environmental engineering Pressure Gauge Model 212.20.100
with Electrical Alarm Contact Model 821
Special Features
T High reliability and long service life

T Can be incorporated within all relevant pressure and
temperature measuring instruments
T Up to 4 switching contacts per measuring instrument
T Also available with liquid filled case for high dynamic
pressure loads and vibration applications
T Inductive alarm contact, also available in safety pattern
T Electronic contact for PLC
Description
Electrical alarm contacts make or break an electric control
circuit depending on the position of the instrument’s
pointer. Points of contact actuation are adjustable over the Thermometer Model 55
full extension of the scale graduation (see DIN 16 085). with Electrical Alarm Contact Model 831
The contacts are mainly installed behind the dial, in some
cases onto the dial.
The instrument pointer’s (actual value pointer) deflection is
not obstructed by the contact’s mechanism. Optional extras
Round case and square edgewise panel mounted gauges
Gauges with special approvals on inquiry, e.g.
feature a hub in the window for an adjustment key.
T Pressure controllers in accordance with the VdTÜV’s
Contacts in flat-case edgewise panel mounted gauges are
note of instructions on pressure 100/1
adjustable with a screwdriver through the window. Alarm
T Pressure and temperature measuring instruments with
contacts consisting of several contacts may be set at
alarm contacts for intrinsically safe electrical systems
exactly the same setpoint. Contact actuation is made when
(mining)
there is an upper or lower deviation of the set desired value
T Pressure gauges for the connection to dust explosion
by the instrument pointer.
proof areas zone 20 or to hazardous areas zone 0
WIKA Data Sheet AC 08.01 · 02/2005 Page 1 of 20
Transmitter to combine with pressure gauges see data sheet AE 08.02
D-300083
Magnetic snap-action contacts model 821 1)
Intended use Specifications and table of contact ratings

This is the universal type of contacts to provide reliable The contact rating values are given in consideration of
service also with liquid filled instruments. many years of reliable service. Unlimited power switching
may be obtained by using the instruments' contacts to trip
The magnetically assisted contact features a small perma- a relay or contactor of appropriate size. WIKA relays of
nent magnet screwed to the setpoint indicator. The magnet model no. 905.1X are found on page 5 of this data sheet.
provides for a snap-action characteristic which considerably
improves contact rating and service life, and also makes Ratings below 24 V line voltage are to be individually
this type less sensitive to vibration, reducing the effect of established upon inquiry.
the spark to a minimum.
The hysteresis, however, is increased from 2 % to 5 % of For low ratings the current to be switched should not be
span. The hysteresis is the difference of the indicated less than 20 mA to maintain reliability.
values which are measured at reverse moving direction and
with unaltered switch point. Signalling is made before or For lower switching powers we recommend our control
after mating in accordance with the movement of the relays (see page 5) or, in programmable logic controllers
instrument pointer. (PLC) for example, our electronic contact model 830 E
1) Sliding contacts model 811 will be used especially in temperature measurement
(see page 9).
instrumentation where the bimetal measuring systems have only minor actuating
power or if there are operating conditions without vibrations. This type of contact
is not suitable for liquid filled instruments.
Specifications
Maximum contact rating Magnetic snap-action contact model 821 Sliding contact model 811
with non-inductive dry gauges liquid filled gauges dry gauges
(ohmic) load
Maximum voltage (MSR) Ueff 250 V 250 V 250 V
Current ratings: 1)
Make rating 1,0 A 1.0 A 0.7 A
Break rating 1,0 A 1.0 A 0.7 A
Continous load 0,6 A 0.6 A 0.6 A
Maximum load 30 W 50 VA 20 W 20 VA 10 W 18 VA
Material of contact points Silver-Nickel Alloy (80% Ag / 20% Ni / 10 µm gold-plated)
Ambient operating temperature -20 °C ... +70 °C
Max. no. of contacts 4
1) The values for nominal working currents shown in the above table apply to instruments with switch version S. For instruments with switch version L these values
should be halved. (refer to page 3 for appropriate version)
Recommended contact ratings with ohmic and inductive load
Voltage Magnetic snap-action contact model 821 Sliding contact model 811
(DIN IEC 38) dry gauges liquid filled gauges dry gauges
DC / AC
ohmic load inductive ohmic load inductive ohmic load inductive

load load load
DC AC DC AC DC AC
cos ϕ >0.7 cos ϕ >0.7 cos ϕ >0.7
V mA mA mA mA mA mA mA mA mA
220 / 230 100 120 65 65 90 40 40 45 25

110 / 110 200 240 130 130 180 85 80 90 45
48 / 48 300 450 200 190 330 130 120 170 70
24 / 24 400 600 250 250 450 150 200 350 100
In order to ensure a high switching reliability of the contacts the switching voltage should not be below 24 V, also
taking environmental influences in the long term into account.
Page 2 of 20 WIKA Data Sheet AC 08.01 · 02/2005
D-300083
Contact points of special material Special features
Contacts made of special materials are available to either T Separate circuits of each set of contacts
improve resistance against wear failure or corrosion failure T Double throw (SPDT) function
in long-term service. T Switch point calibrated and immobilised
T Two contacts linked at a specified distance
Optionally available are: T Contacts with "live zero" shunt 47 kW to monitor circuit
continuity
Silver-nickel alloy T Self-cleaning contacts (NS 160 only)
(80% silver / 20% nickel / 10 µm gold-plated) T Contact setting mechanism with provisions to attach a
This is the standard material used and features: lead seal
Excellent hardness and strength. T Contact setting knob non-detachable
Good resistance against formation of arcs. T Wiring by means of plug and socket instead of junction
Good resistance against contact welding. box or flying lead
Low contact resistance. T Contact points of special material platinum-iridium alloy
We use this alloy as our standard due to it's stable

properties.
Platinum-iridium alloy
(75% platinum, 25% iridium)
This alloy is very hard with excellent resistance against
formation of arcs and excellent performance in corrosive
environments. It is preferred where switching of rather high
current rating frequently occurs as part of regular process
control.
Switch version appropriate to gauge model and range

(in order to define limits, please refer to the table at the top of page 2 and footnote)
WIKA basic Nominal size Number of contacts Measuring ranges Switch version
gauge model sets
2XX.XX 100 and 160 1 ≤ 1 bar L

2XX.XX 100 and 160 1 all others S
2XX.XX 100 and 160 2 ≤ 1.6 bar L
2XX.XX 100 and 160 2 all others S
2XX.XX 100 3 or 4 ≤ 4 bar L
2XX.XX 100 3 or 4 all others S
2XX.XX 160 3 or 4 ≤ 2.5 bar L
2XX.XX 160 3 or 4 all others S
214.11 96x96 and 144x144 1 ≤ 1 bar L
214.11 96x96 and 144x144 1 all others S
214.11 96x96 and 144x144 2 ≤ 1.6 bar L
214.11 96x96 and 144x144 2 all others S
214.11 96x96 3 ≤ 4 bar L
214.11 96x96 3 all others S
214.11 144x144 3 ≤ 2.5 bar L
214.11 144x144 3 all others S
3XX.XX 160 1 ... 4 all L
4XX.XX 100 and 160 1 ... 4 all L
5XX.XX 100 and 160 1 ... 4 all L
6XX.XX 100 and 160 1 or 2 ≥ 100 mbar L
7XX.XX 100 and 160 1 ... 4 all L
55 100 and 160 1 ... 4 all L
73 100 and 160 1 ... 4 all L
D-300083
Contact function index
WIKA-contacts are identified by a 4- to 7-digit type code. The following applies as a general rule to the contact functions
The 3 digits to the left of the full stop indicate the model of of model 821 or 811 in connection with our standard settings.
contacts whereas 1 or more digits to the right of the full Index 1 Contact makes when the instruments' pointer
stop indicate the contact function with rising pressure, approaches the set point in clockwise direction.
respectively, clockwise pointer motion. The number of digits (NO contact)
right of the full stop reflects the number of contacts Index 2 Contact breaks when the instruments' pointer
incorporated. The order of indices reflects the order how approaches the set point in clockwise direction.
the contacts are arranged in clockwise direction. (NC contact)
Index 3 Contact breaks first and makes second circuit
Two or more sets of contacts normally feature one mutual when the instruments' pointer approaches the set
common. Indices separated by full stops indicate contacts point in clockwise direction. (SPDT contact)
with separated circuits.
Note: If the alarm contacts are to be set (adjusted) anticlockwise, the index figures
in brackets have to be used in accordance with DIN 16 085.
Combinations are possible.
Single contacts
Wiring scheme Clockwise pointer motion Model code and function index
Contact function for magnetic snap-action contacts or
sliding contacts (special version)
Contact makes 1
when pointer reaches set point 821.1 or 811.1
(NO - normally open) 4 (.5)
Contact breaks 1
(NC - normally closed) 4 (.4)
SPDT: 1 contact breaks and 1 contact makes 1 2

(change over) 4 (.6)
Double contacts
1st and 2nd contact make 1 2

(.55)
4 4
1st contact makes 1 2

2nd contact breaks 821.12 or 811.12
when pointer reaches set point 4 4
(.54)
1st contact breaks 1 2

2nd contact makes 821.21 or 811.21
when pointer reaches set point 4 4
(.45)
1st and 2nd contact break 1 2

4 4
(.44)
Triple contacts
1st contact breaks 1 2 3

2nd contact makes 821.212 or 811.212
3rd contact breaks 4 4
(.454)
4
when pointer reaches set point
Wiring terminals are identified as per above wiring schemes.

Earth (ground) lead is identified green-yellow.
Configurations feasible in consideration of individual instruments are found on pages 16/17.
D-300083
Control relays
Control relays to combine with contact model 821 and 811. The line converter additionally provides a 24 V/20 mA DC
These relays are intended to provide higher contact rating power source for auxiliary use.
in such a way, that the instruments' contact only energises
the relay, whereas the relay switches the process control Relay operation is particularly recommended with heavy
circuit. duty liquid filled instruments. Although liquid filling
considerably improves service life of the instrument itself,
The WIKA relay "Blackbox'' is completely wired and it inevitably also intensifies the formation of arcs.
includes a line converter of normally 230 V input voltage.
Output provides one each potential free double throw
contact.
The primary relay circuit is energised by means of low

voltage pulsating current to provide safe operation over
several million cycles.
Review of available models
Model Intended for instruments Relay output
905.12 with 1 contact 1 double throw

Control relay
MSR 010 contact
1036688
Contact rating: Auxiliary output:
1840 VA 250 V 8 A 24 V DC
905.13 with 2 contacts 2 double throw

Control relay
MSR 020 contact
1036696

1840 VA 250 V 8 A 24 V DC
905.14 with 2 contacts 1 double throw

Control relay
MSR 011 (function 21 is essential) with flip-flop
characteristic
1036700
(interval switch for

pump controlling)

1840 VA 250 V 8 A 24 V DC
D-300083
Control relays specifications Model 905.12 ... 14
Line voltage AC 230 V - 10 % / + 6 %, 45 ... 60 Hz

Consumption ca. 2.5 VA
Pulsating current voltage 35 to 40 V
Isolated transformer
Pulse rate 1 : 100 typically
Pulse width 250 µs typically
Relay time lag ca. 0.5 s
Relay output Potential free double throw or bistable flip-flop contact (see review of
available models)
Contact rating AC 250 V, 8 A, 1840 VA
Auxiliary output DC 24 V
Current rating 20 mA
Wiring identification DIN 45 410
Protection Insulated system
Insulation class C/250 V per VDE 0110
Enclosure size Form C, page 11
Enclosure material Polyamide 6.6, green
Ingress protection EN 60 529 / IEC 529 Case IP 40, Terminals IP 20
Operating temperature 0 ... +70 °C
Mounting Snap-mounting on DIN 50 022 rail 35 x 7.5 mm
(Surface mounting adaptor inclusive)
Control relays connection examples
Single contact Double contact Double contact, interval switch

Model 821 Model 821 Model 821.21
M1/Z1211.02
D-300083
Inductive alarm sensor contacts model 831
Service intended Advantages of the WIKA inductive system

WIKA inductive contacts are certified for use in hazardous
areas of Zone 1 and Zone 2. T Long service life by means of non-contact sensor
Power supply must be made by means of a power source T Very little effect on gauge accuracy
certified intrinsically safe such as WIKA model 904.15. T No reduced rating with liquid filled gauges
T Fully suitable in corrosive or hazardous atmosphere
Inductive contacts are also recommended for critical non- (electronics resin padded)
hazardous applications where an utmost of failsafe heavy T Ex-approved for service in hazardous area of Zone 1
duty operation is required. or 2
In combination with liquid filled instruments these contacts

are particularly suited for process control circuits in the Components of the WIKA inductive contact system
chemical and petroleum industry. Operation of the inductive contact system requires an
appropriate electronic power supply and control unit.
Operating principle
At the heart of the WIKA inductive contact system is a non- The WIKA control unit consists of
contact sensor attached to an indicating device. T Line transformer
Both sensor and indicator are adjustable over the full length T Amplifier circuit
of the scale. Contact actuation is achieved by means of a T Relay to switch external circuit
metal flag linked to the pointer of the instrument.
The isolated line transformer provides for power supply
The metal flag affects the electric field of the sensor when whereas the amplifier conditions the signal of the inductive
the instruments' pointer overlaps with the contacts' sensor to energise the output relay.
indicator.
Contact actuation is made without any mechanical force Available are two versions of control units
that would affect accuracy of the instrument. T Ex-approved intrinsic safety
T Standard for non-intrinsically safe version
The scheme below reflects the operating principle in
comparison with conventional mechanical contacts: The intrinsically safe version is offered with PTB
certificate of conformity to EN 50 014 and EN 50 020 to be
R < 1.7 kΩ R=0 used with inductive contacts installed in hazardous areas of
Zone 1 or Zone 2.
black (-)
0801-A
8V equals
red (+)
It may be noted that the control unit itself must be installed
outside the hazardous area.
R > 1.7 kΩ R =∞
The switching characteristic of the control unit can be
black (-) affected by replugging wire jumpers or sliding switches
8V equals respectively. Doing so, it it possible to achieve a turnabout
red (+) of the direction of action, e.g. flag matches sensor
T output relay optionally
Dimensions of the basic instrument and provisions for energised or de-energised.
contact adjustment are identical to contacts of model 821. Moreover, it is possible to add on a line break monitoring.
Operating temperature: -25 °C ... +70 °C 1) With non-intrinsically safe control units, inductive alarm
contacts must not be operated in explosion hazardous
Used sensor (slot-type initiator): Type SJ areas. Their direction of action is permanently fixed. The
of the company Pepperl and Fuchs, EC-Type-Examination output relay is de-energised when the flag dips into the air
Certificate PTB 99 ATEX 2219 X and ZELM 03 ATEX 0128 X gap. The line break monitoring is serialised. Apart from the
outputs required for the operation of the alarm contacts,
there is an additional output with direct voltage 24 V (max.
1) For use in hazardous areas, the upper limits for the ambient temperature mentioned in 20 mA). This additional output can be used, for example, to
the test certificate must be complied with! These depend on voltage, current rating,
power consumption and temperature class. supply the operating lights.
D-300083
Contact function index
WIKA-contacts are identified by a 4- to 7-digit type code. Index 1 Contact makes when the instruments' pointer
The 3 digits to the left of the full stop indicate the model of approaches the set point in clockwise direction.
contacts whereas 1 or more digits to the right of the full (Flag disengages from sensor)
stop indicate the contact function with rising pressure,
respectively, clockwise pointer motion. The number of digits Index 2 Contact breaks when the instruments' pointer
right of the full stop reflects the number of contacts approaches the set point in clockwise direction.
incorporated. The order of indices reflects the order how (Flag merges with sensor)
the contacts are arranged in clockwise direction.
Note: If the alarm contacts are to be set (adjusted) anti-
The following applies as a general rule to the contact clockwise, the index figures in brackets have to be used in
functions of model 831 in connection with our standard accordance with DIN 16 085. Combinations are possible.
settings.
Single contacts
Wiring scheme 1) With clockwise pointer motion Contact function Model code and
the metal flag: (principle) function index
of contacts
2
disengages from sensor Contact makes 831.1
(NO-normally open) 1 (.5)
2
merges with sensor Contact breaks 831.2
(NC-normally closed) 1 (.4)
Double contacts
disengages 1st and 2nd 2 4
1st and 2nd contact 831.11

make 1 3 (.55)
1st disengages, 1st contact 4

2
2nd merges makes, 831.12
2nd contact (.54)
1 3
breaks
1st merges, 1st contact

2 4
2nd disengages breaks, 831.21
2nd contact (.45)
1 3
makes
1st and 2nd merges 1st and 2nd 2 4
with sensor contact 831.22

breaks 1 3 (.44)
Triple contacts
A number of instruments will also accept triple inductive contacts (see page 16/17).
Please refer to technical notes on page 9 as to feasibility of overlapping set points.
Wiring schemes and feasible characteristics are the same as above.
1) Thin line: Flag merged, circuit open.

Bold line: Rag not merged, circuit closed.
Wiring terminals are identified as per above wiring schemes.

Configurations feasible in consideration of individual instruments are found on pages 16/17.
D-300083
Triple inductive contacts All feasible configurations of triple inductive contacts:
With triple inductive contacts it is not feasible to set all 1st contact 3rd contact
three contacts overlapping at the same scale value. Either not overlapping not overlapping
the left (= no. 1 contact) or the right contact (= no. 3
contact) is at an approximate distance of 30° to the left or Model Model
the right of the other two contacts, which may be set to the 831.1.11 831.11.1
same value: 831.1.12 831.11.2
831.1.21 831.12.1
≥ 30° Examples ≥ 30°
831.1.22 831.12.2
831.2.11 831.21.1
only the only the
No. 1 second and first and No. 3 contact 831.2.12 831.21.2
contact left the third the second right 831.2.21 831.22.1
deflected contact contact deflected 831.2.22 831.22.2
can be can be
overlapping overlapping
lnductive contacts - Special designs
T Fail safe inductive contacts models 831 SN and T Triple inductive contact NS 160, one set value for all
831 S1N three contacts
Safety codes require that only tested and approved parts lf it is absolutely necessary to set all three contacts to the
be used in applications which play an especially important same value, this can be achieved with the NS 160 design
role with regard to safety. using smaller control heads.
The fail safe inductive contact models 831 SN and 831 S1N Please specify when ordering.
are certified for such applications. These models have to be
operated together with a control unit in a safety design, for T Quadruple contacts
which a type test approval has also been obtained, e.g. The edgewise panel mounting instruments NS 144 x 72 can
model 904.30 KFA6-SH-Ex1 (see page 12). Fail safe accept up to 4 inductive contacts (see page16).
inductive contacts may be used in connection with self-
regulating control systems.
Furthermore, the control circuit is intrinsically safe and
galvanic-isolated from supply voltage and output.
Used sensor (SN/S1N-slot-type initiator):
Type SJ of the company Pepperl and Fuchs, EC-Type-
Examination Certificate PTB 00 ATEX 2049 X and ZELM 03
ATEX 0128 X
Switching behaviour, model 831 SN

When the control flag is positioned within the slot initiator,
the output of the series-connected control unit (0-signal)
is blocked, i.e. the output relay is released / ( = alarm
condition).
Contact function indices, pointer flag behaviour and wiring
schemes are identical to model 831 (see page 8).
Switching behaviour, model 831 S1N

When the control flag is positioned outside of the slot
initiator, the output of the series-connected control unit
(0-signal) is blocked, i.e. the output relay is released
( = alarm condition).
Contact function index scheme is the same as that for
model 831 SN with the following differences:
Index 1 after the contact model no. means
contact makes when set point is reached in
clockwise direction (pointer flag retreats into
control head).
Index 2 after the contact model no. means
contact breaks when set point is reached in
clockwise direction (pointer flag emerges from
control head).
Possible configurations as shown in the tables on pages 16/17.
D-300083
Electronic contact model 830 E
Description, Application Wiring details

Direct switching of small capacities which are usually Control and switching electronics in the sensor,
required in connection with a PLC can be realised by this electric connection via terminal box.
inductive alarm contact with integrated amplifier which is
T To connect a PLC control unit or for direct switching of
factory-installed into the measuring instrument.
small capacities
T PNP transistor
The familiar advantages with inductive contacts, such as an
With PNP switching apparatus, the switched output is
especially safe contact operation, no wear at all by
a connection towards PLUS. The load RL between the
proximity contact operation as well as virtually no reaction
switched output and the MINUS should be selected in
on the measuring system, thus enabling the accuracy of the
a way not to exceed the maximum switching current
indication, are used in this context, too.
(100 mA).
An additional control unit will not be necessary.
T Control vane emerges from slot sensor: contact breaks
(output not active)
The electronic contact with PNP output can be selected in
either 2- or 3-wire design.
T Control vane retreats into slot sensor: contact makes
The operating voltage is 10 ... 30 V DC. The maximum
(output active)
switching current is 100 mA.
The electronic contact model 830 E is not intrinsically safe 2-wire system
and therefore not suitable for applications where explosion
protection is required. Measuring instrument PLC
4
See page 11 for further technical data. +UB
1
-
Contact function index is the same as that for alarm
PNP RL (load)
contact model 831 with the following differences:
Index 1 after the contact model no. means contact makes
when set point is reached in clockwise direction
with double contact
(pointer flag retreats into control head)
2nd contact
Index 2 after the contact model no. means contact breaks
when set point is reached in clockwise direction
2
(pointer flag emerges from control head)
PNP RL (2nd load)
Note: This operation is exactly opposite to that of model
831!
3-wire system
Measuring instrument PLC

2
+UB
1
-
PNP 3
RL (load)
with double contact

2nd contact
4
PNP
RL (2nd load)
D-300083
Technical data Electronic contact Model 830 E
Range of operating voltage DC 10 ... 30 V

Residual ripple max. 10 %
No-load current ≤ 10 mA
Switching current ≤ 100 mA
Leakage current ≤ 100 µA
Function of switching element normally open (make contact)
Type of output PNP transistor
Voltage drop (with I max.) ≤ 0.7 V
Protection against pole reversal conditional UB (the output 3 or 4 switch must never be set directly to minus)
Anti-inductive protection 1 kV, 0.1 ms, 1 kΩ
Oscillator frequency approx. 1000 kHz
EMC acc. EN 60 947-5-2
Ambient conditions
and temperature in accordance with measuring instrument
Installation installed directly in the measuring instrument at the factory, maximum 2 alarm contacts
Dimensions of control units

for inductive contacts
Form C Form E
AC0801P2
1036670
Form D Form F
AC0801P1
AC0801P3
D-300083
Control units for inductive contacts
Ex-certified versions (Connect. examples s. page 19)

Control unit model 904.28 KFA6-SR2-Ex1.W Input
T Intended for instruments having one inductive
AC0801P7
contact incorporated
T Alarm circuit certified intrinsically safe [EEx ia] llC
to EN 50 227 and NAMUR
T Provides 1 SPDT relay output contact
T LED indicating circuit status (green), relay output (yellow) red
and lead breakage (red)

T Case surface-mounting type form D
Note
yellow green
Directions of action adjustable by sliding switch S1:
OPEN CIRCUIT CAUSES ALARM: switch S1 in position I
CLOSED CIRCUIT CAUSES ALARM: switch S1 in position II
CONTINUITY DETECTION: switch S3 in position I Output Power supply
Control unit model 904.29 KFA6-SR2-Ex2.W

Input I Input II
T Intended for 1 instrument having two or two

instruments having one each contact incorporated
AC0801P8
T Alarm circuit certified intrinsically safe [EEx ia] llC
to EN 50 227 and NAMUR
T Provides 2 SPDT relay output contacts
T LED indicating circuit status (green), 2 x relay output red red
(yellow) and 2 x lead breakage (red)
T Case surface-mounting type form F
Note
Directions of action adjustable by sliding switches S1 and S2: yellow yellow
green
OPEN CIRCUIT CAUSES ALARM: switch S1 and S2 in position I
CLOSED CIRCUIT CAUSES ALARM: switch S1 and S2 in pos. II
CONTINUITY DETECTION: switch S3 in position I Output I Output II Power supply
Fail safe control unit
Model 831 SN and S1N, respectively, are "fail safe" model-approved versions intended for services where operational
safety codes, e.g. such as issued by TÜV, require the use of specially approved components. This contact provides
together with the model-approved control unit model 904.30
a self-monitoring and fail-safe alarm circuit.
Input
Voltage breakdown, failure of components, wire interruption
or short circuit will always de-energise the output relay.
AC0801P9
Model 904.30 KHA6-SH-Ex1
T Failsafe circuit control unit

yellow
T Intended for instruments having one SN- or
S1N-type contact incorporated
T Alarm circuit certified intrinsically safe [EEx ia] llC red
green
T 1 safety directed relay output, 1 accelerating output
and 1 passive transistor error message output
T LED indicating circuit status (green), relay output (yellow)
and lead breakage as well as short circuit (red)
T Case surface-mounting type form E
Output III Output II Output I Power supply
D-300083
Specifications for Model 904.28 Model 904.29 Model 904.30 fail safe
control units KFA6-SR2- Ex1.W KFA6-SR2- Ex2.W KHA6-SH-Ex1
Power supply
Line voltage 1) AC 230 V ± 0 %, 45 ... 65 Hz AC 230 V ± 0 %, 45 ... 65 Hz AC 85 ... 253 V, 45 ... 65 Hz
Consumption 1 VA 1.3 VA 3 VA
Input
No. of contacts 1 2 1
Voltage (reactive) DC 8 V DC 8 V DC 8.4 V
Maximum current 8 mA 8 mA 11.7 mA
Contact actuation 1.2 mA ≤ Is ≤ 2.1 mA 1.2 mA ≤ Is ≤ 2.1 mA 2.1 mA ≤ Is ≤ 5.9 mA
Contact hysteresis ca. 0.2 mA ca. 0.2 mA
Control line impedance 100 Ohm 100 Ohm 50 Ohm
Ex-IS data (as PTB-certified) PTB 00 ATEX 2081 PTB 00 ATEX 2081 PTB 00 ATEX 2043
Voltage U o ≤ DC 10.6 V U o ≤DC 10.6 V U o ≤ DC 9.6 V
Current Io ≤19.1 mA Io ≤19.1 mA Io ≤ 19.1 mA
Power rating Po ≤51 mW Po ≤ 51 mW Po ≤55 mW
IS-classification [EEx ia] IIC [EEx ia] IIC [EEx ia] IIC
Ext. capacitance 2.9 µ F 2.9 µ F 650 nF
Ext. inductance 100 mH 100 mH 5 mH
Output
Relay contacts 1 SPDT 1 ea. SPDT 1 safety directed relay output
Contact rating AC 253 V, 2 A, 500 VA, cos ϕ > 0.7 253 V, 2 A, 500 VA, cos ϕ > 0.7 250 V, 1 A, cos ϕ > 0.7
Contact rating DC 40 V, 2 A; ohmic 40 V, 2 A; ohmic 24 V, 1 A; ohmic
Delay making circuit approx. 20 ms approx. 20 ms 20 ms
Delay breaking circuit approx. 20 ms approx. 20 ms 20 ms
Max. ON-OFF frequency 10 Hz 10 Hz 5 Hz
Operating conditions
Min. temperature - 20 °C - 20 °C - 20 °C
Max. temperature + 60 °C + 60 °C + 60 °C
Max. humidity max. 75% max. 75% max. 75%
Ingress protection IP 20 (EN 60 529 / IEC529) IP 20 (EN 60 529 / IEC529) IP 20 (EN 60 529 / IEC529)
Enclosure
Style Surface mounting Surface mounting Surface mounting
Dimensions per drawing Form D, page 11 Form F, page 11 Form E, page 11
Mounting Snap-fit on 35 mm x 7.5 mm (EN 50 022) rail. Direct mounting feasible.
Weight approx. 0.15 kg approx. 0.15 kg approx. 0.28 kg
Product no. 2014505 2014521 2014548
D-300083
Control units for inductive contacts
Non-Ex-certified versions
(Connection examples see page 19)
Control unit model 904.25 MSR 010-I
T Intended for instruments having one inductive contact

1036726
T Surface mounting enclosure of form C
- Non-IS -
Contact rating: Auxiliary output
1760 VA 230 V 8 A 24 V DC
T Intended for 1 instrument having two contacts or two

instruments each having one contact
1036742
T Provides 2 SPDT relay output contacts
- Non-IS -
1760 VA 230 V 8 A 24 V DC
T Intended for 2-point (HI-LO) interval switch for control

circuits with contacts of configuration model 831.12
1036734

- Non IS -

1760 VA 230 V 8 A 24 V DC
D-300083
Specifications for Model 904.25 Model 904.26 Model 904.27
control units MSR 010-I MSR 020-I MSR 011-I
Power supply
Line voltage AC 230 V - 10% / +6%, 45 ... 60 Hz
Consumption 1) approx. 2.5 VA
Input
No. of contacts 1 2 2
Voltage DC 8.5 V (typical)
Maximum current Ik approx. 5 mA
Contact actuation 1.5 mA typical
Contact hysteresis approx. 0.2 mA
Output
Relay contacts 1 SPDT 1 ea. SPDT 2 SPDT
Contact rating AC AC 230 V / 8 A / 1760 VA
Delay making circuit approx. 10 ms
Delay breaking circuit approx. 10 ms
Auxiliary output DC 24 V max. 20 mA
Operating conditions
Min. temperature 0 °C
Max. temperature +70 °C
Max. humidity max. 75%
Ingress protection Case IP 40 / terminals IP 20 (EN 60 529 / IEC 529)
Enclosure
Dimensions per drawing Form C, page 11
Material Polyamide 6.6, green
Mounting Snap-fit on 35 x 7.5 mm DIN 50 022 rail. Direct mounting feasible.
Weight approx. 0.24 kg approx. 0.27 kg approx. 0.24 kg
D-300083
Incorporating contacts into pressure gauges
Number of contacts, size of instrument (NS) and minimum scale value
Pressure gauge Magnetic snap-action contacts lnductive alarm sensors Model 831
Model NS Model 821 Electronic contact Model 830 E 1)
Number of contact sets Number of contact sets
Wiring
1 2 3 4 2) 1 2 3 3) 4
Minimum scale value in bar Minimum scale value in bar
212.20 100, 160 A 1 1.6 4 4 1 1.6 1.6 -
232.20 100, 160 A 1 1.6 4 4 1 1.6 1.6 -
232.50 100, 160 A 1 1.6 2.5 2.5 0.6 1 1.6 -
233.50 100, 160 A 1 1.6 2.5 2.5 0.6 1 1.6 -
232.30, 233.30 100 A 1 1.6 4 4 1 1.6 1.6 -
232.30, 233.30 160 B 1 1.6 2.5 2.5 0.6 1 1.6 -
232.36 100 A 1 1.6 4 4 1 1.6 1.6 -
214.11 single system 96x96 C 1 1.6 4 - 1 1 - -
214.11 single system 144x144 D 1 1.6 2.5 - 1 1 - -
214.11 single system 144x72 D 1 1.6 - - 0.6 0.6 0.6 0.6
214.11 double system 144x72 D - - - - 0.6 0.6 - -
312.20 160 A 1 5) 1 5) 1.6 5) 1.6 5) 1 1 1.6 -
332.30 160 B 1 5) 1 5) 1.6 5) 1.6 5) 1 1 1.6 -
333.30 160 B - - - - 1 1 1.6 -
4X2.12 100, 160 A 0.025 0.025 0.025 0.025 0.025 0.025 0.025 -
4X3.12 100, 160 A 0.025 0.025 0.025 0.025 0.025 0.025 0.025 -
422.20 4) 100, 160 A 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
423.20 4) 100, 160 A 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
4X2.30 4) 100 A 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
4X2.30 4) 160 B 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
4X3.30 4) 100 A 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
4X3.30 4) 160 B 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
4X2.50 4) 100, 160 A 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
4X3.50 4) 100, 160 A 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
432.36 4) 100 A 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
432.36 4) 160 B 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
433.36 4) 100 A 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
433.36 4) 160 B 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
432.56 4) 100, 160 A 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
433.56 4) 100, 160 A 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
532.52 100, 160 A 0.04 0.04 0.04 0.04 0.04 0.04 0.04 -
532.53 100, 160 A 0.04 0.04 0.04 0.04 0.04 0.04 0.04 -
532.54 100, 160 A 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
614.11 96x96, 144x72 D - - - - 0.04 0.04 - -
61X.20 100 A - - - - 0.1 0.1 - -
6XX.50 100 A - - - - 0.1 0.1 - -
632.51 100, 160 A 0.0025 0.0025 - - 0.0025 0.0025 0.0025 -
711.11 160 A 1 1.6 4 - 1 1 - -
711.12 100, 160 A 1 1.6 4 - 1 1 - -
712.20 4) 100, 160 A 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
713.20 4) 100, 160 A 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
732.02 100 A 1 1.6 4 - 1 1 - -
732.12 100, 160 A 0.06 0.06 0.1 0.1 0.06 0.06 0.1 -
732.14 100, 160 A 0.06 0.06 0.1 0.1 0.06 0.06 0.1 -
733.12 100, 160 A 0.06 0.06 0.1 0.1 0.06 0.06 0.1 -
733.14 100, 160 A 0.06 0.06 0.1 0.1 0.06 0.06 0.1 -
732.51 4) 100, 160 A 0.025 0.025 0.04 0.04 0.025 0.025 0.025 -
736.51 100, 160 A 0.0025 6) 0.0025 6) - - 0.0025 0.0025 0.0025 -
1) Electronic contact model 830 E only 1 or 2 contacts 3) With round case gauges it is not feasible to set all contacts overlapping.
2) It is not feasible to set all 4 contacts overlapping. Either the no.1 or the no.3 contact remains at a minimum distance of 30° from the
Either the no.1 or the no. 4 contact remains at a minimum distance of other two. However, a special version of 160 mm gauges is available upon request.
30° with 100 mm gauges See also page 9.
15° with 160 mm gauges. 4) Pressure range 0 ... 0.025 bar: class 2.5
However, a special version of 160 mm gauges is available upon request. 5) Without magnet
6) Inquire feasibility when intended for flammable gases
D-300083
Incorporating contacts into thermometers
Number of contacts and size of instrument (NS)
Thermometer Magnetic snap-action Sliding contacts 1) lnductive alarm sensors Mod. 831
Model NS contacts Model 821 Model 811 Electronic contact Model 830 E 2)
Wiring
Number of contact sets Number of contact sets Number of contact sets
1 2 3 1 2 3 1 2 3
55 100 A on inquiry x x x x x x
55 160 B on inquiry x x x x x x
73 100 E x x x x x x x x -
73 160 E x x x x x x x x x
73 144x144 D x x on inquiry x x on inquiry x x on inquiry
1) Not for liquid dampened gauges

2) Electronic contact model 830 E only 1 or 2 contacts
Wiring index as indicated in column "wiring"

The letter indicates the standard wiring method of pressure
gauges and thermometers incorporating 1 or 2 contacts.
"Left" or "right" refers to an observer facing the dial of the
instrument.
A Junction box at right-hand side of the instrument.

Material: Black PA 6-Nylon
Ingress protection: IP 65
11346210y
Suitable temperature: -40 °C to +80 °C
Insulation: Group C / 250 V
Approval reference: VDE 0110
Entry: M20x1.5 bottom entry cable gland with retainer
clamp, 6 + PE(Earth) terminals
Wiring: 2.5 mm2 to accept stranded wire
B Junction box at right-hand side of the instrument.

Material: Black PA 6-Nylon
Ingress protection: IP 65
2438794y
Suitable temperature: -40 °C to +80 °C

Insulation: Group C / 250 V
Approval reference: VDE 0110
Entry: M20x1.5 bottom entry cable gland with retainer
clamp, 4 + PE(Earth) terminals
Wiring: 2.5 mm2 to accept stranded wire
C Block of terminals 2.5 mm2 to accept

stranded wire at back of case
D Block of rack-mounting terminals

DIN 41 611 / VDE 0110,
2.5 mm2 insulation group C at back of case
E Junction box as A, but mounted at left-hand side of case
Wiring of instruments incorporating 3 or more contacts and

special versions of contacts may vary, depending on size
and specifications of the instrument. Please inquire.
Optional: Plug connection (e.g. DIN 43 650, DIN 43 651)

on inquiry
D-300083
Dimensions in mm (Examples)
Gauge with contacts NS 100
1346210x
Kind of contact Dimension X in mm
Single or double contacts 88
Double contacts (change-over) 113
Triple contacts 96
Quadruple contacts 113
Gauge with contacts NS 160
1556053x
Kind of contact Scale range Dimension X

Single or up to 0 ... 60 bar 1) 102 mm
double contacts ≥ 0 ... 100 bar 116 mm
Triple or up to 0 ... 60 bar 1) 116 mm
Quadruple contacts ≥ 0 ... 100 bar 129.5 mm
1) also for thermometers
D-300083
Connection examples for inductive alarm sensors
Ex version, with control units model 904.28/29/30, K*A6-SR2(SH)-Ex
Single contact Double contact Single contact

Model 831 Model 831 Model 831.SN
Hazardous area
M1/PF.03
Non-hazardous area
Model 904.28 Model 904.29 Model 904.30
KFA6-SR2- KFA6-SR2- KHA6-SH-
Ex1.W Ex2.W Ex1
Non-Ex version, with control units model 904.2X
Single contact Double contact Double contact, interval switch

Model 831 Model 831 Model 831.12
M1/Z1210.02
D-300083
Modifications may take place and materials specified may be replaced by others without prior notice.
Specifications and dimensions given in this leaflet represent the state of engineering at the time of printing.

9029265 02/2005 GB
WIKA Alexander Wiegand GmbH & Co. KG

Alexander-Wiegand-Straße 30
63911 Klingenberg/Germany
Phone (+49) 93 72/132-0
Fax (+49) 93 72/132-406
E-Mail info@wika.de
www.wika.de
D-300083
TM 73.03
Gas Actuated Thermometers

Process Industry Series • Model 73
Distant Reading with Capillary
Thermometers
Service intended
All stainless steel thermometer. Suitable for corrosive media and
environments in chemical process, petroleum and food industry.
The instruments meet the highest standards of measurement
technique.
Nominal size
100 and 160 mm
Temperature element
Inert gas expansion system (non-toxic)
Accuracy
Class 1 per DIN EN 13 190
Working range
Permanent (1 year): measuring range per DIN EN 13 190
Short time (24 h max.): scale range per DIN EN 13 190
Pressure rating of stem
25 bar maximum
Nominal use
DIN EN 13 190
Ingress protection
IP 56 / IP 65 per EN 60 529 / IEC 529
IP 65 per EN 60 529 / IEC 529 for gauges with alarm contacts
Standard features
Distant reading capillary entry
Centre back or radial bottom
Case material
Stainless steel
Scale, measuring ranges 1) , limits of error
Bezel
per DIN EN 13 190, class 1
Cam ring (bayonet type) bezel, natural finish stainless steel
Scale range Scale spacing Measuring range 1) Limit of error
Connection
Plain stem, stainless steel 1.4571 °C °C °C °C
- 80 ... + 60 2 - 60 ... + 40 2
Capillary - 60 ... + 40 - 50 ... + 30
Length to user specifications, 2 mm diameter, - 40 ... + 60 - 30 ... + 50
stainless steel 1.4571, bending radius no less than 6 mm
- 30 ... + 50 - 20 ... + 40
Stem - 20 ... + 60 - 10 ... + 50
8 mm diameter, stainless steel 1.4571 1 1
- 20 ... + 80 - 10 ... + 70
The active length of the stem depends upon the diameter and 0 ... 60 +10 ... + 50
the scale range. 0 ... 80 +10 ... + 70
Dial 0 ... 100 +10 ... + 90
White aluminium with black lettering per DIN EN 13 190 0 ... 120 + 10 ... + 110
Pointer 0 ... 160 2 + 20 ... + 140 2
Adjustable black aluminium pointer 0 ... 200 + 20 ... + 180
0 ... 250 + 30 ... + 220 2.5
Window
Laminated safety glass 0 ... 300 + 30 ... + 270
5
0 ... 400 + 50 ... + 350 5
Mounting provisions 0 ... 500 + 50 ... + 450
- 3-hole surface mounting flange (code H), stainless steel 0 ... 600 +100 ... + 500
10 10
- Surface mounting bracket made of die cast aluminium (code M) 0 ... 700 +100 ... + 600
- 3-hole panel mounting flange (code V), stainless steel 1) The measuring range is indicated on the dial by two triangular marks.
- Triangular bezel with clamp (code D), stainless steel Within this range the stated limit of error is valid according to DIN EN 13 190.
D-300104
Models Optional extras
Model Nominal size Capillary entry - Liquid damping
- Ingress protection IP 66 (not for gauges with alarm contacts)
H 7308 100
- Scale °F, K; dual scale °C/°F
H 7309 160 - Window of non-splintering plastic
Radial bottom
M 7310 100 - Stem 6, 10 or 12 mm diameter
M 7311 160 - Armoured or coated capillary
V 7312 100 - Capillary entry other than radial bottom
V 7313 160 - Thermowells per DIN 43 772 or to user specifications
Back - Alarm contacts (see data sheet AC 08.01)
D 7340 1) 100
- Surface mounting bracket made of other material
D 7350 1) 160
- Other mounting provisions
1) not suitable for alarm contacts
D-300104
TM 73.03
Dimensions in mm
3-hole surface mounting flange ( H ) Surface mounting bracket ( M)
3073 165
3073 270
3-hole panel mounting flange ( V) Triangular bezel (D ) 1)
3073 289 3073 297
Nominal size Dimensions in mm
alarm contacts of model 811, 821, 830 E or 831

without 1 or 2 3
A a a1 a2 a3 b b1 b2 b b2 b b2
100
100 19 22 65 56 50 51 53 88 91 97 100
160
Nominal size Dimensions in mm Weight in kg
d d1 d2 d3 d6 d7 D1 D2 D3 h
100 116 132 4.8 101 99 107 107 1.400
8 18 7
160 178 196 5.8 161 159 166 172 1.800
1) not suitable for alarm contacts
D-300104
Design of connection Dimensions in mm
Connection 1
Plain stem
Length of stem I = 140, 200, 240 or 290 mm
Stainless steel 1.4571
To suit compression fitting of connection no. 4
Connection 2 Male thread G SW i

Male nut G ½ B G½B 27 20
Length of stem l 1 = 80, 140, 180 or 230 mm
Connection 3 Female thread G 1 SW i

- Union nut G ½, G ¾ or M 24 x 1.5 G½ 27 8.5
Length of stem l 1 = 89, 126, 186, 226 or 276 mm
G¾ 32 10.5
M 24 x 1.5 32 13.5
Connection 4
Male thread G SW d4 i
Compression fitting (sliding on stem)
G ½ B, G ¾ B, M 18 x 1.5, ½ NPT or ¾ NPT G½B 27 26 14
ca. 40
Minimum insertion length l min approx. 60 mm G¾B 32 32 16
Length of stem l 1 = variable M 18 x 1.5 24 23 12
Length L = l 1 + 40 mm ½ NPT 22 – 19
¾ NPT 30 – 20
Sealing ring
Connection 5 Male thread G SW d4 i

- Union nut G ½ G½B 27 26 14
with fitting G ½ B, G ¾ B , ½ NPT or ¾ NPT
G¾B 32 32 16
Length of stem I 1 = 63, 100, 160, 200 or 250 mm
Stainless steel 1.4571 M 18 x 1.5 24 23 12
- Union nut M 24 x 1.5 with fitting M 18 x 1.5 ½ NPT 22 – 19
¾ NPT 30 – 20
Connection 6 Male thread G SW d4 i

Compression fitting (sliding on capillary) G½B 27 26 14
G ½ B, G ¾ B , ½ NPT or ¾ NPT
G¾B 32 32 16
Length of stem I = 100 mm (other on inquiry)
Stainless steel 1.4571 ½ NPT 22 – 19
¾ NPT 30 – 20
Sealing ring
3073 300.02
Ordering information
Model / Nominal size / Scale range / Location of capillary entry / No. and size of connection / Mounting provisions /
9019324 03/2004 GB
Length of stem I, I 1 / Length of capillary I F / Optional extras required
Specifications and dimensions given in this leaflet represent the state of engineering at the time of printing.
Modifications may take place and materials specified may be replaced by others without prior notice.
WIKA Alexander Wiegand GmbH & Co. KG

Alexander-Wiegand-Straße . 63911 Klingenberg
Tel.: (0 93 72) 132- 0 . Fax: (0 93 72) 132- 406
http://www.wika.de . E-mail: info@wika.de
D-300104

Manual de Operaciones Turbina de Vapor .

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_______________________________________________________________

Engine type SST-050 (AF 4 Gs)

Engine number 4.144.242

Engine control Speed control

Year of construction 2009

Release date 10.2009

The operating manual contains important notes and notes on

Please read carefully before commissioning.

The operating manual must by all means be available on the

Siemens Turbomachinery Equipment GmbH

Phone ++49 (0) 6233 / 85 - 0

Version Date Description State

0.9 10.2009 Preliminary until Start-up preliminary

Part number 41300001300

The operating manual must be constantly available on the turbine site.

1.3 Notes for the user

When hazardous substances must be handled, the user is obligated to make

Responsibilities of the staff for operation and maintenance must be clearly

Authorized staff are persons who were authorized by SIEMENS to do the

With these operating instructions we furnish you with important notes on

Notes on safety included in these operating instructions are marked as follows:

 Arrow indicating direction of rotation,

They must not be removed and are to be maintained in a perfectly

The operating instructions must be constantly available on the turbine site.

First-aid equipment (first-aid kit, etc.) must be stored in close proximity.

Staff to be trained or instructed or receiving general training may handle the

Safety-relevant functions are to be monitored constantly.

Maintenance work may be carried out by authorized staff only.

We recommend to have erection, commissioning, maintenance and revisions

An adequate workshop equipment for the maintenance work to be carried out is

Maintenance and inspection activities as well as inspection dates specified in the

Hoses (hydraulic or energy) must be replaced at specified intervals even if no

Cleaning the turbine using a high-pressure cleaner is not permissible.

Tighten loose screw connections during maintenance/repair work to the specified

Do not stay or work under suspended loads.

A safe and environmentally friendly disposal of operating supplies as well as

2.6.1 Electric energy

Use only original fuses with the specified amperage.

Work on electric units or turbine equipment may be done only by an electrics

Components on which maintenance and inspection work is carried out must be

The electric equipment of the turbine must be inspected visually at regular

Do not carry out any work on alive parts.

2.6.5 Oils, greases and other chemical substances

Be cautious when handling hot or etching operating supplies (danger of

Never store hazardous substances in tanks or containers of food. Only use

3.1 Transport with hoists

Special attention has to be paid to signs and symbols on the crates.

1. Use only hoists and suspension devices with an adequate

Climatic condition Storage Durability of the conservation

This information is based on experience and is not guaranteed.

4.1.1 Turbine rotor

4.1.2 Turbine housing and nozzle system

Turbine and gear shafts are accommodated in pressure-oil lubricated sleeve

An auxiliary oil pump is available for starting and stopping.

When there is a risk of frost and in case of longer standstills of

Blocking valve is strictly prohibited.

4.4.2 Speed governor

4.5.1 Trip valve

Blocking the valve is strictly prohibited.

4.5.3 Lube oil pressure

4.5.4 Steam pressures and temperatures (customer side)

4.5.5 Oil temperature downstream of oil cooler

4.5.6 Bearing temperature - turbine (at the gearbox)

Important functions such as