Instruction Manual

Screw pumps
A Member of the Low pressure pumps

COLFAX PUMP GROUP
Installation and Start-up Instruction
This instruction is valid for all standard low pressure pumps:

LPD, ACD, ACE, ACG/UCG, ACF/UCF, LPQ and ABQ
Contents Page
Pump identification 2
Installation 3
Start-up 8
Trouble shooting 10
Before commencing any work, read this instruction carefully! Failure to comply
! with these instructions may cause damage and personal injury!
LP 1205GB
July 2001
These instructions are valid for all low pressure pumps as specified in the Pump identification chart below.
Pump identification
Pump name Size Rotor Design Material Shaft- Mounting Valve Also Comments
(1) lead modification pump- seal (2) (3) valid for
(1) body design option
(1) (1)
LPD 015 N 1 I V B P Pumpunit

020 without shaft
coupling
ACD 025 L 6 I V B P Pumpunit

N N T without shaft
coupling
ACE 025 K V
032 L T
038 N 3 N B P A101
Q
ACG/UCG 045 K 6 I V B E A101 O = max 6 bar

052 N N T F G A327
060 O A020
070 P A385
ACF/UCF 080 K 4 I R B E A020 O = max 10 bar

090 L N V F O A084
100 N P A087
110 A101
125
LPQ 100 L 1 I R Y P
110 N
125 P
140 J
ABQ 160 B 5 I R Y O A328 O = max 5 bar

180 L P
N
(1) See Product description or Service instruction for specified Option

pump model A020 Pump with surface treated casing(s)
A084 Pump with lifetime greased ball bearing
(2) B = Flange mounting
A087 Pump with CCW-rotation and lifetime greased ballbearing
F = Foot mounting
A101 Pump with CCW-rotation, when not standard
Y = Vertical foot mounting
A327 Pump with Tuning®
(3) E = Without valve A328 Pump with Tuning®
G = Valve with external return A385 A101 + A327
O = Valve with internal return for reduced pressure range
P = Valve with internal return for total pressure range
2 IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 LP 1205GB

E-mail: info@imo.se, Web: www.imo.se July 2001
Identification of safety instructions Safety instructions which shall be considered for
Non compliance of safety instructions Safety instructions where reasons of safe operation of the pump or pump
identified by the following symbol - electrical safety is involved, unit and/or protection of the pump or pump unit
could affect safety for persons. are identified by: itself are marked by the sign:
ATTENTION
Installation
BEFORE COMMENCING ANY WORK, READ THIS INSTRUCTION CAREFULLY!
Design limitations and technical data for each pump are found in the Product description.
Installation of IMO AB low pressure pumps does not require special skills. However, these instructions
presume that the work is carried out by experienced fitters.
Maintenance and service instructions, which are specific for each pump are presented in a separate docu-
ment.
Failure to comply with these instructions

! may cause damage and personal injury!
Transport and storage

Always protect the pump against ingress of water
and other impurities. Store the pump in a clean, dry
and warm environment. The pump is delivered with
the internals oiled and with protective covers over
the pipe connections and drain openings. These
covers should remain in place for as long as possible
during the mounting and installation procedure but
must be removed before start up.
All work carried out on the pump has to be

! performed in such a manner that risks for
personal injury are observed!
Fig. 1 Clean and dry environment.
max 90°
Lifting of pump min 60°
max 90°
All pumps should be lifted with straps min 60°
! securely attached to the pump or pump unit,
so that the center of gravity is located be-
tween the straps in order to avoid tipping of
the pump.
Use two eye bolts (M 20) securely fastened to the max 90°
front cover for pumps LPQ and ABQ. Pump and min 60°
connecting frame are lifted together using two eye
bolts securely fastened to the top of the connecting
frame. (Thread dimension is M 16, except for frame
size 600, where it is M 20).
Fig. 2 Lifting of pump

LP 1205GB IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 3
July 2001 E-mail: info@imo.se, Web: www.imo.se
Lifting of the complete pump unit with the lifting
device attached to the motor, should be avoided as
A
the motor’s lifting provisions may not be able to
carry the combined weight of the pump and motor.
Lifting a complete pump unit, using slings

! or hooks attached to the pump or connecting
frame may be dangerous since the centre of
gravity of the pump unit may be higher than Distance Circular Angular
the points of attachments. between run-out alignment
coupling halves
t
Mounting
The pump must be securely mounted on a firm
stable foundation and positioned so that it is easily D
accessible for inspection and servicing.
Provisions for collecting oil spillage when servicing max
0.1°
the pump should be considered.
See table below D4 ø max 0.3 mm An angular

ATTENTION D6 ø max 0.4 mm
E4 ø max 0.4 mm misalignment of
The installation must always be designed to 0.1° corresponds to
minimise damage. Should an operational or approx. 0.2 mm
functional failure occur. E.g. precautions deviation/100 mm.
should be considered to collect oil spillage
due to a broken pipe or pump housing, to
stop pump operation if overheating should B
occur or if the oil volume is below a mini-
mum tank level.
Alignment and shaft couplings

The pump shall be connected to its driver via a
flexible shaft coupling. Pumps of type ACG/UCG
and ACF/UCF may also be driven via gears or
pulleys as specified in the Product Description,
ØD
provided the radial forces are kept within the

specified range.
x=y-t
t
An angular misalignment of 0.1° corresponds to X Y
approx. 0.2 mm deviation/100 mm.
The coupling and alignment shall be selected not to
transmit any axial or radial loads on the shaft ends.
IMO AB standard couplings shall have a distance
between the coupling halves as per table, fig 4. the
coupling halves shall be secured by lock screws.
For other types of couplings, please refer to respec-
tive maker’s manual.
Fig. 3 Alignment of the IMO AB standard coupling

When fitting the shaft coupling, do not use a
! hammer or similar as this may damage the
ball bearing and shaft seal.
Use some kind of press tool. Outer diameter Distance between Outer diameter Distance between
of coupling coupling halves of coupling coupling halves
(D mm) (t mm) (D mm) (t mm)
A B A B
When handling liquids that may harm skin 50 26 2.0 8 148 3.5
! use gloves and/or protective clothing. 67 40 2.5 16 168 3.5
82 55 3.0 18 194 3.5
97 65 3.0 20 214 4.0
112 80 3.5 24 240 4.0
128 95 3.5 26
When handling liquids which may involve
! fire hazards appropriate precautions to avoid Fig 4. Distance between coupling halves.
danger are to be taken. (IMO AB standard coupling)

Measures shall be provided to avoid acci- For direct driven pumps the alignment between
! dental contact with the rotating shaft cou- pump and motor shafts must be kept within the
pling. Any installed coupling guard following limits:
shall permit easy access to the pump shaft
for maintenance and inspection of the Max run-out Max angular
pump bearing and seal housing. misalignment
(mm) (degrees)
Type LPD
Pipe connections and ACD (n/a short coupled)
The pipe work shall be installed and supported so Other types 0.3 0.1
that no pipe stresses are transfered to the pump
body. Fig 5.
The pipe work should be tight in order to avoid
leakage and infiltration of foreign particles and/or
air.
Shut off valves should be installed in both suction
and discharge pipes, so that the pump can be hy-
draulically isolated.
Suction line
The suction pipe should be designed so that the total
pressure drop, measured at the pump inlet flange,
does not exceed the suction capability of the pump.
Make a proper calculation of the suction line includ- Fig. 6 Pipe connections
ing components such as valves, strainer, pipe bends
etc. Generally, the pressure drop in the suction line
should be as low as possible, which is achieved if the
suction pipe is short, straight and has a suitable
diameter.
The velocity in the suction line should be kept in the
range 0.5 - 1.2 m/s. For L.O. circulating systems, we
recommend to keep it as low as possible.
The suction line must be equipped with a port that
allows filling the pump before start.
Discharge line
The discharge line should be dimensioned to keep
the velocity in the range 1 - 3 m/s. Fig.7 Suction line
Deaeration
In installations with negative suction head, where
the pump might be started against a pressurized
system, a deaeration pipe with an orifice (2-3 mm
recommended) has to be installed. The deaeration
pipe should be connected to the outlet pipe’s highest
point.
This must also be installed when the pump is used
as an stand-by pump.
Fig. 8 Deaeration
Strainer
The pump has to be protected from foreign matter,
such as weld slag, pipe scale, etc., that could enter
the pump via the suction line. If the cleanliness of
the system cannot be guaranteed, a strainer must be
installed in the inlet pipe near the pump. For practi-
cal reasons a suction strainer with 0.5 - 2 mm mesh
openings is recommended:
Small pumps (LPD, ACD, ACE) 0.5-0.8 mm
Large pumps (ACG/UCG, ACF/UCF, LPQ,/ABQ)
0.8-2.0 mm
The size of the strainer should be selected so that it
is large enough to allow adequate pressure at the
pump inlet. The pressure drop across the strainer Fig. 9 Strainer
should preferably not exceed 0.1 bar at max. flow
rate and normal operating viscosity. A vacuum
gauge between the strainer and the pump inlet is
recommended to indicate when the strainer needs
cleaning.
Shaft seal drain

The pump should be installed so that any leakage
from the shaft seal does not become a hazard. As the
shaft seal has to be lubricated a small amount of oil
dripping cannot be avoided.
Provisions to collect the leakage from the shaft seal
must be made.
A drain pipe can be connected to the drain connec-
tion on the pump, (not applicable to pump series
LPD). However, when pumping heavy fuel oil or
any other liquid that is likely to become very viscous
at ambient temperature, we recommend that the
liquid is allowed to drop freely from the drain
;;;;
opening.
Fig. 10 Shaft seal drain
;;;;
SealGuard
;;;;
For heavy fuel oil high temperature applications, a
SealGuard should be applied to the pump. Further
information about SealGuard, read the Installation
and Start-up Instruction for SealGuard.
Liquid trap
In some mounting arrangements the pump may not
retain the liquid at stand still. In such installations
the suction pipe should be arranged so it forms a
liquid trap together with the pump, keeping the
pump half filled with liquid. See fig. 11.
Fig. 11 Liquid trap

Gauges
Gauges for monitoring the pump’s working condi-
tions are recommended. These gauges should be
placed readable as close to the pump’s in- and outlet
flanges as possible. On standard pumps, series ACE,
ACG/UCG, ACF/UCF and LPQ, there are gauge
connections for both in- and outlet.
bar
Fig. 12 Gauges
Pressure relief valve

All systems with screw pumps must be equipped
with a pressure relief valve installed immediately
adjacent to the pump.
In the standard versions of IMO AB low pressure
pumps, this pressure relief valve is an integral part
of the pump to protect the system against excess
pressure.
When liquid is circulated through the valve it heats
up in proportion to the set pressure level and the
percentage of by-passed liquid. 100% by-pass can
only be tolerated for less than about 3 minutes, 50 %
by-pass generally for unlimited periods of time. Fig. 13 Pressure relief valve
If more than 50% recirculation is anticipated, a value
specific to each application should be determined by
closely monitoring the pump body temperature.
If the pump is operating in line with a separate
pressure control valve (see fig. 13), the setting of the
relief valve should be high enough so as not to
interfere with the control valve. Likewise, if two
pumps are operating in parallel, the setting should
be such that interference between the two valves is
avoided.
Pressure testing and flushing

The system must be flushed and pressure tested
before connecting the pump. If corrosive liquid, such
as water is used, the system must be thoroughly
drained, dried and protected against corrosion after
having been flushed.
Oil leakage may make the floor slippery and

! cause personal injury.
Fig. 14 External control with pressure relief valve

Start-up
Before starting
After installation and whenever it can be assumed
that the pump has been emptied, the pump must be
thoroughly filled with liquid. See fig 15.
For ACE Generation 3, ACG Generation 6 and ACF
Generation 4 delivered after 1997, the pumps has
been fitted with deaeration plugs making venting of
the shaft seal compartment easy before start-up.
In installations with positive suction pressure: After
opening the inlet and outlet valves, simply open the
deaeration plug a few turns until oil sips out.
Tighten the plug.
In installation with negative suction pressure: After
opening the inlet and outlet valves, remove the
deaeration plug and fill the shaft seal compartment Fig. 15 Filling the pump
with oil. Fit and tighten the plug. See fig. 16.
Note! Not applicable on LPQ/ABQ.
Deaeration
plug
Deaeration
Make sure the prime mover is locked out plug
! and can not be started accidentally.
ACE
Rotate the shaft by hand while filling the pump, to Deaeration
ensure that the rotor bores and the shaft seal cavity plug
is filled. On the smaller pumps: (LPD, ACD, ACE,
ACG/UCG), this is done by rotating the fan on the
electric motor after removing the fan cover.
ACG
Do not forget to fit the motor fan cover again
! before making start of motor possible.
IMO AB
Deaeration plug
On the ACF/UCF, LPQ and ABQ pumps, the pump
can be turned using the shaft coupling. If the suction
pipe cannot be completely filled, it is important to
ensure that the trapped air is evacuated without any
pressure build up. (See fig. 8 Deaeration).
ACF
ATTENTION
Starting a dry pump is likely to cause
damage, especially to the shaft seal.
Fig. 16 Deaeration plugs
Direction of rotation
When the pump is ready to be started, switch the
motor briefly on and off and check that the drive
motor rotates in the correct direction as indicated by
the rotation arrow.
The arrow is placed on different spots depending on

the pump series.
ATTENTION
Don't mix up with arrow for inlet and outlet!
Fig. 17 Direction of rotation

Starting 3. Turn the upper screw and continue to reduce the
Check that all valves necessary for the operation are noise level. (If turned too much the noise will
fully opened in both discharge and suction lines. increase again).
The first time, the pump should be started with the 4. Repeat item 2. and 3. in order to achieve the
adjusting spindle of the pressure relief valve tight- lowest possible noise level.
ened to half of the available turns (the valve setting
Setting of tuning of the ACG/UCG and ACF/UCF:
is increased when the spindle is turned clockwise).
By monitoring the pressure gauge it can be deter- 1. Before starting the setting, check that the setting
mined when the suction line is primed and the screw (8 mm: ACG/UCG, 12 mm: ACF/UCF,
pump begins to work. Should the pump not operate socket head cap screw on the discharge side) are
normally soon after start, stop the pump within half closed.
a minute. Start again after about 3-5 minutes (the 2. Turn the screw CCW until the noise level be-
shaft seal must have time to cool off) and run for comes the lowest (if turned too much the noise
half a minute. This procedure may need to be will increase again).
repeated a couple of times if the suction line is
Once set, the tuning needs no further adjustment,
extremely long. Should the pump still not work, it
providing the operating conditions stay the same.
must be assumed there is a problem in the system
that needs to be remedied. Check the suction line NOTE: It´ s not possible to accidentally turn the
calculation on page 5 and/or see ”Trouble shoot- tuning spindle too far.
ing”, page 10.
If operating temperature exceeds 60°C
Pumps with external ball bearing including ! (149°F), appropriate measures to avoid
! grease nipple, must be regreased after one skin contact shall be provided.
hour of running, while the pump is
operating
Use hearing protections whenever high
! noise can be expected from pump, motor
Setting the pressure relief valve and/or environment.
The setting of the opening pressure is made as
follows: Tighten the valve spindle by rotating
clockwise to the maximum extent. The system
pressure is regulated by throttling to required value.
The pressure relief valve is eased until the pressure
is just beginning to decrease by turning the spindle
CCW. The valve is now preset for desired opening
pressure. Open the throttling valve entirely.
NOTE: The set screw on LPD is hidden behind a
plate.
Adjusting the tuning

The tuning adjustment, which is a standard feature
on ACF/UCF and LPQ (option on ACG/UCG and
ABQ) pumps, is a device for minimizing the effects Fig. 18 Adjusting the tuning
of dissolved and free air in lube oil systems. The
tuning principle is described in the Product Descrip-
tion.
The tuning should be adjusted while the pump is
working under normal operating conditions. This is
done by turning the tuning spindle with an Allen
key (size 8 mm for ACG/UCG , 12 mm for ACF/
UCF and LPQ ) to a position where the noise level
comes to a minimum. On a double acting pump like
the LPQ pump, there are two tuning valves, which
must be adjusted individually.
Setting of tuning of the LPQ:
1. Before starting the setting check that both setting
screws (8 mm socket head cap screw on the
discharge side) are closed.
2. Turn the lower screw until the noise level obtains
a minimum.(If turned too much the noise will
increase again).

Trouble shooting
Problem Cause What to do
Wrong direction of rotation - Electric cables to motor wrongly Reverse the terminal connection
connected. on electric motor.
Connecting and discon-

necting of electric cables
must be done only by
personnel authorized to
do such work.
The pump cannot be primed - Wrong direction of rotation. See above.

- Suction line is not open or Check all components in suction
pressure drop in the suction line line. The inlet condition should
is too high. be checked with a vacuum
gauge at the pump inlet.
- Major air leakage into the Check the suction line.
suction line.
- The pump cannot evacuate the See the chapter on Deaeration
air through the discharge line (see page 5).
due to excessive counter
pressure.
No flow - The pump is not primed. See above.
- The pressure relief valve is set Readjust the pressure relief
below the counter pressure. valve to a value above counter
pressure.
Flow too low - The pressure relief valve is set Readjust the pressure relief
too low (Discharge pressure also valve
low).
- Something is restricting the flow Check all components in the
in the suction line. (This would suction line (strainers, valves
usually cause noise). etc.).
- The pumped liquid contains a See the chapter on Noise and
significant amount of com Vibration. ( Page 11).
pressible gas, such as free air.
(This would usually cause
noise).
Pressure too low - The pressure relief valve is set Readjust the pressure relief
too low. valve.
- Counter pressure in the dis- Check the components in the
charge line is too low due to a discharge line inclusive the
major leakage. recipients.
- The valve piston is stuck in open Check the valve. See Mainte-
position. nance and Service instruction for
respective pump.
- Something is restricting the flow Check all components in the
in the suction line. (This would suction line (strainers, valves
usually cause noise). etc.).
- The pumped liquid contains a See the chapter on Noise and
significant amount of com- Vibration. ( Page 11).
pressible gas, such as free air.
(This would usually cause
noise).
- A too small pump has been Contact your IMO AB
chosen. representative.

Disturbance Cause What to do
Pressure too high - The pressure relief valve is set Readjust the pressure relief valve.
too high.
- The oil is too cold (or has higher Reduce the pressure setting until
viscosity than anticipated). operational temperature has been
reached.
- Counter pressure in the dis- Check the discharge line.

charge line is too high.
Drive motor difficult to start - Counter pressure too high. See above: Pressure too high.
or tends to stop by tripping
the motor overload relay - Liquid too cold. Readjust the pressure relief valve
to a lower value. Thus the power
consumption for the pumping is
relieved and overloading due to
the high viscosity may be
avoided. When the liquid has
reached normal temperature and
thus flows easily, the relief valve
is reset to normal pressure.
- Motor is undersized for the Check the motor.

prevailing conditions.
- Electrical power supply faulty. Check the motor and motor

connection.
- Motor overload relay set too low Readjust or replace the relay.
or is faulty.
- Incorrect setting of Y/D starter. Readjust the setting of the start-

ing sequence. The time before the
motor overload relay is tripped
should not exceed 10-15 seconds.
Noise and vibrations - The flow to the pump is insuffi- See chapter: The flow is too low.
cient.
Monitor the pump - Insufficient support of pipe Check for pipe vibrations in the
! function and shut down work. pump connections. Check that
if any sign of mal- the pipes are sufficiently
function is noticed. clamped.
- Bad alignment Check alignment, see page 4.
- Air leakage into the suction line. Check the suction line for air
leakage.
- Free air in the liquid or gas For pumps with Tuning:

cavitation. Adjust the Tuning. If this does
not help or for pumps without
Tuning: Contact your IMO
representative or IMO service
dept.
- Faulty electrical supply. Check all three phases of the

supply.

Screw pumps
A Member of the
COLFAX PUMP GROUP
ACE3
Maintenance and Service
Instruction
This instruction is valid for all ACE pump models shown on page 2
Contents Page
List of components 2
Exploded view 3
Ordering code/Service intervals 4
Sectional view 5
Useful tools/Shaft seal-assembly drawing 6
Dismantling/reassembly 7
Pressure relief valve/SealGuard 11
ACE 0620GB
June 2000
Before commencing any work, read this instruction carefully! Failure to comply with
! these instructions may cause damage and personal injury!
For more information about the pumps identification code, technical data and performance we refer to the
ACE Product description. For more information about the pumps installation, Start-up and trouble shooting
we refer to the IMO Installation and Start-up instruction for Low Pressure Pumps.
List of components
Valid for all pumps in sizes: ACE 025/032/038 Rotor diameter and Generation: L3/K3/N3
With version codes: N V B P Also valid for pump options: A101
T The version code is composed of the letters in the 4 columns.
Q Example of pump designations std: ACE 025L3 NTBP;
option: ACE 038N3 NVBP A101
Components included in spare parts sets:
Pos Denomination Q-ty G011 G012 G050 G053 G054 G057 G070 G082 Notes Explanations:
no
1010 Power rotor 1 x (x)
1020 Power rotor 1 x x G011: Rotor set
113 Key 1 x x x
122 Ball bearing 1 x x x G012: Rotor set
125 Secondary seal 1 x x x x 1
201 Idler rotor 2 x (x) G050: Shaft seal
202 Idler rotor 2 x x
351 Balancing bush 1 x x x G053: Minor kit
401 Pump body 1
416 Suction flange 1 G054: Major kit
417 Screw 8
418 Gasket to 1 x x x G057: Joint kit
suction flange
423 Gasket to 1 x x x G070: Valve element
discharge flange
427 Discharge flange 1 G082: Seal Guard kit
440 Return valve 1
451 Screw 4 Notes:
453 Screw 4 1) Version NTBP
462 Plug 1 and NQBP
462A Sealing washer 1 x x x 2) Version NQBP
463 Plug 1 only
463A Sealing washer 1 x x x 3) Including
501 Front cover 1 Gasgenerator
506 Gasket 1 x x x
509 Shaft seal 1 x x x
537 Deaeration plug 2
537A Washer 2 x x x
551 Rear cover 1
556 Gasket 1 x x x
557 Plug 1
557A Washer 1 x x x
605 O-ring 1 x x x x
608 Valve spindle 1 x x
608A Tension pin 1 x x
6120 Set screw 1 x x
613 Pin 1 x x
614 Valve piston 1 x x
615 Valve spring 1 x x
7310 Compl. Seal 1 x 2,3
Guard
732 Gas generator 1 x 2
ACE 0620GB 2
June 2000
Exploded view
202
1020
113
351
122
509
462
462A
417 416
418
427
xVxx
453
423
xTxx
xQxx
551
537 556
537A
(608A)
451 463 463A 401
440 (605)
506 (608)
537A 537
(6120)
(613)
557A 557 (615)
(614)
125 501 7310
732
xTxx, xQxx xQxx
xQxx
Fig. 1
All work carried out on the pump has to be When handling liquids which may involve
! performed in such a manner that risks for ! fire hazards appropriate precautions to
personal injury are observed! avoid danger are to be taken.
When handling liquids that may harm skin In case of failure for a system with elevat-
! use gloves and/or protective clothing. ! ing pressure fluid jets may cause injury
and/or damage.
Before any maintenance work, ensure that
! the driver is deenergized and the pump Oil leakage may make the floor slippery
hydraulically isolated. ! and cause personal injury.
Connecting and disconnecting of electric

cables must be done only by personnel
authorized to do such work.
3 ACE 0620GB
June 2000
Ordering code
Part numbers for pump size
Item Spare Parts sets 025 032 038 Recommendation:
For maintenance the following spare
G012 Rotor set CW-rotation (std) part sets are recommended:
Low lead-L3 190486 190485 –
Low lead-K3 – – 190482 Set: To be used:
Normal lead-N3 190487 190484 190483 G057 Joint kit
G011 Rotor set CCW-rotation For dismantling the pump.
Normal lead-N3 190492 190491 190488
G050 Shaft seal-xVxx 189964 189964 189964 G053 Minor kit
Shaft seal-xTxx 190495 190495 190497 For service.
Shaft seal-xQxx 190495 190495 190497
G054 Major kit
G053 Minor kit-xVxx 190501 190710 190500 For repair after damage or greater
Minor kit-xTxx 190503 190712 190499 wear.
Minor kit-xQxx 190503 190712 190499
G054 Major kit=G012(G011)+G053+G070
Ordering example:
G057 Joint kit-xVxx 190525 190714 190522 For IMO-pump ACE 032N3 NVBP,
Joint kit-xTxx 190524 190713 190523 serial number 456789:
Joint kit-xQxx 190524 190713 190523 Shaft seal pos G050 p/n 189964
G070 Valve element 189873 189873 189873 Valve element pos G070 p/n 189873
G082 Sealguard-kit xQxx 190526 190526 190527
125 Secondary seal xTxx, xQxx 190469 190469 190468
732 Gas generator xQxx 190530 190530 190530
Service intervals Inspection of shaft seal

The intervals for inspection and replacement of wear Excessively leaking shaft seals (more than 10 drops
parts vary greatly with the properties of the pumped per hour) should be changed without delay, as the
liquid and can only be determined by experience. leakage normally will grow worse and cause addi-
Pumping liquid which contains abrasive materials, tional damage.
or liquid that is corrosive, will significantly reduce In installations where unplanned shut downs must
service life and call for shorter service intervals. be avoided, it is advisable to dismantle the pump for
Wear will normally show as unnormal: a thorough inspection and thereby change out shaft
• Vibration seal and ball bearing, every three years as a max
period.
• Noise It is recommended always to have the spares in-
• Loss of capacity cluded in minor spare part kit available.
• Reduction in flow/pressure
• Leakage Inspection of rotors
A quick inspection of the idler rotors can be made
If the pumps operating temperature exceeds simply by removing the rear cover. Note that the
! 60°C let the pump cool off before any service, driver must be deenergized and the pump hydrauli-
maintenance or dismantling work is com- cally isolated before the rear cover is removed.
menced to avoid burn injury. If a more thorough investigation is needed, proceed
as under ”Dismantling/Reassembly”.
ACE 0620GB 4
June 2000
Sectional view
125 (xTxx, xQxx)
C-C E-E
463 463A
732
7310
537 537A
(xQxx)
Fig. 2
5 ACE 0620GB
June 2000
Useful tools
d
Allen key Fine Oil can

5 mm and emery
3 mm Mounting tool kit
D
Plastic D= 25,5 mm Screw
Screw mallet driver
spanner
16 mm
Puller
Tool 1 Tool 2
Sliding calliper
For dimension and material,
please contact IMO AB Service.
Fig. 3
Shaft seal - assembly drawing

Shaft seal G050 (509)
Seat slot
S2 S6 S4 S8
S7 S1 Version code xVxx
Front S1 Seat
cover S2 O-ring
retaining S4 Seal ring
tab S6 O-ring
S7 Spring unit
S8 Stop screw
Seat retaining lug
Stationary member Rotating member
S5 S8 Version code xTxx

S3 S2 S1 S4 S7 S6 S1 Seat
S2 O-ring
Seat slot
S3 Retainer
S4 Seal ring
S5 Carrier
S6 O-ring
S7 Spring unit
S8 Stop screw
Retainer lug
+ Secondary seal 125
Stationary member Rotating member
Version code xQxx
S4, S7 is one unit
xTxx + Complete
SealGuard 7310
Fig. 4
ACE 0620GB 6
June 2000
Dismantling
B.
A. OFF ON
• Turn the electricity OFF.
• Close the valves.

• Remove the pump
from the system.
ATTENTION
Use appropriate vessels to collect oil spill- • Note the position of the shaft coupling.
age when removing and opening the pump.
• Release the stop screw.
Fig. 5 Fig. 6
C. D.
113
• Remove the shaft • Remove the key 113.

coupling.
Fig. 7 Fig. 8
E. F. 1020
451
5011
• Remove the • Remove the front cover 501 and power

screws 451. rotor 1020.
Fig. 9 Fig. 10
7 ACE 0620GB
June 2000
G. H. xTxx and xQxx
501 125
501
1020
• Separate the front

cover 501 and the
power rotor 1020.
• Remove the secondary seal 125 with a
suitable screw driver.
Fig. 11 Fig. 12
I. J. xVxx
xTxx
xQxx
501
xVxx
• Place the front cover 501 on a pair of

wooden pieces.
• Press out the shaft seal, stationary member
• Loosen the shaft seal rotating member.
with a suitable tool.
Fig. 13 Fig. 14
K. xTxx and xQxx L. 202

Rotating
Member
• Insert two suitable

screw drivers in the
carrier S5 slots and
gently push the
rotating member
S4, S7 off the rotor
shaft.
S8 S5
• Loosen the two
stop screws S8
(3 mm Allen key)
on the carrier S5 • Remove and inspect the
and pull it off. idler rotors 202.
Fig. 15 Fig. 16
ACE 0620GB 8
June 2000
Reassembly
B.
A. • Un-pack a new shaft seal 509.
202
S8
xVxx xTxx, xQxx S8
S6 S6
S4 S5
401
• Lubricate S4,S7
the idler rotors 202 • Check that the O-ring S6 is in place.
and fit them into the pump body 401.
Fig. 17 Fig. 18
Oil can
C. xVxx D. xTxx and xQxx
S5 Emery
122
• Polish the power rotor shaft
1020 with a fine emery and oil.
• Fit the carrier S5 tight against the
ball bearing. Make sure the carrier
is not fitted upside down.
Rotating
• Firmly tight the two stop screws S8. member
• Lubricate the O-ring S6 in the rotat-
ing member with oil.
• Polish the power rotor shaft
• Press the rotating member S4, S7
1020 with a fine emery and oil.
gently on to the rotor shaft and make
• Fit the rotating member above sure the driving lugs enters the slots
the ball bearing 122 and lock it in the carrier S5.
with its stop screws S8.
Fig. 19 Fig. 20
E. F. xTxx and xQxx
1020
Tool 1 1 2 Tool 2
125
401 • Press the Secondary
seal 125 in place with
a suitable tool in two
steps as shown. Use a
column drill machine
as a press tool.
NOTE! 501
Tool nr 2 has
one end for sizes
025, 032 and one
• Insert the Power rotor 1020 into the pump
body 401. end for size 038
Fig. 21 Fig. 22
9 ACE 0620GB
June 2000
G. xVxx H. xTxx and xQxx Tool 1
Tool 1
S1
• Fit the spring unit S7 in place. • Fit the retainer S3 S2
Note the position for the Seat S1 in place. Note the
slots and lugs. position for the S3
S2 501
(See fig 4.) retainer lugs and
• Lubricate the O-ring S7 cover slots.
501 (See fig 4.)
S2 and put it on the
seat S1. Fit the seat • Lubricate the
S1 on top of the O-ring S2 and
spring unit. Watch put it on the
position of the Seat seat S1. Fit the seat S1
slots and lugs. on top of the retainer.
(See fig 4.) Watch the position of the seat
• Press the seat gently into the recess in the slots and lugs. (See fig 4.)
front cover 501 with a suitable tool as • Press the seat gently into the recess in the
shown. front cover 501 with a suitable tool as shown.
• Turn the front cover 501 up-side down. The • Turn the front cover 501 up-side down. The
seat shall now remain in the cover. seat shall now remain in the cover.
Fig. 23 Fig. 24
I. J.
451
501
506 • Fit the screws

451.
• Tight them crosswise,
step by step to avoid
deformation on bearing
• Replace the gasket outer ring and seal
506. damages.
• Carefully fit the • Turn the shaft to check
Front cover 501 on that it moves without
the pump. too much force.
Fig. 25 Fig. 26
K. L.
• Press on the shaft coupling
to its original position.
• Tighten the stop screw.
• Install the pump

back into the
113 system and proceed
according to in-
structions under
• Fit the key 113 back in place. ”Start-up” in the
Installation manual.
Fig. 27 Fig. 28
ACE 0620GB 10
June 2000
453
551
ATTENTION
Spring tension.
• Release spring tension by turning set screw 6120 612

6120
CCW as much as possible. 605
• Loosen and remove the screws 453.

• Separate the valve element from the rear cover
551.
556
• If necessary, replace the gasket 556 and the
O-ring 605.
• Reassemble the parts in reverse order. Be careful
to tighten the screws 453 crosswise.
• Readjust the valve pressure according to the
”Installation and Start-up Instruction for IMO Fig. 29
Low pressure pumps”.
SealGuard
Version code N Q B P
Recharging
1) Disconnect the pipe connector (4) from the ATTENTION 9
0 12
6
1 3
dispenser (2). Remove the check valve (3). The SealGuard can be
readjusted or switched off
2) Remove the cover disk (10). Remove the gas Gas generator
during operation.
generator (9) from the dispenser (2) with a 21 10
Depending on temperature
mm socket. Dispose the generator in the recyc-
and setting, it can take from 9
ling system for batteries, where available. Push
hours to a couple of days
the piston to its ”filled” position, and fill the
after starting, until oil is 2
dispenser with high-temperature resistant engine
being dispensed.
oil. Fit the check valve (3) and the connector (4)
to the dispenser.
1
3) Feed oil into the hose (5) and seal compartment,
For more information about
for example with an oil-filled grease gun. Recon-
SealGuard, read the Installa-
nect the hose (5) to the connector (4). 3
tion and start-up Instruction
4) Fit a new gas generator (9) to the dispenser (2). for SealGuard. 4
Tighten with approx. 2 Nm. Clip on the cover
disk (10). Note!
Must be open
5) Turn the gas generator set knob (3 mm Allen
key) to no. 6 which will make the oil last for
about 3 months.
5
NOTE!
For longer periods of stand-by, the gas gene-
rator set-knob could be set to zero to avoid
unnecessary oil consumption. 8 7
6
Keep away from open fire when

!
removing the gas generator.
Fig. 30
11 ACE 0620GB
June 2000
Screw pumps
ACG/UCG
Maintenance and Service
Instruction
ACG1 © IMO AB
This instruction is valid for all ACG/UCG pump models shown on page 2
Contents Page
List of components 2
Exploded view/Ordering code 3
Service intervals 4
Shaft seal/Service for ball bearing 4
Lubricating intervals/Useful tools 5
Inspection of rotors 5
Sectional view 6
Dismantling 7
Reassembly 9
Pressure relief valve 11
ACG 0620GB
September 1999
Before commencing any work, read this instruction carefully! Failure to comply
! with these instructions may cause damage and personal injury!
For more information about the pumps identification code, technical data and performance we refer to the
ACG/UCG Product description. Fore more information about the pumps installation, Start-up and trouble
shooting we refer to the IMO Installation and Start-up instruction for low pressure pumps.
List of components
Valid for all pumps in sizes: ACG/UCG 045/052/060/070; Rotor diameter and generation: K6/N6
With version codes: I T B E Also valid for pump options: A020, A101, A327
N V F O Example of pump designations
R P std: ACG 045N6 IVBP; option ACG 070N6 IVBO A101
G
Qty Components included in Spare parts sets: Explanations:

G011: Rotor set
PosNo Denomination G011 G012 G050 G053 G054 G057 G070 Note CCW-rotation option
1010 Power rotor CCW-rot. 1 x (x)
1020 Power rotor CW-rot. 1 x x G012: Rotor set
106 Balancing piston 1 x x x 5 CW-rotation (std)
113 Shaft key 1 x x x
120 Distance sleeve 1 G050: Shaft seal
122 Ball bearing 1 x x x
124 Retaining ring 1 x x x G053: Minor kit
124A Support ring 1 x x x (G050 + G057)
133 Dust protection ring 1 x x x
201 Idler rotor CCW-rot. 2 x (x) G054: Major kit consisting
202 Idler rotor CW-rot. 2 x x of: G053+G012 (G011)
359 Distance washer 1 +615
359A Support ring 1 x x x
401 Pump body 1 G057: Joint kit
424 Sleeve 1 4
424A Washer 1 4 G070: Valve element
429 Spindle 1 4
437 O-ring 1 4 ACG Pump with DIN
440 Return valve 1 flanges
451 Screw 4/6
453 Screw 4 UCG Pump with ANSI
462 Plug 2 1 flanges
462A Sealing washer 2 x x x 1
473 Grease nipple 1
473A Grease nipple cover 1 Notes:
480 Valve housing 1 2 1) Excluded in xxxG
5010 Front cover 1 2) Excluded in xxxE
502 Tension pin 1 6 3) Valid for xxxE
502A Plug 1 6 4) Valid for pump option
506 Gasket 1 x x x A327
509 Shaft seal 1 x x x 5) Included in item 1020
514 Retaining ring 1 x x x or 1010
520 Cover 1 6) Included in item 5010
520A Screw 4
537 Plug 2
537A Sealing washer 2
545 Tension pin 1 6
551 Rear cover 1 3
556 Gasket 1 x x x
601 Valve cover 1 x 2
602 Sealing washer 1 x x x x 2
605 O-ring 1 x x x x 2
606 Valve housing plug 1 x 2 IMO AB
ACG2 © IMO AB
607 Sealing washer 1 x x x x 2

608 Valve spindle 1 x 2
608A Retaining ring 1 x 2
612 Set screw 1 x 2
614 Valve piston 1 x 2
615 Valve spring 1 x x 2
Name plate of the pump
631 Dog washer 1 x 2
ACG 0620GB 2
September 1999
Exploded view
551 453
ACG/UCG xxBE/BO/BP/BG xxxE 462
462A
608A
462 601
401 602
556 480
537 453 605
5010
537A
608
462
612
506 462A
451 615
462 631
607 614
124A 122 120
606
124
520
133 xxxO/xxxP
359 202 453

514 480
520A
359A 473A
537 473 xxxG
537A 607
Vxx
T 606
iion x
VVeerrss 113
202
1020
509
CW rotation 201
ACG3 © IMO AB
113
Details in pump option A327

xxxx See the sectional view p. 6 1010
onnxxVT
Veerrssiio
CCW rotation (non-standard)
Fig. 1
Ordering code
Pos Spare parts sets Part numbers, sizes Recommendation:
No 045 052 060 070 For maintenance the
following spare part
Rotor set CW-rotation (std): sets are recommen-
G012 Normal lead - pump version N6 178913 179507 179515 179523 ded:
" Low lead - pump version K6 187542 187559 187567 187575 Set: To be used:
G057 Joint kit
Rotor set CCW-rotation (non-std): For dismantling of
G011 Normal lead - version N6 186478 186486 186494 186502 the pump
Low lead - version K6 189641 189642 189643 189644
G050 Complete shaft seal - version code xVxx 190335 190336 190338 190340 G053 Minor kit
” ” - version code xTxx 174094 174102 174110 174128 For service
G053 Minor kit - version code xVxx 189196 189198 189200 189202 G054 Major kit
” ” - version code xTxx 189197 189199 189201 189203 For repair after
G054 Major kit=G012(G011)+G053+615 - - - - damage or greater
wear.
G057 Joint kit 179531 179549 179556 179564
Ordering example:
G070 Valve element - version code xxxP/G 190201 190201 190202 190202 For IMO-pump ACG 045N6
” ” - version code xxxO 190200 190200 190203 190203 IVBP, serial number 456789
Shaft seal
615 Valve spring - version code xxxP/G 074294 074294 074302 074302
pos G050 p/n 176198
” ” - version code xxxO 157370 157370 157388 157388
Valve spring
Fig. 2 pos 615 p/n 074294
3 ACG 0620GB
September 1999
Service intervals Inspection of shaft seal
The intervals for inspection and replacement of wear As the seal faces of a mechanical shaft seal are
parts vary greatly with the properties of the pumped lubricated by the fluid a certain leakage will always
liquid and can only be determined by experience. be present. Ten drops per hour can be considered as
All internal parts of the ACG-pump are lubricated acceptable.
by the pumped liquid. Pumping liquid which An external visual inspection of the pump is advis-
contains abrasive materials, or liquid that is corro- able at least every two days to assure that the shaft
sive, will significantly reduce service life seal is not leaking too much.
and call for shorter service intervals. Excessively leaking shaft seals should be changed
Wear in the pump may be indicated by: without delay, as the leakage normally will grow
• Vibration worse and cause additional damage.
• Noise Follow the instructions in the dismantling/reassem-
bly session.
• Loss of capacity
When working with a shaft seal, cleanliness is of
• Reduction in flow/pressure utmost importance. Avoid touching the seal faces. If
• Leakage necessary, the seal faces should be cleaned immedi-
In installations where unplanned shut downs must ately prior to assembly, using a dustfree cloth and
be avoided, it is advisable to have a complete pump clean solvent.
available for replacement, should any malfunction Never use grease on the seal faces.
occur. Furthermore we recommend planned inspec-
tion and overhaul at regular intervals, not exceeding Connecting and disconnecting of electric
3 years. ! cables must be done only by personnel
It is recommended always to have the spares in- authorized to do such work.
cluded in minor spare part kit available.
If the pumps operating temperature exceeds
All work carried out on the pump has to be ! 60°C let the pump cool off before any
! performed in such a manner that risks for service, maintenance or dismantling work is
personal injury are observed! commenced to avoid burn injury.
Shaft seal - assembly drawing

Shaft seal G050 (pos 509)
S1 Seat
S2 O-ring
Version code xTxx S4 Seal ring
S5 Seal ring carrier
ATTENTION S6 O-ring
Be careful to mount S7 Spring
these parts in right S2 S1 S4 S6 S9 S7 S5 S9 Stop washer
order and in right
direction. S1 Seat
ACG8 © IMO AB
S2 O-ring
Version code xVxx S4 Seal ring
S5 Bellows unit
S2 S1 S4 S5
Fig. 3
Service for ball bearing

The ACG-pump is fitted with an external grease Use an appropriate type of grease, as per table and a
lubricated ball bearing. grease gun suitable for grease nipple (pos 473)
When delivered from IMO AB, the ball bearings in according to DIN 71 412 (ISO 6392).
pump version xRxx and xVxx are filled with grease On vertical mounted units the greasing intervals are
of type B. For version xTxx, type C is used. reduced to half.
Whenever the ball bearing is removed, it is recom- Installed in dusty or dirty premises or in a corrosive
mended to exchange it for a new one. environment it should be lubricated at more fre-
Fit the new ball bearing properly greased and quent intervals.
regrease it after one hour of running, while the If using others than these recommended greases
pump is operating. check if it is possible to mix them with each other,
otherwise clean before using a new grease.
ACG 0620GB 4
September 1999
Lubricating intervals in working hours
Temp Pump sizes 045 and 052 Pump sizes 060 and 070
max Grease Speed, r/min Speed, r/min
°C type 3500* 2900 1750 1450 1150 950 3500* 2900 1750 1450 1150 950
70 A 8500 10000 10000 10000 10000 10000 7500 8500 10000 10000 10000 10000
90 A 3350 3950 5350 5950 6350 7500 2950 3350 4750 5150 5950 6750
110 B 2650 3150 4250 4700 5000 5950 2350 2650 3750 4100 4700 5350
130 B 1050 1250 1650 1850 2000 2350 900 1050 1500 1600 1850 2100
155 C 650 750 1050 1150 1250 1500 600 650 950 1000 1150 1300
*) at rotation speed > 3 500 r/min special instructions are given by IMO AB.
Recommended greases (the availability of the greases can differ locally):
Type A: BP Energrease LS 3, Esso Beacon 2, Mobilgrease HP 222, Shell Alvania G3, Texaco Multifak EP2, SKF LGMT2,
Q8 REMBRANDT EP2, CASTROL APS2, ELF ROLEXA 3, TOTAL MULTIS TIR EP3, FINA MARSON L3.
Type B: BP Energrease LC2, CHEVRON SRI GREASE 2, Esso Unirex N3, Mobilith SHC220, SHELL RETINAX LX,
SHELL Albida LX, VAL-PLEX EP GREASE, Texaco Hytex EP2, SKF LGHQ 3, Q8 RUBENS, CASTROL LMX,
INDUSTRIAL GREASE HEAVY, TOTAL MULTIS THT2, FINA PLUTON L2.
Type C: Mobilith SHC 460
When handling liquids which may involve

Pump size 045 052 060 070 ! fire hazards appropriate precautions to
Grease amount (g) 4 6 7 9 avoid danger are to be taken.
Before any maintenance work, ensure In case of failure for a system with elevated
! that the driver is deenergized and the ! pressure, fluid jets may cause injury and/or
pump hydraulically isolated. damage.
Useful tools Inspection of rotors

If an indication of a worn pump is noticed (see service
intervals above), a brief inspection of the idler rotors
is recommended.
A quick inspection of the idler rotors can be made
simply by removing the rear cover or valve cover.
Note that the driver must be deenergized and the
pump hydraulically isolated before the rear cover is
removed. Provisions to handle the fluid are to be
ACG7 © IMO AB
made. If a more thorough investigation is needed,

Plastic Pair of
mallet pliers proceed as under ”Dismantling”.
Puller Internal clearances in the pump, which are vital for its
Slide calliper proper function, may have been affected by wear.
Acceptable wear can be determined only by experi-
d
ence of the actual application. As a rule of thumb the
following max clearance values may apply:
L • Between rotor and bores or bushings: 0.2 mm
GREASE
• Between rotor flanks: 0.4 mm
Allen Fine Oil can Grease For light duties (low pressure, medium viscosity)
keys D emery even bigger clearances may be acceptable but for low
Moun- 2 pcs of visc./high pressure duties the limit will be lower.
ting screw Also check if there are major scratches on these parts.
sleeve driver
Mounting sleeve dimensions When handling liquids that may harm

Pump size D d L Part No ! skin use gloves and/or protective clothing.
ACG/UCG 045 ø 25.0 ø 21.0 100 188887
ACG/UCG 052 ø 31.0 ø 26.0 100 188888
ACG/UCG 060 ø 35.0 ø 31.0 100 188889 Oil leakage may make the floor slippery
ACG/UCG 070 ø 42.0 ø 36.0 100 188890 ! and cause personal injury.
Fig. 4
5 ACG 0620GB
September 1999
Sectional view
506 440 556
(502A) 537A 537 608A

601
(502) 602
520A 605
520 612
122 615
124A 608
124 614
1020 631
133 480
514 462
520 462A
359 607
451 606
5010 473 473A (545) (106)
401 202 453

509
359A
120
537 537A
Version xxBO and xxBP
Version xxBO and xxBP
608A
601
602
556
605
551
612
462A 615
424A 462 608
424 614
437 480
ACG5 © IMO AB
ACG6 © IMO AB
429 631
607
556 606
Option A327 Version xxxE Version xxxG
Fig. 5
ACG 0620GB 6
September 1999
Dismantling
A. B.
• Turn the
electricity OFF.
• Close the valves.

• Remove the pump ACG9 © IMO AB
from the system.
ACG10 © IMO AB
ATTENTION
Use appropriate vessels to collect oil spill- • Note the axial position of the shaft coupling.
age when removing and opening the pump.
• Release the stop screw.
Fig. 6 Fig. 7
C. D.
113
• Remove the shaft • Remove the key

coupling. 113.
ACG12 © IMO AB
ACG11 © IMO AB
Fig. 8 Fig. 9
E. F.
133
451
520
4 mm 124
• To remove the dust
124A
protection ring 133
520A
514 and the cover 520,
lift the cover 520
with two screw
drivers from the
shaft.
ACG13 © IMO AB
• Remove the re-

taining rings 124
ACG14 © IMO AB
and 514.
• Remove the sup-
• Remove the screws 451 and 520A. port ring 124A.
Fig. 10 Fig. 11
7 ACG 0620GB
September 1999
G. H.
122
120
359
359A
• Remove the • Push out the ball

front cover 5010
bearing 122 together
5010 with a with the distance
sleeve 120. If there is
ACG15 © IMO AB
puller.
5010 tight fit use a mount-
ing sleeve and a
mallet.
ACG16 © IMO AB
Fig. 12 • Remove the distance
washer 359 and the
Mounting support ring 359A.
I. sleeve
Fig. 13
S1
S2
No tools
J – xVxx.
506 from this Shaft seal S4
side
5010 Version xVxx
S5
The sealing
! surfaces of the S4
shaft seat
ACG17 © IMO AB
should not be S5
touched with
the fingers.
• Turn the front cover 5010 upside down.

• Push out the seat from the front cover 5010.
ACG18 © IMO AB
• Remove the o-ring S2.

• Remove the gasket 506.
1020
Fig. 14
• Pull the power rotor 1020 out of the pump
body and place it into the jaws of a jaw vice
J – xTxx. with soft jaws or a column drilling machine.
Shaft seal • Unscrew the • Push with two drivers as shown on the
Version xTxx seal ring sketch, to remove the shaft seal.
carrier S5
S4 screws and
Fig. 15
take off the
S6 seal ring
carrier S5
S5
together with
the seal ring S4 K. 202
• Take out the
and the o-ring idler rotors.
S6.
• Clean all parts
that are going
to be used
ACG20 © IMO AB
again.
ACG19 © IMO AB
Fig. 16 Fig. 17
ACG 0620GB 8
September 1999
Reassembly
A. B–xVxx.
202
Version xVxx • Carefully place the
• Lubricate the power rotor 1020
idler rotors and into the jaw vice
fit them into the with soft jaws.
pump. • Lubricate all
Lubrication S4 surfaces of the
groove turned power rotor 1020.
ACG21 © IMO AB
downwards. S5
• Open a package
with a new sealing
509, version xVxx.
1020
• Place the bellows
Fig. 18
S5 and the seal
ACG22 © IMO AB
ring S4 on the shaft
of the power rotor
B–xTxx. 1020.
Version xTxx
• Open a package
with a new shaft Fig. 19
seal 509 version
xTxx.
• Lubricate the O-
S4 • Place the seal ring
S6 ring S2 and the
carrier S5 on the C.
S5 recess of the front
shaft of the power
cover 5010.
rotor 1020 flush S1
Balance against the bal- • Clean the sealing
piston ance piston and S2 faces and fit the
lock it with its seat S1 into the
stop screws. Fit front cover 5010.
Mind the position
ACG24 © IMO AB
the o-ring S6 and

ACG23 © IMO AB
the seal ring S4. of the retaining

5010 pin if applicable.
Fig. 20 Fig. 21
D. Mounting sleeve
122
120 Grease • Lubricate the balance piston 106 with a
thick oil (ISO VG 460).
359 • Fit the front cover 5010 on the power rotor
1020 and press the shaft seal 509 into place
359A with the front cover 5010.
• Fit the support ring 359A and the distance
5010 washer 359 into the front cover. Mind the
1020 position of the distance washer 359.
• Fit the distance sleeve 120 into the front
cover 5010.
106
• Lubricate the new ball bearing 122 and
press it into the front cover 5010 with a
mounting sleeve. Make sure that the power
rotor is standing on firm support.
Fig. 22
9 ACG 0620GB
September 1999
E. 133
520
• Fit the support ring 124A and the retain-
124 ing ring 124 on the shaft.
124A • Fit the retaining ring 514 back in place.
• Place the cover 520 and the dust protec-
514 tion ring 133 on the shaft according to the
dimensions A above. If there is a tight fit
use the mounting sleeve, see page 5.
G26 © IMO AB
Fig. 23
F. G.
520A Pump size A A
045-052 4.0 mm
060-070 4.5 mm
• Fit the screws
520A and
tighten them
crosswise. ACG27 © IMO AB
ACG28 © IMO AB
133
Fig. 24 Fig. 25
H. Only use a mallet on the shaft coupling

• Fit the key back in position, see fig. 9. ! if the power rotor is standing on firm
• Fit the shaft coupling back into place, support. If not, heat up the coupling half
(see fig. 7 and 8) and lock with locking screw. before mounting.
Fig. 26
I. 537
537A
• Remove the plug 537 and washer 537A.
• Hold the rotor unit horizontally with the
bore for 537 upwards. Carefully fill the
space completely with thin oil
(f. ex. ISO VG 46).
• When the oil is flooding, reassemble the
above parts in reverse order.
1020
• Slowly turn the shaft a few turns to make
sure it moves freely (a certain resistance
5010 from the shaft seal is normal but it must be
the same during the turns).
Fig. 27
ACG 0620GB 10
September 1999
J.
• Place the gasket 506 on the pump body 401.
• Lubricate the power rotor 1020 and fit the
451 front cover 5010 together with the rotor set
into the pump body. Mind the position of
the tension pin 545.
5010
• Fit the screws 451 and tighten them cross-
wise.
1020
506
ACG29 © IMO AB
401
Fig. 28
K.
• Put the pump back into the system and
proceed according to instructions under
”Start-up” in the installation manual.
Fig. 29

ATTENTION
608A
Spring tension.
601
Version
• Release spring tension by turning the spindle 608 P and O 602
480
CCW with an allen key. 453 605
• The valve piston 614, the dog washer 631 and 462
608
valve spring 615 can be pulled out by unscrew-ing 612
the plug 606. 462A
615
• To replace the O-ring 605 do as follows: 462 631
- Unscrew the valve cover 601. 607 614
606
- Remove the retaining ring 608A.
- Pull off the valve spindle 608 from the valve
housing 480.
Version G
- Replace the O-ring 605.
453
ACG30 © IMO AB
- Reassemble in reversed order. 480

• Readjust the valve pressure according to the
”Installation and Start-up Instruction for IMO
Low pressure pumps”. 607
606
Fig. 30
11 ACG 0620GB
September 1999
IMO AB: P.O. Box 42090, S-126 14 STOCKHOLM, Sweden. Telephone: + 46 8 50 622 800
Telex: 11548 IMO S, Telefax: + 46 8 645 15 09, E-mail: info@imo.se
Valve block for dual pump installation
In all application were there is a demand for two pumps, either for redundancy or for operational
reasons, a valve block is an option to save space and installation cost.
The valve block can be equipped with IMO ACE series of pumps that have a flow range up to
11 m3/h.
The valve block is a substitute for a number of components normally installed in a dual pump
application such as:
• Welding joints
• Shut off valves on in and outlet side
• Non return valves
• Strainers
• Pressure gauge adapters
System drawing of the T5 Valve Block. In a conventional system each component has to be added
manually
11
10
8
2
7 6 5
Components
1. Valve Block Body

2. Inlet pressure gauge adapter (Outlet pressure gauge on backside of block, not shown)
3. In and outlet flange set, including bolts, washers and o-rings
4. Shut off valves inlet side
5. Drainage plug
6. Combined shut off and non return valves, outlet side
7. Outlet valve covers, including bolts, washers and o-rings
8. Inlet valve covers, including bolts, washers and o-rings
9. Blind flanges for optional in and outlet position, including bolts, washers and o-rings
10. Filter baskets
11. Filter chamber covers, including bolts, washers, gaskets, plugs and protection plate
Function of the valve block
The block is equipped with inlet and outlet ports on both sides; hence there are several options for
inlet outlet configurations. The valve block is delivered with one set of inlet - outlet flanges and
one set of blind flanges.
The inlet and outlet chambers are equipped with a shut off valves regulated by an Allen key if one
of the pumps or the filter has to be removed during operation. The shut off valves on the outlet side
are a combined non return valve that prevents reversed flow through the non operating pump.
Before the inlet of the pump, flow passes through the filter chamber equipped with 500 µm
strainers. The covers for the filter chambers are equipped with de-pressurizing plugs and a
protection cover to avoid opening when the chambers are pressurized.
In the lower end there is a drainage plug to drain the valve block in case of service or inspection.
Cross section of the T5 Valve Block showing the inlet flow passing by the open shut off valve
through the strainer and into the pump. From the pump the flow is transported to the outlet side
were the combined shut off/non return valve is located.
Operating modes
1. One pump in operation and one in stand-by

2. Both pump are operating
The valve block can be equipped with different size pumps to full fill three flow demands;
Low flow pump in operation, large flow pump in operation, both pumps in operation.
Accessories
Additional flange set

Pressure gauge panel set
• Panel stand
• 2 inlet pressure gauges and 2 outlet pressure gauges.
• Root valve or 3 way test valve
• Seal pot
Spare Parts – Repair – Maintenance
CONTOIL® control (VZF / VZFA) DN 15…50

standard (VZE / VZEA)
classic (VZO / VZOA)
VI 14-419 def 09.2006 1

Table of Contents Page
Meter configuration .................................................................................................................................... 3
Supplementary Instructions ....................................................................................................................... 3
Version of Measuring chamber .................................................................................................................. 3
List of Spare parts and part numbers ........................................................................................................ 4
Flow sensors for CONTOIL® .........................................................................................................................................................4
Screw torque ..................................................................................................................................................................................4
VZF(A) Meter with transducer and multifunctional display ..............................................................................................................5
Conversion Kit VZE(A) / VZO(A) to VZF .........................................................................................................................................5
VZE(A) Meter with electronic counter .............................................................................................................................................6
VZE(A) Meter with electronic counter and NAMUR pulser type INA ...............................................................................................6
VZO(A) Meter with roller counter 130°C / 180°C ............................................................................................................................7
VZO(A) Meter with roller counter and Reed pulser type RV 130°C ................................................................................................ 8
VZO(A) Meter with roller counter and Reed pulser type RV 180°C ................................................................................................ 9
VZO(A) Meter with roller counter and NAMUR pulser type IN 10
........................................................................................................
Figures ...................................................................................................................................................... 11
Fault analysis ........................................................................................................................................... 14
Repair instructions and trouble shooting ................................................................................................ 15
2 VI 14-419 def 09.2006

Meter configuration
VZO / VZOA
VZF / VZFA VZE / VZEA
Transducer Ancillary modules
130°C / 180°C 70°C / 130°C / 180°C
Flow sensors
130°C / 180°C
CONTOIL® oil meters consist of a flow sensor and a measurement transducer with display, totaliser and signal
outputs where applicable. The flow rate range determines the nominal size of the flow sensor. The measurement
transducer is either one complete ("universal") unit (e.g. VZF) or is a combination of ancillary modules (transducer
group) which can be chosen to suit a particular application ( VZO, VZE).
The flow sensor and the measurement transducer are calibrated jointly and form one metering unit.
If the measurement transducer is replaced at a later stage, a certain divergence in measured values is to be
expected.
Supplementary Instructions
Part number
Mounting instructions
20288
CONTOIL® DN15 … 50
Operating instructions
20312
CONTOIL® classic: VZO / VZOA, standard: VZE / VZEA
Operating instructions
20313
CONTOIL® control: VZF / VZFA
Conversion Kit for CONTOIL® classic and standard to VZF
20328
Version of measuring chamber

Measuring chamber, single part with integrated flange Measuring chamber with separate flange
DN 20 all
DN 40 serial no. ≤ 3'741'525 DN 15/25 all
DN 50 serial no. ≤ 3'587'216 DN 40 serial no. > 3'741'525
DN 50 serial no. > 3'587'216
Description Quantity Part number
VI 14-419 def 09.2006 3

CONTOIL® Flow sensors for : VZF(A) / VZE(A) / VZO(A)
DN15 DN20 DN25 DN40 DN50

Housing (no spare part)
Cap nut for version USA 2 37470 2961 2887 -- --
Inlet filter 1 12968 19021 12969 12970 12971
Gasket, FPM 1 13002 13002 12985 12985 12985
PN 16,25 1 12856 19008 12861 12859 12860

Cover of the measuring chamber PN 40 1 12857 19389 12862 12864 12866
Gasket, FPM 1 13003 19020 16028 12994 13004
max. 130 °C 1 19154 19155 19156 19157 19383

Driver max. 180 °C 1 19095 19045 13160 13161 13162
1 12790 19022 12881 12882 12883

Rotary piston
max. 130 °C 1 13024 19848 12963 12965 12967

Separating plate max. 180 °C 1 13025 19390 13026 13027 13028
VZFA / VZEA / VZOA max. 130 °C 1 20003 20005 20008 20011 20013
Guide roller VZFA / VZEA / VZOA max. 180 °C 1 13146 19391 13147 13148 13149
VZF / VZE / VZO max. 130 °C 1 20004 20006 20009 20012 20014
VZF / VZE / VZO max. 180 °C 1 19163 19763 19164 19165 19166
PN 16 1 -- 19007 -- -- --
Measuring chamber PN 25 1 12841 19032 12851 19551 19506
PN 40 1 12842 19387 12844 19550 19507
DN 40, DN 50:
When replacing a measuring chamber with integrated flange by the current version, the two
following positions (flange and screws) are needed too. See remark on page 3.
PN 16 1 12874
Flange of measuring chamber PN 25…40 1 12877
PN 16…40 1 -- -- 12978 19547 19508
M 6 x 16 PN 16 4 12958 -- -- -- --
Screws M 6 x 16 PN 25/40 6 12958 -- -- -- --
M 6 x 12 PN 16 4 -- 19035 -- -- --
M 6 x 16 PN 25/40 6 -- 12958 -- -- --
M 8 x 25 6 -- -- 13101 -- --
M 12 x 40 8 -- -- -- 19548 --
M 16 x 50 10 -- -- -- -- 19549
Screw torque
Nominal size DN 15 DN 20 DN 25 DN 40 DN 50
Screws M6 M6 M8 M 12 M 16
Screw torque 6 Nm 6 Nm 16 Nm 47 Nm 100 Nm
4 VI 14-419 def 09.2006

Meter with transducer and multifunctional display VZF / VZFA
DN15 DN20 DN25 DN40 DN50_
Transducer with display130 / 180 °C 1 20319 20320 20321 20322 20322

(incl. material for fastening)
Conversion Kit
DN15 DN20 DN25 DN40 DN50_
Conversion kit CONTOIL to VZF130 / 180 °C 1 20319 20320 20321 20322 20322
(incl. manuals)
This conversion kit upgrades the VZO(A) or VZE(A) to the VZF version to take full advantage of
all the functions offered by the new transducer.
Modifying a Meter
All ancillary modules are to be replaced. The flow sensor remains in place throughout.
A power supply of 6 to 30 V DC is required.
The electronics has preset values for each nominal diameter being used. Individual preadjustment to a particular
hydraulic sensor must be carried out by personnel installing the kit.
The electronic and insulation modules are a single unit. Modifying a meter invalidates any type approval that may
have been issued. (Exception: type approval for ships. GL, DNV and LRS remain valid). Modifying a meter used in
custody transfer applications is not permitted.
VI 14-419 def 09.2006 5

Meters with electronic register
Cover 1 13423 13423 13423 13423 13423
M 6 x 16 max. 70 °C 4 12958 12958 12958 12958 12958

Screws M 6 x 93 130 / 180 °C 4 13167 13167 13167 13167 13167
Head ring RW 1 12903 12903 12903 12903 12903
Electronic register, Litres or US gallons 1 19757 19757 19757 19757 19757
max. 70 °C 1 13221 13221 13222 19740 19741

Adaptation piece 130 / 180 °C 1 19742 19743 19744 19745 19746
VZE / VZEA with pulser INA
Cover 1 13423 13423 13423 13423 13423
M 6 x 55 max. 70 °C 4 12959 12959 12959 12959 12959

Screws M 6 x 93 max. 180 °C 4 13167 13167 13167 13167 13167
Head ring RW 1 12903 12903 12903 12903 12903
Electronic register, Litres or US gallons 1 19757 19757 19757 19757 19757
max. 70 °C 1 19747 19748 19749 19750 19751

Pulser module (without detector ) max. 180 °C 1 19752 19753 19754 19755 19756
Plug-in detector INA 1 13240 13240 13240 13240 13240
following accessories included
Contact pins 4 5560 5560 5560 5560 5560
Plug body 1 13243 13243 13243 13243 13243

Options
Plug-in detector for Japan 1 20080 20080 20080 20080 20080
cable mounted 1 80019 80019 80019 80019 80019
6 VI 14-419 def 09.2006

Meters with roller register

VZO max. 130°C
Cover 1 13423 13423 13423 13423 13423
M 6 x 16 4 12958 12958 12958 -- --

Screws M 6 x 55 4 -- -- -- 12959 12959
Head ring RW 1 12903 12903 12903 12903 12903
Roller counter, litres 1 40247 40250 40252 40236 40237
or
Roller counter, US gallons 1 40255 40256 40257 40260 40260
Adaptation piece 1 13221 13221 13222 -- --
Adjustment gear, litres 1 -- -- -- 12943 12888
or
Adjustment gear, US gallons 1 -- -- -- 19451 19452

VZOA / VZO max. 180°C
Cover 1 13423 13423 13423 13423 13423
M 6 x 16 4 12958 12958 12958 -- --

Screws M 6 x 55 4 -- -- -- 12959 12959
Head ring RW 1 12903 12903 12903 12903 12903
Adjustment gear, litres 1 12889 12944 12942 12943 12888
VI 14-419 def 09.2006 7

Meters with pulser RV

VZO… RV max. 130°C
Cover 1 13423 13423 13423 13423 13423
M 6 x 16 4 12958 12958 12958 -- --

Screws M 6 x 55 4 -- -- -- 12959 12959
Sight glass 1 13558 13558 13558 13558 13558
Head ring RV, without sight glass 1 13070 13070 13070 13070 13070
RV 0.1 l 1 40248
Roller counter, litres RV 1 l 1 40249 40251 40253 40240
RV 10 l 1 40241 40242
RV 100 l 1 40243
or
RV 10ppg 1 40261 40262
Roller counter, US gallons RV 1ppg 1 40263
RV 0.1ppg 1 40264 40264
Adaptation piece 1 13221 13221 13222 -- --
Adjustment gear, litres 1 -- -- -- 12943 12888
or
Adjustment gear, US gallons 1 -- -- -- 19451 19452
8 VI 14-419 def 09.2006

Meters with pulser RV

VZO… RV max. 180°C
Cover 1 13423 13423 13423 13423 13423
Screws M 6 x 55 4 12959 12959 12959 12959 12959
Sight glass 1 13558 13558 13558 13558 13558
Head ring RV, without sight glass 1 13070 13070 13070 13070 13070
RV 0.1 l 1 40238 -- -- -- --
Roller counter, litres RV 1 l 1 40239 40245 40240 40240 --
RV 10 l 1 -- 40246 40241 40241 40242
RV 100 l 1 -- -- -- -- 40243
or
RV 10ppg 1 -- -- -- -- --
Roller counter, US gallons RV 1ppg 1 -- -- -- -- --
RV 0.1ppg 1 -- -- -- 40264 40264
or
Adjustment gear, US gallon 1 19449 19075 19450 19451 19452
VI 14-419 def 09.2006 9

VZO/VZOA Meters with pulser IN

VZO… IN / VZOA … IN
Cover 1 13423 13423 13423 13423 13423
Screws M 6 x 93 4 13167 13167 13167 13167 13167
VZOA / VZO max. 180°C additionally

4 13166 13166 13166 13166 13166
Extension
Head ring RW 1 12903 12903 12903 12903 12903
or
Roller counter, US gallons 1 40258 40259 40259 40260 40260
IN 0,01 l 1 13261 13261 -- -- --

Pulser module without detector IN 0,1 l 1 -- -- 13261 13261 --
IN 1 l 1 -- -- -- -- 13261
or
IN 1000ppg 1 13261 -- -- -- --
Pulser module, US gallons IN 100ppg 1 -- 13261 13261 -- --
IN 10ppg 1 -- -- -- 13261 13261
Plug-in detector IN 1 13240 13240 13240 13240 13240
following accessories included
Contact pins 4 5560 5560 5560 5560 5560
Plug body 1 13243 13243 13243 13243 13243
Options
Plug-in detector for Japan 1 20080 20080 20080 20080 20080
cable mounted 1 80019 80019 80019 80019 80019

or
Adjustment gear, US gallon 1 19449 19075 19450 19451 19452
VZOA / VZO max. 180°C additionally
Isolating piece (incl. screws and extensions) 1 13172 13172 13172 13172 13172
10 VI 14-419 def 09.2006

figures

Housing and sealing face

Positioning of rotary piston within measuring chamber

Positioning of driver within cover of measuring chamber

Positioning of cover and measuring chamber

Location of Gaskets

Positioning of housing onto measuring chamber
VI 14-419 def 09.2006 11

Fault analysis
Fault symptoms Possible causes Procedures 1)

• Pointers on roller counter • This is normal at high flow rates • No action required
rotate irregularly and has no effect on accuracy of
measurement
• Counter runs backwards • Meter mounted in wrong direction • Install meter with arrow pointing in
flow direction
• No reading 2)3) • No power supply 2) • Check wiring
• Battery discharged 3) • Replace battery
• Transducer defective 2) • Replace transducer
• Electronic counter defective 3) • Replace electronic counter
• Counter not running • Flow rate outside allowed range • Check flow rate
• No flow rate indicated 2) 3) (below Qmin or above Qmax of • If too high, reduce flow or install
• Indicated quantity or flow meter) larger meter
rate too small • If too low, increase flow or install
smaller meter
• Moving parts heavily worn out due • install larger meter
to continuous overload
• Dirt trap / filter heavily soiled • Clean dirt trap, replace filter
• Safety filter in meter intake clogged • Replace safety filter
• Install dirt trap / filter with correct
mesh size
• Moving parts jammed • clean measuring chamber, replace
defective parts
• Separating plate broken by • Check and rectify operating
o Pressure hammer conditions and meter position
• Fill pipes slowly
o Gas inclusions
• De-aerate pipes thoroughly
• Indicated quantity or flow • Meter positioned wrongly (e.g. at • Check and rectify operating
rate too high highest point) conditions and meter position
• Gas or air inclusion in fluid • De-aerate pipes carefully
• pressure drop at meter too • Dirt trap or filter heavily soiled • Clean dirt trap, replace filter
high
• No frequency signal 2) • No flow • Check flow using Indication
• No current signal 2) • Wrong parameterisation 2) • Set correct parameters for outputs
• No pulse output signal • Transducer defective 2) • Replace transducer
• Pulser sensor defective 4) • Replace sensor
• Pulser module defective 4) • Remove sensor and check if pulser
disk does rotate
• Pulser disk does not rotate 4) • Remove pulser module, place
counter on first module, and check
flow indication
• If indication is positive, replace
pulser module
• otherwise see ‘Counter not running’
• Reed pulser defective 5) • Replace roller counter
1) Consult operating instructions
2) CONTOIL® control VZF, VZFA only
3) CONTOIL® standard VZE, VZEA only
4) pulser type IN / INA only
5) pulser type RV only
12 VI 14-419 def 09.2006

Repair instructions and trouble shooting
This meter is a measuring instrument and should be treated accordingly.
Fuel Oil meters must only be tested and operated with fluids with lubricating properties!
The electronic transducer has to be replaced completely as it cannot be repaired.
Safety notes
⋅ The applicable working regulations must be complied with during all work on the plant
⋅ When removing from pipe or reinstalling, safety instructions in the operating manual must be observed.
⋅ Extra caution is required when using inflammable cleaning substances. Room must be ventilated well.
⋅ Prior to disassembly, the measuring instrument must be free from dangerous or noxious residues. Clean and
rinse thoroughly as necessary.
Repair instructions for measuring sensors

Detaching of measuring chamber
Mark or memorise markings (dot, dash, embossment) at measuring chamber and housing.
⋅ Remove screws of measuring chamber.
⋅ Remove measuring chamber and cover from housing.
⋅ Remove deposits from housing surface and seating using fine emery cloth (Fig. 1).
⋅ Clean housing connections with a cloth.
⋅ For cleaning the use of non-fraying cloths and kerosene or solvents is recommended.
Replacing of filter
When removing the filter, small chips may form, which must not be allowed to enter the measuring chamber.
Therefore its recommended to remove the housing from the measuring unit first (as above).
⋅ Pull filter out using a screwdriver or similar and replace it.
⋅ Put new filter in place. Press the metal ring into position using an appropriate tool (cylindric bar).
Take care, not to press on the bottom of the filter!
⋅ Rinse housing or remove possible chips with a cloth.
Cleaning or repairing measuring unit
⋅ Pull off cover from measuring chamber.
⋅ Remove driver, rotary piston, separating plate, and guide roller from measuring chamber. Clean and check if
worn or damaged. Replace such parts and clean all others.
Assembly of measuring chamber
⋅ Place guide roller onto pin at bottom of measuring chamber.
⋅ Insert separating plate into measuring chamber.
⋅ Insert the rotary piston with eccentric driver pin (∅ 3 mm) pointing upwards into the measuring chamber.
Position it so that the driver pin and separating plate lie on one axis.
Note: The centric guide pin of the rotary piston is now seated in the bottom of the measuring chamber
⋅ Place the driver onto the pin of the cover of the measuring chamber and align the driver’s long, deep groove
to the axis of the separating plate (Fig. 3).
⋅ Place cover of measuring chamber with aligned driver onto the measuring chamber, so that the separating
plate and driver pin of the rotary piston engage into the corresponding groove and driver (Fig. 4).
The cover should be flush and the rotary piston should move freely.
Mounting of measuring chamber
⋅ Fit the new gaskets lightly greased with silicon (Fig. 5).
⋅ Align inlet/outlet openings of the housing to the openings in the cover of the measuring chamber (Fig. 6).
⋅ The openings must correspond to each other.
⋅ Join housing and measuring chamber and check the markings
Align marking (dot, dash, embossment) on the measuring chamber base at right angles to the meter axis.
⋅ Insert measuring chamber screws and tighten them with correct torque (see page 4).
Repair instructions for ancillaries

The modules are not screwed together individually and may fall apart when being dismounted.
⋅ Mark or memorise the position of lid, modules and pulser connection in relation to the meter housing.
⋅ Remove Allen screws.
⋅ Lift off head ring with cover and counter module with spring ring.
⋅ Replace worn or damaged modules.
After replacement of adjustment gear, the meter is considered to be uncalibrated.
⋅ Reassemble in reverse order.
VI 14-419 def 09.2006 13

Aquametro AG Aquametro SA Aquametro Aquametro Aquametro s.r.o.
Messtechnik GmbH BELGIUM SPRL
Ringstrasse 75 Rue du Jura 10 Zum Panrepel 24 Dallaan, 67 Prosecká 811 / 76a
CH-4106 Therwil CH-1800 Vevey D-28307 Bremen B-1933 Sterrebeek CZ-190 00 Praha
Tel. 061 725 11 22 Tel. 021 923 51 30 Tel. 0421 / 871 64-0 Tel. 02 / 241 62 01 Tel. 02 / 86 88 77 78
Fax 061 725 15 95 Fax 021 922 58 44 Fax 0421 / 871 64-19 Fax 02 / 216 22 63 Fax 02 / 86 88 95 59
info@aquametro.com info@aquametro.com info.amd@aquametro.com info.amb@aquametro.com info.amc@aquametro.com
14 VI 14-419 def 09.2006

INSTRUCTIONS FOR SHELL & TUBE HEATER
Instruction Manual
TM
for VESTA MX
Table of contents for instruction manual
1. General Description......................................................................................... 1
2. Installation Space Requirements ..................................................................... 2
3. Storage............................................................................................................. 2
4. Mounting and Installation ............................................................................... 2
5. Connecting the Heat Exchanger ...................................................................... 3
6. Operation ......................................................................................................... 3
7. Conservation during shut down periods .......................................................... 4
8. Maintenance and Cleaning .............................................................................. 4
9. Dismantling and reassembling of the tube section .......................................... 5
10. Safety measures ............................................................................................... 5
11. Spare Parts ....................................................................................................... 6
Appendix:
- Spare Parts Drawing
- Dimensional Drawing
1. General Description
Aalborg Industries' Vesta MX heat exchangers are of the shell and tube type with
u-tubes.
The Vesta MX heaters range from 0,5 m² to 60 m² heating surface with design
pressures 16 or 30 BAR.
Other capacities may be manufactured at request.
All heaters may be delivered as immersion or outflow heaters for insertion in
tanks.
Vesta MX heat exchangers are primarily used as fuel oil, lubrication oil, or water
heaters (JCW).
The heating media used is either steam, hot water or thermal oil.
Safety valve, thermometer, and pressure gauge may be mounted on a standard

outlet tube (optional).
Regulating equipment for either oil, steam or water is optional.
Vesta MX heat exchangers have been type approved by all major classification
societies.
2. Installation Space Requirements

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

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

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

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

The heat exchanger is designed for vertical or horizontal installations.
In case of horizontal installation, the inlet pipe and media outlet pipe must face
upwards.
Instruction manual for heat exchanger type VESTATM MX 2/8

Manufactured in Aalborg, Denmark
APR. 2001, rev. 3 – Project specification deleted. OKT 2002, rev. 4 – Reference to steam replaced with
heating media. DEC 2005 T30 series torque added.
C:\Documents and Settings\LJW\바탕 화면\F.O SUPPLY UNIT 업무 관련 사항\MANUAL\3.HEATER_1_2.doc
If the heater is placed vertically the inlet and outlet tubes as well as the media
inlet must be at the bottom and the heater must be equipped with an air escape
screw at the top end.
The steam regulator (optional) must always be placed horizontally.
The steam trap (optional) should be mounted as close to the condensate outlet as
possible and somewhat lower. The steam trap is always to be placed horizontally.
Place the heater on the surface and drill the holes for the foundation bolts. Place
the bolts into the holes and tighten up at one end, while the other is left suffi-
ciently loose to allow for movement caused by thermal expansion. The bolts at
the expansion end must be secured with counter nuts.
5. Connecting the Heat Exchanger

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

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

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

MX25 12 M24 137 1 7 11 4 9 2 6 12 5 10 3 8

MX30 12 M24 186 1 7 11 4 9 2 6 12 5 10 3 8
MX40 16 M27 245 1 9 5 13 8 16 12 4 15 7 3 11 6 14 10 2
Heater main flange bolts tightening schedule (dry & smooth values) – T30 types
No bolts Size Torque [Nm] Tightening schedule
MX15 8 M16 164 14725836
MX20 12 M20 158 1 7 11 4 9 2 6 12 5 10 3 8
MX25 12 M20 234 1 7 11 4 9 2 6 12 5 10 3 8
Always use a torque wrench when tightening the flange bolts.
Both sides of the heater must be carefully vented and the circuits carefully in-
spected for leakage during the whole start-up period.
6.4. Output
The output of the heater is subject to the supply of heating media at the inlet
steam valve. The steam pressure/heating media temperature applied, is to be ac-
cording to heater size calculation.
The output is furthermore subject to correct type of steam trap being used. Cor-
rect layout of the condensate system avoids negative effect of counter pressure.
7. Conservation during shut down periods

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

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

8.2. Cleaning of tubes

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

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

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

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

During installation, commissioning, operation and maintenance, the following
measures must be observed:
10.1. Installation
10.1.1. Lifting
When lifting the heat exchanger, following methods are allowed:

a) Two or four point lifting with straps and shackles in the holes or lifting lugs
on the mounting brackets.
b) Two point lifting with wide support straps around the heater body.
Other ways of lifting the heat exchanger may damage it or cause risk of dropping
it.
10.1.2. Connecting the flanges

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

The heat exchanger is a part of a large pressurised system, and does as such not
carry an individual warning sign. This is considered unnecessary, since there are
no quick opening devices on the pressure part and since safety valves and valves
for drain and venting must be installed with discharge piping.
10.2.2. Maintenance
During disassembly, inspection, reassembly and testing it is important that safety
measures of this manual as well as the ships safety procedures are observed. The
fluids in the systems can be both hot and flammable as well as posing a health
risk if ingested. Therefore it is important that proper depressurising, isolation and
draining is performed, as well as spillage control during disassembly and clean-
ing. Procedures for reassembly must be followed and the mandatory pressure test
be carried out with great care. Insulation and splash guards must be fitted during
recommissioning.

11. Spare parts

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

Operating instructions for automatic filter
Type 6.72.1
Nominal diameter DN 65
Filter element Filter candle
Print document on both sides
NOTE:
Siemensstraße 10 - 14
50170 Kerpen
Germany
www.bollfilter.de
Date Version Language Order No. Item No.

08.2009 001 en - -
1/72
2 / 72 Operating instructions 6.72.1
Betriebsanleitung 6.72.1
Table of Contents
1 Preamble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Obligations of the user/operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Selection and qualifications of staff . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.6.2 Maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7.1 Filtered media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7.2 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Transportation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Packaging material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Overview of automatic filter assembly group . . . . . . . . . . . . . . . . . . 15
5.3 Overview of bypass filter and plug valve circuit assembly group. . . 19
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.1 Special safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 Filter installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2.1 Floor fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2.2 Installation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2.3 Identifying the flow direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2.4 Filter inlet/outlet pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.5 Flushing oil outlet pipe connection. . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.6 Filter heating (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.7 Connection of compressed air supply . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.8 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2.9 Potential equalisation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1 Functional description of the automatic filter . . . . . . . . . . . . . . . . . . 29
7.1.1 Filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1.2 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1.3 Differential pressure monitoring system . . . . . . . . . . . . . . . . . . . . . 29
7.1.4 Air tank and flushing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1.5 Pivoting actuator (pneumatic) with limit switch . . . . . . . . . . . . . . . . 32
7.1.6 Flushing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Operating instructions 6.72.1 3 / 72

7.1.7 Filtration stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.1.8 Backflushing stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
7.2 Functional description of the plug valve switch-over circuit . . . . . . . 37
7.2.1 Pressure compensation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.3 Functional description of the bypass filter . . . . . . . . . . . . . . . . . . . . 39
7.3.1 Housing cover safety device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.4 Automatic filter filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.4.1 Filter insert with filter candles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.4.2 Functional description of the filter insert with filter candles . . . . . . . 41
7.5 Bypass filter filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.5.1 Star-pleated filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.5.2 Functional description of the star-pleated filter element . . . . . . . . . 43
7.6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.6.1 Determination of time interval for time-controlled backflushing . . . . 45
7.7 Removal from service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.7.1 Short-term removal from service . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.7.2 Longer term removal from service / removal . . . . . . . . . . . . . . . . . . 46
7.7.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8 Maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.2 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.3 Special tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
8.4 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8.5 Cleaning/replacing the filter element on the automatic filter . . . . . . 51
8.5.1 Preparatory work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.5.2 Removing the filter insert with filter candles. . . . . . . . . . . . . . . . . . . 54
8.5.3 Cleaning the filter insert with filter candles. . . . . . . . . . . . . . . . . . . . 55
8.5.3.1 Cleaning the filter candles in case of stubborn soiling . . . . . . . . . . . 56
8.5.4 Installing the filter insert with filter candles. . . . . . . . . . . . . . . . . . . . 57
8.5.5 Concluding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.6 Cleaning/replacing the filter element on the bypass filter . . . . . . . . 59
8.6.2 Removing the star-pleated filter element . . . . . . . . . . . . . . . . . . . . . 60
8.6.3 Cleaning the star-pleated filter element . . . . . . . . . . . . . . . . . . . . . . 61
8.6.4 Installing the star-pleated filter element . . . . . . . . . . . . . . . . . . . . . . 62
8.6.5 Concluding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
8.7 Manually backflushing the filter in the event of power failure. . . . . . 63
8.8 Remedying faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.8.1 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
9.1 Supplier's documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9.2 Cleaning devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
9.3 BOLL CLEAN 2000 cleaning agent product information . . . . . . . . . 69
9.4 Worldwide sales and service network, subsidiaries and
representatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

1 Preamble
1.1 General
These operating instructions are designed to make it easier to get to know the
BOLL & KIRCH filter and make use of its proper intended uses.
The operating instructions contain all important instructions on how to operate
the filter safely, properly and economically. Adherence to the operating
instructions helps to prevent hazards, repair costs and reduce down times and
increase the reliability and even the serviceable life of the filter. Read the
operating instructions carefully and attentively.
Supplement the operating instructions with any instructions required due to
existing national and international regulations for the prevention of accidents and
environmental protection. Make sure that the operating instructions are always
available in the place of use for the filter. The operating instructions must be read
and applied by every person given the task of performing the following work:
• transportation,
• installation,
• operation,
• maintenance and servicing,
• Disposal.
1.2 Warranty and liability

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

1.3 Copyright
These operating instructions are a certified document as per the terms of the law
against unfair competition.
The copyright of the document is held by

BOLL & KIRCH Filterbau GmbH
50170 Kerpen
Germany
These operating instructions are for the user of the filter and the user's staff. They
contain text and drawings which, without the express permission of the
manufacturer must not be
• reproduced,
• distributed or
• otherwise made available to others, either in full or in part.
Failure to comply will require compensation.

2 Basic safety instructions
2.1 Proper use
The filter is constructed with state-of-the-art technology and according to the
recognised rules of safety. However, use of the filter may result in risks to the life
and limb of the user or third parties and/or damage to the filter or other objects of
material value.
Only use the filter if it is in a technically perfect condition and only use it properly;
paying due attention to safety and hazards, and in adherence to the operating
instructions. It is particularly important to remedy any faults (or have them
remedied), which may compromise safety.
The filter is designed for filtering liquid media only. The filter is designed for
installation in pipelines. The type of medium agreed in the order, and the limit
values for operating pressure and temperature as set out in the technical data
sheet, must be adhered to. Any other type of use or use going beyond this use,
is regarded as improper use. The manufacturer/supplier shall not be liable for
any damage caused as a result of improper use. The user bears the sole risk.
Proper use includes observance of the operating instructions and adherence to
the inspection and maintenance conditions.
Operationally safe function is only ensured if all the instructions, settings and
performance limits for the filter, are adhered to.
2.2 Warnings and symbols

The following designations and symbols are used in the operating instructions to
denote particularly important information:
DANGER!
Denotes immediate hazard with high risk which will cause death or serious
physical injury if not avoided.
WARNING!
Denotes possible hazard with medium risk which may cause death or serious
CAUTION!
Denotes a hazard with low risk which could cause light or medium physical injury
or material damages if not avoided.
NOTE
Denotes special user tips and other particularly useful or important information.
DISPOSAL
Denotes special measures for environmental protection.
2.3 Target group

The operating instructions apply for use by qualified specialist staff only.

2.4 Obligations of the user/operator
• Always keep the operating instructions at hand at the place of use of the filter.
• Adhere to general legal and other binding regulations for the prevention of
accidents and environmental protection, and provide supplementary
instructions in the operating instructions accordingly. This type of obligation
can apply to the handling of hazardous substances or the provision/wearing
of personal safety clothing and equipment, for instance.
• Supplement the operating instructions with your own instructions, including
supervision and reporting obligations for specific operational matters, e.g.
with regard to organisation of work, working sequences and the appointed
staff.
• Observe all existing safety instructions and hazard warnings on the filter.
• Keep all existing safety instructions and danger signs on the filter complete
(in number) and in a legible condition.
• Do not make modifications of any kind to the filter which may compromise
safety, without the permission of the manufacturer.
• The spare parts which are used must comply with the technical requirements
set out by the manufacturer. This is always guaranteed by the use of original
spare parts.
• The user is responsible for the selection of materials and the chemical
resistance of the installed components, internal linings and coatings. The
user must specify the technical details when ordering the filter.
2.5 Selection and qualifications of staff

• All work on the filter must be performed exclusively by reliable staff. Staff
must not be under the influence of drugs or medication. Adhere to the legal
minimum age requirement.
• Only appoint trained staff or staff who have received appropriate instruction.
Clearly delegate the areas of responsibility of staff for installation, operation
and maintenance and servicing.

2.6 Organisational measures
2.6.1 General
• Follow the respective valid national and international regulations for the
prevention of accidents.
2.6.2 Maintenance and servicing
• Adhere to the maintenance tasks and intervals set out in the operating
instructions, including instructions on the replacement of parts/equipment.
• Only use original spare parts.
• If the filter is subject to a regular inspection by an inspection and testing
organisation, with regard to temperature, steam pressure and the
dangerousness of the medium, the inspection periods must be adhered to by
the user.
2.7 Consumables
• Observe the regulations for environmental protection. Make sure that
consumables are disposed of properly and in an environmentally friendly
manner.
2.7.1 Filtered media
• When handling media which are to be filtered, make sure you follow the
respective safety regulations for the media.
2.7.2 Cleaning agents
• When handling the cleaning agents, make sure you follow the respective
safety regulations for the cleaning agents.

3 Transportation and storage
3.1 Transportation
DANGER!
Risk of accidents from falling loads
During transportation of the filter, accidents may occur due to sizes and weights.
• Exercise extreme caution when transporting the filter in order to prevent
damage to or deformation of the filter.
• Only use suitable means of transport and lifting gear with sufficient load-
bearing capacity.
• Do not stand underneath suspended loads. Do not work underneath
suspended loads.
• Wear the appropriate safety equipment and clothing.
3.2 Storage
CAUTION!
Improper storage will cause damage to the filter and filter elements
If stored incorrectly and improperly, moisture and contamination, for example,
may cause damage to the filter and the filter elements.
• Protect the filter and filter elements from moisture and contamination during
storage.
• Do not store the filter and filter elements below the frost line.
• If the filter and the filter elements have been stored for more than one year,
check that all seals are fully functional before installation.
3.3 Packaging material

CAUTION!
Risk of explosion from electrostatic charge
Packaging material, such as paper or plastic, can become statically charged and
generate sparks when discharged.
• Remove the packaging material before transportation into an explosion
protected zone.
DISPOSAL
Observe the regulations for environmental protection. Make sure that the
packaging material is disposed of properly and in an environmentally friendly
manner.

4 Scope of delivery
Immediately after receiving the delivery, check that the content is not damaged
and that it corresponds to the scope of the order. In case of discrepancies,
contact the manufacturer.

5 Technical data
NOTE
The filter described in these operating instructions is a combination of an
automatic filter and a bypass filter. The switchover between the two filters is
performed using a plug valve switch-over circuit.
NOTE
You will find the technical data in the appendix of these operating instructions.
5.1 Type plate

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

NOTE
The description of assembly groups can be found in the "Operation" chapter of
these operating instructions.

1
13 14 13 12
12 2
11
10 8
Fig. 5-1 Overview of assembly groups (view I)
1 Air tank 8 Flushing valve

2 Pressure gauge 9 Draining
3 Safety valve 10 Type plate
4 Pressure controller 11 Terminal box (optional)
5 Solenoid valve (flushing valve) 12 Pressure gauge (optional)
6 Ball valve 13 3-way ball valve (optional)
7 One-way restrictor valve 14 Differential pressure
monitoring system
NOTE
Depending on the filter configuration, the differential pressure monitoring system
can be fitted to the bypass filter, see section 5.3.

1
Fig. 5-2 Overview of assembly groups (view II)
1 Filter housing 5 Pivoting actuator (pneumatic)

2 Cam disc 6 Upper section of housing
3 Limit switch 7 Lower section of housing
(optional)
4 Solenoid valve (pivoting 8 Shut-off valve
actuator)
NOTE
In conjunction with a bypass filter, the shut-off valve are positioned on the plug
valve switch-over circuit, see section 5.3.

1
3
6
N1
5
N2
N4
N5 N3
Fig. 5-3 Overview of assembly groups (cross sectional view)
1 Vent (automatic) 7 Spacer

2 Filter candle N1 Filter inlet
3 Valve tappet N2 Filter outlet
4 Candle holder N3 Flushing oil outlet
5 Plug valve N4 Heating medium inlet
6 Change-over housing cover N5 Heating medium outlet

5.3 Overview of bypass filter and plug valve circuit assembly
group
1 2 3 4
8
7
9
14
N1 10
11
12
14
N2 7
N4
N5
13
1 Wrench 10 Drain valve (partial draining)

2 Spring-type dowel pin 11 Element support
3 Cover (Bypass filter) 12 Drain valve (final draining)
4 Housing cover safety device 13 Filter heating (optional)
including vent
5 Seal 14 Shut-off valve
6 Filter element N1 Inlet
7 Seal N2 Outlet
9 Housing N5 Heating medium outlet

1
Fig. 5-5 Overview of assembly groups (view II, with differential pressure signal)
1 Differential pressure monitoring system

2 Shut-off valve
3 Pressure compensation
4 Floor fastening

6 Installation
6.1 Special safety instructions
DANGER!
Risk of accidents from improper installation
Incorrect installation and failure to observe the listed safety instructions can lead
to accidents or damage to property.
Make sure of the following:
• The filter must be installed by qualified specialist staff or persons who have
received appropriate instruction.
• Wear the appropriate safety clothing.
• Only use suitable lifting gear with sufficient load-bearing capacity.
• Only use lifting gear on the provided suspension points (if available).
• Use lifting gear in such a way that the filter does not become damaged.
• Raise the filter evenly. Avoid tilting.
suspended loads.
• Additional devices to prevent maximum temperatures being exceeded and
temperatures dropping below the minimum and for compensation and relief
of overpressure, must be provided by the user throughout the entire system
of the plant. Observe the minimum and maximum permitted operating
temperatures and pressure values for the filter.
• Additional devices for monitoring the ambient temperature of the filter must
be provided by the user throughout the entire system of the plant.
• Install a ground cable with a cross section of at least 10 mm² as a potential
equalisation for the filter.
NOTE
Contact the manufacturer with any special questions you may have regarding
installation. The contact data for the respective national subsidiaries can be
found in the appendix of the operating instructions.

6.2 Filter installation
CAUTION!
Risk of damage to the filter housing
The filter housings are only designed for internal overpressure.
• The housing and connection flanges of the filter must not be exposed to any
external force or moment.
DANGER!
Combustible medium
When filtering combustible medium expelled medium may cause fires and
personal injuries.
• Adhere to the valid fire safety regulations when carrying out any work on the
filter.

6.2.1 Floor fastening
A B
1 3 2 3
Fig. 6-1 Automatic filter, floor fastening
1 Lower section of housing A with filter heating

2 Floor fastening B without filter heating
3 Fastening point
A B
1 2 3 3 2
Fig. 6-2 Bypass filter, floor fastening

2 Fastening point B without filter heating
3 Floor fastening
X Make sure the foundation has sufficient load bearing capacity.

X Make sure that there is sufficient space in the vicinity of the filter for
maintenance and servicing work.
X Align the filter.
X Screw the filter housing to the fastening points. When fastening the filter in
place, the filter housing must not be twisted.

6.2.2 Installation diagram
2
3
6
8
7 6
Fig. 6-3 Installation diagram
1 Filter 5 to the consumer

2 Scope of delivery (standard) 6 Pump
3 Vent (automatic) 7 Tank
4 Flushing oil line 8 Filter heating (optional)
6.2.3 Identifying the flow direction
NOTE
• The filter inlet/outlet and flushing oil outlet are indicated by the inscriptions
(Ein/In), (Aus/Out) and (Spülölaustritt/Flushing oil).
• The direction of flow is also shown in the technical data sheet which is
included in the appendix of these operating instructions.

6.2.4 Filter inlet/outlet pipe connections
X Establish the connections between the filter and piping.

X Welded joints must be made in line with the valid regulations.
X Use the appropriate seals.
X The pipes for the filter inlet and outlet may need to be provided with additional
supports, depending on the installation conditions. When installing the piping,
the filter housing must not be twisted.
NOTE
BOLL & KIRCH Filterbau GmbH recommends installing shut-off fittings in the
piping in front and in back of the filter.
6.2.5 Flushing oil outlet pipe connection
X Establish the connection between the flushing oil outlet and piping.
X Use the appropriate seal.
X Select a pipe cross section which is at least equal in size to the pipe cross
section shown in the technical data sheet. A cross section which is too small
may cause backpressure. The pipe must also be laid with an inclination and
bled.
X The pipe may need to be provided with additional supports, depending on the
installation conditions. When installing the piping, the filter housing must not
be twisted.

6.2.6 Filter heating (optional)
The filter heating is used during the filtering process to cover heat loss in the filter
and before starting up the plant in order to heat up the medium in the filter. The
filter can be heated with water vapour, hot water or thermal oil.
DANGER!
Risk of accidents from expelled hot medium
Too much pressure in the heating system can cause hot medium to be expelled
and lead to damage to the filter and accidents.
• Adhere to the maximum permitted operating temperature and operating
pressure for the filter heater.
X Connect the medium-carrying pipes to the filter heating on the plant side.
X The pipes for the heating medium inlet and outlet may need to be provided
with additional supports, depending on the installation conditions. When
installing the piping, the filter housing must not be twisted.
6.2.7 Connection of compressed air supply
2
3
Fig. 6-4 Connection of compressed air supply
1 Air tank
2 Ball valve
3 One-way restrictor valve
X Connect the plant's compressed air supply line to the one-way restrictor
valve on the ball valve.

6.2.8 Electrical connections
DANGER!
Risk of accidents from electric shock
When connecting to the power supply, the supply voltage can cause accidents
from electric shock.
• All the electrical connections on the filter must be made by a qualified
electrician and in line with the rules of electrical engineering.
Controller
NOTE
If you are using a BOLL & KIRCH Filterbau GmbH controller, you will find more
detailed information in the documentation for the controller.
If you are using your own controller or another manufacturer's controller, the
respective documentation must be followed.
Differential pressure monitoring system, electrical
NOTE
You will find more detailed information on the differential pressure monitoring
system in the appendix of these operating instructions or in the manufacturer's
documentation.
NOTE
BOLL & KIRCH Filterbau GmbH differential pressure indicators have potential-
free contacts.
6.2.9 Potential equalisation
X For potential equalisation, install a ground cable with a cross section of at

least 10 mm² on the filter.
X Connect the ground cable to the fastening screw on the filter. If necessary,
prior to the installation of the ground cable, remove the paint from the
fastening point to ensure sufficient electrical contact.

7 Operation
7.1 Functional description of the automatic filter
The filter is used to filter particles from media in order to protect the downstream
parts of the plant.
The filter candles are cleaned automatically so that the plant does not have to be
switched off for cleaning.
7.1.1 Filter housing
The filter housing, comprising the lower housing section with the filter heating or
floor fastening without filter heating (optional), the upper housing section and
filter housings, contains all the pipe connections. The flushing valve is installed
on the upper section of housing.
The filter housings are arranged around the central drilled hole for fitting the plug
valve on the upper section of housing. A cover seals the plug valve off from the
outside, The pivoting actuator is fitted to it with a spacer.
7.1.2 Controller
The controller regulates and monitors all automatic filter functions.
NOTE
7.1.3 Differential pressure monitoring system
The differential pressure monitoring system measures the differential pressure

between the filter inlet and filter outlet. As the soiling increases, the differential
pressure in the filter also increases.
The controller processes the electrical signals from the differential pressure
monitoring system and triggers a backflushing process when the set maximum
value is reached.
NOTE
• You will find more detailed information on the differential pressure monitoring
system in the appendix of these operating instructions or in the
manufacturer's documentation.
• The differential pressure can also be displayed optically on the differential
pressure monitoring system.
• The control line for the differential pressure monitoring system is fitted with
shut-off valves (e.g. shut-off valves).

3 2 1 2 3
Fig. 7-1 Differential pressure monitoring system installation example
1 Differential pressure 4 Shut-off valve

monitoring system
2 3-way ball valve (optional) 5 Terminal box (optional)
3 Pressure gauge (optional)
The location for installation of the differential pressure monitoring system varies
depending on the filter configuration
Optional pressure gauges allow you to quantify the differential pressure.
The optional 3-way ball valves make it possible to check that the differential
pressure monitoring system is fully functional as and when required. The levers
have to point downwards when in operation.

7.1.4 Air tank and flushing valve
1
2
Fig. 7-2 Overview of the air tank
1 Air tank
2 Pressure gauge
3 Safety valve
4 Pressure controller
5 Solenoid valve (flushing valve)
6 Ball valve
The compressed air in the air tank expands explosively when the solenoid valve
(flushing valve) is switched and opens the flushing valve. The flow which this
causes, pushes the medium on the clean side through the filter candles in the
counterflow direction at high speed. The pressure level in the air tank can be read
from the pressure gauge and set using a pressure controller. The air tank is
equipped with a safety valve to prevent the air tank from being damaged by
excessive positive pressure.

7.1.5 Pivoting actuator (pneumatic) with limit switch
If the pressure gradient between the dirty side and the clean side reaches a set
value due to the growing layer of dirt on the filter material, the automatic filter
chamber regeneration is triggered. The pivoting actuator turns the plug valve so
that the flow to the soiled filter chambers is shut off and, at the same time, the
stand-by filter chamber is activated. If the plug valve reaches the filter chamber
which is to be cleaned, the pivoting movement is stopped. The pivoting actuator
is actuated by a solenoid valve (pivoting actuator). The limit switch monitors the
position of the plug valve. If the plug valve is in the incorrect position, the flushing
process in the soiled filter chamber does not start.
7.1.6 Flushing valve
The pneumatically actuated flushing valve opens and closes the flushing oil
outlet at the start and end of the backflushing phases respectively. After a delay,
when the flushing valve is opened by the valve tappet, the compressed air supply
for backflushing flushing from the air tank is opened. A solenoid valve (flushing
valve) regulates the supply of compressed air for actuation of the flushing valve.

7.1.7 Filtration stage
N1
N2
3
Fig. 7-3 Filtration stage
1 Filter candle 5 Air tank

2 Plug valve N1 Filter inlet
3 Flushing valve N2 Filter outlet

The medium being filtered flows through the lower inlet flange into the housing,
from where it flows into the activated filter chamber and to the filter candles. The
medium flows through the filter candles from the outside to the inside and the
particles in the medium are held back on the filter medium of the filter candles.
The cleaned medium proceeds to the filter outlet below.
The solenoid valve (flushing valve) is switched so that the flushing valve is
closed.
The plug valve isolates the cleaned filter chamber.
In the air tank, compressed air is available for the next backflushing.

7.1.8 Backflushing stage
11
5
10
6
N1 9
8
N2
N3
Fig. 7-4 Backflushing stage
1 Vent (automatic) 8 Flushing valve

2 Filter candle 9 Valve tappet
3 Limit switch and cam disc 10 Solenoid valve (flushing valve)
4 Solenoid valve (pivoting 11 Air tank
actuator)
5 Pivoting actuator (pneumatic) N1 Filter inlet
6 Differential pressure N2 Filter outlet
monitoring system
7 Plug valve N3 Flushing oil outlet

The foreign substances held back on the filter candles generate a growing
differential pressure between filter inlet and outlet.
Backflushing is triggered by the controller when the differential pressure reaches
a certain value.
When backflushing is triggered, the pneumatic pivoting actuator is switched over
by the solenoid valve (pivoting actuator) and the plug valve is pivoted from the
contaminated filter chamber to the filter chamber which is on stand-by.
The switch-over to the stand-by filter housing with a clean filter candles causes
immediate differential pressure relief. If the plug valve reaches the filter chamber
which is to be cleaned, the pneumatic pivoting movement is switched off. The
limit switch checks the position of the plug valve.
The solenoid valve (flushing valve) is then switched over electrically, causing the
flushing valve to open and the isolated filter chamber to depressurise.
Whilst the flushing valve is performing the opening movement (depending on the
depressurisation of the filter candles) the compressed air from the air tank enters
into the shut-off filter chamber and accelerates the medium in the filter chamber,
pressing it through the filter candles in the counterflow direction.
The drop in pressure which this creates causes the foreign substances deposited
on the filter material to be flushed off and flushed out of the filter housing via the
open flushing valve.
After the flushing time has elapsed, the solenoid valve (flushing valve) is
switched over electrically, causing the flushing oil outlet to close. At the same
time, the supply of stored backflushing air is ended. Once the flushing valve is
closed, the air tank is re-filled with compressed air.
The backflushed filter chamber is then filled with cleaned medium through a filling
hole until the correct operating pressure is achieved. In the process, the air in the
filter chamber is discharged by an automatic vent.
NOTE
After backflushing is complete, the next backflushing cycle (manual or triggered
by the differential pressure monitoring system) can only be started with a time
delay. This time delay is the time set on the time relay or the preset time on the
controller. It is needed to ensure that the cleaned filter chamber can be filled.
The backflushing process is completed; the cleaned filter chamber remains shut
off from the filtration process until the next backflushing process.
CAUTION!
Risk of damage to the filter from improper flushing
Flushing an only partially filled filter causes increased strain on the filter candles.
• Never perform backflushing due to installation or control circumstances in an
only partially filled filter. A completely drained filter can be flushed for test
purposes without any restrictions.

7.2 Functional description of the plug valve switch-over circuit
The plug valve switch-over circuit is used to switch between the connected
automatic and bypass filter. The special shape of the plug valve prevents
interruptions in the flow of medium and pressure surges when switching over
and, at the same time, guarantees freedom of movement due to lower levels of
frictional force. The plug valve requires a seal in three positions.
A B C
1 2 1 2 1 2
Fig. 7-5 Position of the plug valve circuit
1 Automatic filters
2 Bypass filter
A Automatic filter in operation
B Automatic filter and bypass filter in operation
C Bypass filter in operation
The switch-over is performed manually using the attachable lever. The mark
sawn into the neck of the plug valve shows the direction of flow and indicates
which filter is in operation. The construction of the circuit prevents both filters
from being shut down at the same time.
A pressure compensation valve is fitted to the plug valve switch-over circuit to
compensate pressure between the two connected filters. It is opened and closed
manually.
NOTE
The measuring points for the differential pressure monitoring system are situated
at the inlet and outlet to the plug valve switch-over circuit.

7.2.1 Pressure compensation
CAUTION!
Risk of damage or expelled medium if the pressure compensation is
positioned incorrectly
Depending on the operating stage, if the pressure compensation valve is in the
wrong position, medium may be expelled or damage may be caused.
• The pressure compensation valve must always remain open during
operation.
• The pressure compensation valve must only be closed when cleaning the
automatic filter or bypass filter.
1 2
Fig. 7-6 Pressure compensation
1 Pressure compensation valve

2 Pressure compensation
Lever pointing - Pressure compensation valve open

lengthways along the line
Lever pointing across the - Pressure compensation valve closed
line

7.3 Functional description of the bypass filter
The bypass filter is used to filter particles from media in order to protect the
downstream parts of the plant. The bypass filter is used in situations in which the
filtering process must not be stopped even whilst maintenance or repairs are
being performed on the automatic filter.
The medium being filter flows into the housing through the upper inlet flange and
from there into the filter chamber. The medium flows through the filter element
from the inside to the outside and the particles in the medium are held back on
the filter material of the filter element.
7.3.1 Housing cover safety device
1 2 3 4
Fig. 7-7 Housing cover safety device
1 Cover 3 Housing cover safety device

2 Vent 4 Threaded connector
The housing cover safety device has the task of preventing pressurised medium
from being expelled uncontrolledly in case of incorrect operation. The cover
sheet covers a minimum number of cover screws so that the cover cannot be
removed without opening the vent to bleed the system.
The filter chamber is relieved via the vent. When the filter is shut off, the operating
pressure is immediately relieved and hardly any medium is expelled. Otherwise,
close the vent immediately and the expulsion of medium is limited.

7.4 Automatic filter filter insert
7.4.1 Filter insert with filter candles
1
1
2 2
3
3
Fig. 7-8 Construction of the filter insert with filter candles
1 Filter candle
2 Candle holder
3 Seal

7.4.2 Functional description of the filter insert with filter candles
Filter inserts with filter candles are used for filtration. The flow runs from the
outside to the inside into the individual filter candles.
Particles of dirt in the flow are thus filtered off by the filter material in the filter
candles. The cleaned medium exits from the bottom of the filter candles and is
fed back into the plant.
The filter insert comprises several filter candles arranged in parallel. The filter
candles all have the same dimensions; they are interchangeable and can also be
removed separately. They are screwed into the candle holder.
The type, design and number of filter candles used depends on the medium
being filtered.
For media with a high ferrite content, the filter candle on the filter candle insert
can be replaced with an optional magnetic primary filter.
The candle holder secures the filter candles and thus protects the filter material
on the filter candles from damage during removal and installation.
The dirty side is sealed off from the clean side by a seal on the candle holder.

7.5 Bypass filter filter insert
7.5.1 Star-pleated filter element
1
2
5
4
Fig. 7-9 Construction of star-pleated filter element
1 Threaded connection piece 4 Sieve ring

2 Filter bottom 5 Seal
3 Filter material

7.5.2 Functional description of the star-pleated filter element
Star-pleated filter elements are used for filtration. The direction of flow through
the star pleated-filter element is from the outside to the inside.
Particles of dirt in the flow are thus filtered off by the star-pleated filter element.
The cleaned medium then exits from the star-pleated filter element and is fed
back into the plant.
The bypass filter is fitted with a star-pleated filter element.
The star-pleated filter element is attached with the open end on the element
support.
The dirty side is sealed off from the clean side by seal on the star-pleated filter
element.

7.6 Commissioning
CAUTION!
Risk of damage to the filter from improper filling
If the filter is filled improperly, the filter elements may be damaged.
• Filling the filter against the indicated direction of flow of the filter elements is
not permitted.
NOTE
X Check whether all connections have been made properly.

X Open the shut-off valves in the control line to the differential pressure
monitoring system.
X Check the position of the 3-way ball valves (if fitted) on the differential
pressure monitoring system (levers must point downwards).
X Open the pressure compensation valve (lever pointing lengthways along the
line).
X Make sure that there is compressed air with sufficient operating pressure on
the filter's ball valve.
CAUTION!
Risk of damage to the filter if operated without compressed air supply
If the controller is switched on and the filter is commissioned without compressed
air supply, the solenoid valves may become damaged.
• Always open the filter's ball valve first when commissioning in order to ensure
that compressed air is supplied.
X Open the compressed air shut-off valve on the filter.

X Check the set pressure on the air tank's pressure gauge. If necessary, adjust
the pressure on the pressure controller.
X Set the key on the plug valve switch-over circuit to the "Automatic filter in
operation" position.
X Put the filter heating (if fitted) into operation and wait until the filter has heated
up.
X Put the filter into operation using the controller. Backflushing is automatically
performed in one of the filter chambers.
NOTE
X Check that the controller is functioning by performing backflushing manually.

X Open the filter outlet shut-off valve
X Slowly open the filter inlet shut-off valve. Avoid pressure surges.

DANGER!
Risk of accidents from expelled medium
Hot medium may be expelled when opening the vent.
• Proceed with extreme caution.
DISPOSAL
Leaks must be caught immediately. Make sure that expelled medium is disposed
of properly and in an environmentally friendly manner.
X Open the vent on the top of the housing of the bypass filter. The bypass filter
is filled via the open pressure compensation valve.
X Close the vent as soon as medium is expelled from a vent without any
bubbles.
X Carry out backflushing once more manually using the controller.
X The filter is ready for operation.
DISPOSAL
X After each time you commission the filter, check the filter for leaks and
eliminate them as necessary.
7.6.1 Determination of time interval for time-controlled backflushing
X Allow the filter to operate for 24 hours with differential pressure and record
the number of flushes from the flushing cycle counter or the controller. In
order to allow the filter to operate for 24 hours with differential pressure, you
have to deactivate the intervals for forced flushing on the controller.
X Calculate the average of all flushing intervals.
X Reset the flushing interval time (which should be 30 % shorter) on the
controller.

7.7 Removal from service
7.7.1 Short-term removal from service
NOTE
When using the filter in watery media, it is imperative to adhere to the following:
• Do not allow the filter to run to empty after switching off the supply pump. Dirt
may otherwise be allowed to harden.
• If the above condition cannot be met, set the controller so that backflushing
is triggered every 2 hours even if the supply pump is switched off.
7.7.2 Longer term removal from service / removal
NOTE
When removing the filter and taking it out of service for longer periods, pay
attention to the following points:
• The filter must be completely emptied.
• Disconnect all connections from the filter.
• The filter must be thoroughly cleaned.
• The filter must be sealed by applying an appropriate anticorrosive, if
necessary.
• The connection flange openings must be sealed with plastic (or similar)
dummy plugs.
7.7.3 Disposal
DISPOSAL
When the filter or individual components and consumables are finally disposed
of, make sure that they are disposed of in an environmentally friendly manner.

8 Maintenance and servicing
DANGER!
Risk of accidents from improper maintenance and servicing
Incorrect maintenance and servicing and failure to observe the listed safety
instructions can lead to accidents or damage to property. Make sure of the
following:
• Maintenance and servicing work must only be carried out by qualified
specialist staff or persons who have received appropriate instruction.
• When performing any work on the filter, always wear the appropriate safety
clothing.
• Only perform maintenance and servicing work when the filter is cooled,
depressurised and drained. Depending on the operating temperature, there
may be a risk of burns.
• Ensure the highest levels of cleanliness when opening the filter. No foreign
substances, e.g. tools, cleaning cloths, impurification etc., must be allowed
to remain in the filter.
• Visually inspect all seals during maintenance and replace them as
necessary.
• Clean all sealing surfaces thoroughly before assembly.
• On completion of the maintenance work, re-fit all available safety equipment
properly.
not permitted.
• Remove the filter from service if the inspection periods (if indicated) have
elapsed.
• Filter elements are sensitive to pressure and impact. Always exercise
extreme caution when installing and removing the filter elements. Before
installation, check all filter elements/seals and replace any damaged filter
elements/seals as necessary.

8.2 Cleaning agents
CAUTION!
Risk of damage to the filter from incorrect use of cleaning agents
The components of the filter may become damaged if cleaning agents are used
incorrectly. The correct cleaning agent is selected in accordance with the type of
medium being filtered and the associated contaminations.
• BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning
agent. For more detailed information, see the appendix of these operating
instructions.
8.3 Special tool

The manufacturer provides the following special tools for the filter:
Wrench for removing the filter elements
Key for opening the controller
Key for fitting filter housings
Guide pins for filter housing removal

8.4 Maintenance intervals
Even automatic filters have to undergo regular checks and maintenance.
It is particularly important to note that the filter material on the filter elements may
become blocked over time despite regular backflushing. This depends largely on
the quality of medium and the available partial flow cleaning function. The soiling
can be removed by cleaning the filter elements by hand using a suitable cleaning
agent.
NOTE
BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning
instructions.
You can tell that the filter elements are becoming increasingly blocked because
the flushing intervals become shorter and shorter.
The number of backflushing cycles performed is recorded by the controller.
CAUTION!
Risk of damage to the filter and the plant from damaged filter elements
If the flushing intervals suddenly become longer, this may indicate that the filter
elements are damaged.
• In such an event, check all filter elements for damage immediately. Replace
any damaged filter elements as necessary.
In order to make sure the automatic filter continues to operate properly,

observe the following points for maintenance:
• Regularly check:
– the differential pressure,
– the leak tightness of the automatic filter, especially all connections and
seals and
– the automatic filter for corrosion and other damage,
– the condition of the filter elements and
– the condition of all screw connections and whether they are firmly
tightened.
• Check all filter elements for soiling after the first 500 flushes, then after a
further 5,000 and afterwards, every 10,000 flushes. To do so, remove the
filter inserts and clean the filter elements. If the backflushing intervals shorten
considerably beforehand, you must carry out checks and cleaning earlier.
• Check the flushing oil outlet for leaks every 10,000 flushes. No medium must
be expelled at the end of the flushing oil line during the filtration stage.
• The automatic filter must be inspected annually for leaks.
• Replace all seals at least every 2 years and when overhauling the automatic
filter.
NOTE
The filter elements are subject to wear from two-way strain. It is therefore
recommendable to keep a complete set of filter elements in stock.

In order to make sure the bypass filter continues to operate properly,
– the leak tightness of the bypass filter, especially all connections and seals
and
– the bypass filter for corrosion and other damage,
– the condition of the filter element and
tightened.
• The bypass filter must be inspected annually for leaks.
• Replace all seals at least every 2 years and when overhauling the bypass
filter.
In order to make sure the plug valve switch-over circuit continues to
operate properly, observe the following points for maintenance:
– the leak tightness of the complete plug valve circuit, especially all
connections and seals,
– the freedom of movement of the plug valve,
– the plug valve switch-over circuit for corrosion and other damage and
tightened.
• The plug valve circuit must be inspected annually for leaks.
• Replace all seals at least every 2 years and when overhauling the plug valve
circuit.

8.5 Cleaning/replacing the filter element on the automatic filter
8.5.1 Preparatory work
NOTE
X Set the key on the plug valve switch-over circuit to the "Bypass filter in
operation" position. The bypass filter is thus in operation.
X Close the pressure compensation valve.
X Trigger backflushing on the controller.
X Afterwards, close the ball valve for the filter's compressed air supply.
X Then, carry out manual backflushing for the filter chamber which has not yet
been flushed.
X Switch off the controller.
DANGER!
Risk of accidents due to controller being switched on unintentionally
During maintenance accidents may be caused if the controller is switched on
unintentionally, e.g. by starting up the drives or from expelled medium.
• Secure the controller to prevent it from being switched on unintentionally, e.g.
by attaching a lock.
X Check the pressure gauge to establish whether the air tank is genuinely
depressurised.
X The filter chambers are now drained and depressurised.
CAUTION!
Risk of accidents from hot components
Hot surfaces can cause serious injuries if touched.
• Take the filter heating out of operation and allow the filter to cool down.
DANGER!
Hot medium may be expelled when opening the filter chamber.
• Depressurise and lower the level of medium before removing the filter insert.

1
Fig. 8-1 Removing the filter housing
1 Venting line
2 Filter housing
3 Screw
4 Upper section of housing
X Disconnect the venting lines from the filter housings.

X Unfasten the screw connection for the filter housings with the key included in
the scope of delivery.

A B
2
3
5
6
Fig. 8-2 Lifting off / setting down the filter housing
1 Filter housing 5 Change-over housing

2 Filter element 6 Seal
3 Guide pins A Inserting guide pins
4 Screw B Lifting off / setting down the
filter housing
CAUTION!
Risk of damage to the filter elements due to improper installation / removal
for the filter housings
• When installing / removing the filter housings, proceed with extreme care.
• Use the guide pins to install / remove the filter housings.
X Screw the guide pins into the change-over housing.

X Lift the filter housings off the upper section of housing.

8.5.2 Removing the filter insert with filter candles
Fig. 8-3 Removing the filter insert with filter candles
1 Filter element
2 Candle holder
3 Seal
X Remove the filter inserts from the housing by pulling vertically upwards.
X Allow the filter inserts to drip dry in a suitable container.

8.5.3 Cleaning the filter insert with filter candles
CAUTION!
Risk of damage to the filter insert from improper cleaning
If the filter insert is cleaned or handled improperly, the filter insert may become
damaged. Observe the following safety instructions:
• Proceed with extreme caution when performing all cleaning work.
• The soaking time in the "BOLL CLEAN 2000" cleaning agent must not
exceed 24 hours.
• The cleaning temperature, when using "BOLL CLEAN 2000" must not
exceed 60 °C.
• When cleaning using a high-pressure cleaner, the pressure must not exceed
a maximum of 60 bar. When cleaning using a high-pressure cleaner, keep a
sufficient distance (at least 20 cm) from the filter material to prevent damage.
• When cleaning the filter insert using a cleaning gun and compressed air, the
pressure must not exceed a maximum of 4 bar.
• Particles of dirt must not be allowed to enter the clean side of the filter
element.
• Do not place the filter elements on top of each other as you may otherwise
cause damage.
NOTE
instructions.
X Place the filter insert in a container with cleaning agent, with the opening of
the filter elements facing downwards. This way, particles detaching from the
filter elements can sink to the bottom.
X Remove loose particles which float on the top of the cleaning agent during
the soaking stage.
X After soaking, remove the filter insert from the container and place it on a
suitable surface (e.g. perforated plate) with openings of the filter elements
facing downwards. Allow the cleaning agent to drip dry.
X Turn the filter insert around and place it down with the openings facing
upwards.
X Blow out the filter elements with compressed air from the inside to the
outside.
X Then dip the filter insert in the container with fresh cleaning agent again, with
the openings of the filter elements facing downwards. Rinse the filter insert
through again by turning it and moving it up and down in the cleaning agent.
X Allow the filter insert to drip dry again.
outside.
X Then check all filter elements for damage. Replace any damaged filter

NOTE
Sufficient cleaning results (approximately 60 %) have been achieved using the
described manual cleaning process for filter elements in similar applications.
In our experience, a cleaning effect of almost 100 % can only be achieved
manually by using the type 5.04 filter element cleaning unit with BOLL CLEAN
2000.
X In case of heavier soiling, you can clean using the high-pressure cleaner
procedure mentioned above. For cleaning, use water or water with cleaning
agent.
8.5.3.1 Cleaning the filter candles in case of stubborn soiling
In case the filter elements are heavily soiled (lacquer contamination, incrustation,
tar residue, fibres, chippings), the individual filter elements will have to be
removed and cleaned.
NOTE
BOLL & KIRCH Filterbau GmbH recommend the use of the BOLL & KIRCH
cleaning unit with rotating nozzle and flat-jet nozzle for cleaning purposes.
If you do not have a filter element cleaning unit available, proceed as follows:
NOTE
instructions.
the filter elements facing upwards. The openings on the filter elements have
to protrude out of the cleaning agent. This prevents dirt from penetrating into
the clean side.
the soaking stage.
X Remove the filter insert from the cleaning agent. Allow the filter insert to drip
dry with the openings pointing downwards.
X Unscrew and remove the filter elements from the candle holder using the key
included in the scope of delivery.
X Then spray the filter elements through using the high-pressure cleaner with
suitable cleaning agent. First clean from the inside to the outside, then from
the outside to the inside. Repeat the process several times as necessary.
Finally, spray the filter elements from the inside to the out.
X Carefully rinse out the filter elements in fresh cleaning agent and allow the
filter elements to drip dry.
outside.
X Remove any particles collected on the magnetic candle (if fitted).
X Re-assembly is performed by carrying out the steps for disassembly in
reverse order. Clean the candle holder as necessary before assembly.

CAUTION!
Risk of damage to the filter elements from incorrect installation
Improper installation can cause damage to the filter elements.
• Adhere to the recommended tightening torque values for filter candles: 25
Nm for filter candles with a candle diameter of 28 mm or 50 mm.
8.5.4 Installing the filter insert with filter candles
X Clean any soiling which has collected on the inside of the filter.
X Check all the seals for damage. Replace any damaged seals as necessary.
X Insert the filter inserts vertically into the housing from above.
X Make sure that the seals are properly in place.

8.5.5 Concluding work
Fig. 8-4 Vent (automatic)
1 Double nipple
2 Float ball
3 Filter housing
X Check the condition of the vent (automatic) and check that it is functioning:
X Check the condition of the double nipple and
X the condition of the float ball and make sure it moves easily,
Replace any damaged components as necessary.
X Check the seals for damage. Replace any damaged seals as necessary.
X Place the filter housings on the upper section of housing. Make sure that the
seals are properly in place.
X Unscrew and remove the guide pins from the change-over housing.
X Screw the filter housings to the upper section of housing. Tighten the screw
connection evenly, gradually tightening opposite screws step-by-step.
X Connect the venting lines to the filter housings.
X Put the filter back into operation. See the section "Commissioning".

8.6 Cleaning/replacing the filter element on the bypass filter
operation" position. The automatic filter is thus in operation.
X Close the pressure compensation valve.
DANGER!
DANGER!
DISPOSAL
X Depressurise the filter. Carefully open the vent.
DANGER!
Hot medium may be expelled when opening the drain hole.
• Collect the expelled medium in a suitable container.
DISPOSAL
X Empty the filter. Carefully open the drain valve (partial draining).
NOTE
If required, you can fully drain the filter housing by opening the drain (complete
drainage).
X Close the drain hole.

X Unscrew the vent screw far enough so that the securing plate on the cover
safety device can pivot to the side over the covered screws.
X Unfasten the screw connection on the cover.
X Lift the cover off the housing.

8.6.2 Removing the star-pleated filter element
X Remove the filter element from the housing by pulling it vertically upwards.
X Allow the filter element to drip dry in a suitable container.

8.6.3 Cleaning the star-pleated filter element
CAUTION!
Risk of damage to the filter element from improper cleaning
If the filter element is cleaned or handled improperly, the filter element wire mesh
may become damaged. Observe the following safety instructions:
• The soaking time in the cleaning agent is 1 - 4 hours, depending on the level
of contamination. Check the progress of cleaning whilst the element is
soaking.
exceed 60 °C.
sufficient distance (at least 20 cm) from the surface of the filter material to
prevent damage.
element.
X Shake the filter element to remove the coarsest dirt.
NOTE
instructions.
X Place the filter element in a container of suitable cleaning agent with the
opening pointing upwards.
X Allow the filter element to soak.
the soaking stage.
NOTE
X Then spray the filter element with a filter cleaning unit. Cleaning is performed
from the inside to the outside and from the outside to the inside. In the final
working step, the filter element has to be jet cleaned in the opposite direction
to the direction of filtration, i.e. from the inside to the outside.
X Rinse the filter element carefully and allow it to drip dry.
X Check the filter element for damage. Replace any damaged filter elements/
seals as necessary.

8.6.4 Installing the star-pleated filter element
X Clean any contamination which has collected on the inside of the filter
chamber.
X Check the seal for damage. Replace any damaged seals as necessary.
X Insert the filter element into the housing from above.
X Make sure that the seal is properly in place.
X Place the cover on the housing. Make sure that the seal is properly in place.
X Screw the cover to the housing. Tighten the screw connection evenly,
gradually tightening opposite screws step-by-step.
X Pivot the securing plate on the housing cover safety device by the screws
which have to be secured, and screw the vent screw tight.

8.7 Manually backflushing the filter in the event of power failure
CAUTION!
Risk of accidents caused by the filter starting back up
The filter can start up again when electrical power returns and the movement of
the pivoting actuator may injure you.
• Before manually actuating the filter, first switch off the controller.
The manual backflushing process is performed in two steps:

• The plug valve pivots to the soiled filter chamber and
• backflushing is performed by opening the flushing valve.
Fig. 8-5 Manual actuation of the solenoid valve
1 Manual actuation on the solenoid valve

2 Solenoid valve (pivoting actuator)
X Check whether there is compressed air on the filter,

X Actuate the solenoid valve (pivoting actuator) manually with a screwdriver to
pivot the plug valve to the soiled filter chamber, Do not move the manual
actuator back into the initial position.
X Trigger backflushing directly by manually actuating the solenoid valve
(flushing valve) with a screwdriver. Manual actuation must last for at least 8 s.

X Move the solenoid valve's (flushing valve) manual actuator back into the
initial position.
X Move the solenoid valve's (pivoting actuator) manual actuator back into the
initial position.
X The automatic venting process in the filter chamber is not completed until the
filling time has elapsed.

8.8 Remedying faults
NOTE
In case of any faults or repairs which are not listed here, contact the BOLL &
KIRCH customer services department.
8.8.1 Trouble shooting
Fault Possible cause Remedy

Differential pressure too Air pressure too low Check the compressed
high, no flushing air supply on the filter
connection (see
respective operating
instructions for the entire
plant)
Flushing performed High level of soiling in Determine the cause of
often the medium soiling in the plant
Filter elements blocked Change / clean the filter
elements
Air pressure too low Check the compressed
air supply on the filter
connection (see
plant)
Piping on the flushing oil Clean the piping (see
outlet blocked respective operating
plant)
The solenoid valve Replace the solenoid
(solenoid valve) or the valve (flushing valve) /
flushing valve is stuck check the flushing valve /
replace
Pivoting actuator not Plug valve is stuck Open the filter and
functioning remove the cause of the
blockage
The filling hole is Clean the filling hole in
blocked the filter housing
No pressure supply Check the compressed
connection (see
plant)
(pivoting actuator) or valve (pivoting actuator)
pivoting actuator are or pivoting actuator
stuck

Differential pressure will Piping on the flushing oil Clean the piping (see
not reduce outlet blocked respective operating
plant)
elements
No differential pressure Shut-off valves in Open shut-off valves
indicator control line closed
3-way ball valves (if Check the position of the
fitted) in the incorrect levers (the levers have to
switching position point down)
Differential pressure Check / replace the
monitoring system faulty differential pressure
monitoring system
No pressure display on Air pressure too low Check the compressed
the pressure gauge for air supply on the filter
the air tank connection (see
plant)
Set the air pressure on
the pressure controller
Ball valve on the filter Open the ball valve
closed
Pressure gauge faulty Replace the pressure
gauge

9 Appendix

9.1 Supplier's documentation
NOTE
Documentation for any components or assembly groups purchased externally by
BOLL & KIRCH Filterbau GmbH is enclosed with these operating instructions.
Adhere to the information contained, in particular information on the subject of
safety.
9.2 Cleaning devices

For particularly good cleaning results, BOLL & KIRCH Filterbau GmbH
recommends the filter element cleaning unit type 5.04 with rotating nozzle and
flat jet nozzle or optionally, the type 5.05 ultrasonic cleaning unit.

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

representatives
If you require service or spare parts, please contact the main site or our
subsidiaries, representatives or service points.
Deutschland Croatia Poland

1 2 3 BOLL & KIRCH Filterbau GmbH 1 Marine Trade d.o.o. 1 TRIMOR sp. z o. o.
Postfach 1420, D-50143 Kerpen Vladimira Nazora 6 ul. Andersa 17
Siemensstr. 10-14, D-50170 Kerpen HR - 47000 Karlovac PL-81-831 Sopot
Tel.: +49/(0)2273/562-0 Tel.: +385/(0)47/ 61 19 07 Tel.: +48/(0)58 551 66 40
Fax: +49/(0)2273/562-223 Fax: +385/(0)47/ 43 12 61 Fax: +48/(0)58 555 19 29
E-Mail: info@bollfilter.de E-Mail: marine-trade@ka.t-com.hr E-Mail: trimor@trimor.com.pl
www.bollfilter.de www.trimor.com.pl
Cyprus
1 3 BOLL & KIRCH Filterbau GmbH 1 M.I.E. Services Ltd. Russia / Ukraine / Belarus
Geschäftsstelle Nord The Hawk Building 1 2 3 000 BOLLFILTER Russland
An der Strusbek 34 124 Gladstonos Street Datschnyi prospekt, 2
D - 22926 Ahrensburg CY - 3032 Limassol Geb. 1, Lit. A, Raum 23N
Tel.: +49/(0)4102/4740-0 Tel.: +357/(0)25 889 999 RUS - 198207 St. Petersburg
Fax: +49/(0)4102/4740-22 Fax: +357/(0)25 763 902 Tel.: + 7/(0)812-364-61-80
E-Mail: ursula.bauer@bollfilter.de E-Mail: info@mieserv.cy.net Fax: + 7/(0)812-364-61-80
www.bollfilter.de www.miegroup.com.cy E-Mail: info@bollfilter.ru
1 IVG Pumpen- und Filtrationstechnik Gera Denmark / Sweden / Norway / 1 2 3 Switzerland / Liechtenstein
Prehlis 13 A Iceland / Finland / Lithuania / EIG CRUSTAG
D - 07552 Gera Latvia / Estonia 120 Route de Frontenex
Tel.:+49/(0)365/42 00 07 4 1 2 3 BOLLFILTER Nordic ApS CH - 1208 Genève
Fax: +49/(0)365/42 00 07 5 Hammerbakken 21 Tel.: +41/(0)22/73 59 50 0
E-Mail: ivg-neubert@superkabel.de DK - 3460 Birkerød Fax: +41/(0)22/78 66 17 1
www.ivg-neubert.de Tel.: +45/(0)45/42 12 00 E-Mail: info@eig-crustag.ch
Fax: +45/(0)45/42 12 99 www.eig-crustag.ch
1 BOLL & KIRCH Filterbau GmbH E-Mail: info@bollfilter.dk
Geschäftsstelle Süd www.bollfilter.dk 1 2 3 Spain / Portugal / Argentina /
Rangaustraße 7a Chile / Peru / Uruguay
D - 91639 Wolframs-Eschenbach BOLLFILTER España S.L.
Tel.: +49/(0)9875/884 (Herr Henkelmann) Greece / Bulgaria Zona Cami Ral
Tel.: +49/(0)9875/971 865 (Herr Pirkl) 1 2 3 FILTERKON Paseo del Ferrocarril, 339 3ª – 2 a
Fax: +49/(0)9875/885 8, Mitsaion Str. E - 08860 Castelldefels
E-Mail: norbert.henkelmann@bollfilter.de GR - 117 42 Athen Tel.: +34/(0)93/634 26 80
www.bollfilter.de Tel.: +30/(0)210/92 17 671 Fax: +34/(0)93/665 22 79
Fax: +30/(0)210/92 42 242 E-Mail: info@bollfilter.es
Europe E-Mail: filterkon@filterkon.com www.bollfilter.com
Austria / www.filterkon.com
Czech Republic / 1 2 3 The Netherlands
Slovakia / Slovenia Great Britain and Ireland Lubrafil B.V.
1 2 3 Schmachtl GmbH 1 2 3 BOLLFILTER UK Limited Aalborg 2
Pummererstrasse 36 Unit 9 Station Way NL - 2993 LP Barendrecht
A - 4020 Linz UK - Tolleshunt D'arcy, Essex CM9 8TY Tel.: +31/(0)180/55 62 55
Tel.: +43/(0)732/76 46 0 Tel.: +44/(0)1621/86 21 80 Fax: +31/(0)180/55 62 65
Fax: +43/(0)732/78 50 36 Fax: +44/(0)1621/86 92 57 E-Mail: lubrafil@lubrafil.nl
E-Mail: g.oehler@schmachtl.at E-Mail: sales@bollfilter.co.uk www.lubrafil.nl
www.schmachtl.at www.bollfilteruk.co.uk
1 Turkey
Belgium/Luxembourg Italy ARES MAKíNA LTD. STI.
1 2 3 AUXIMECA N.V. 1 2 DECOSTA S.r.l. Ataúehir Bulvari 48.
Wijtschotbaan 3/3 Via Bicetti de Buttinoni, 12 Ada Mimoza 2/4 Daire : 1
B - 2900 Schoten I - 20156 Mailand Ataúehir, Istanbul
Tel.: +32/(0)3 646 61 80 Tel.: +39/(0)0238/00 52 83 Tel.: +90/(0)216/580 92 15
Fax: +32/(0)3 646 93 98 Fax: +39/(0)0238/00 36 31 Fax: +90/(0)216/580 92 19
E-Mail: info@auximeca.be E-Mail: sales@decosta.it E-Mail: sami.uygurer@aresmakina.com
www.auximeca.com www.decosta.it www.aresmakina.com

America Africa
Brazil Middle East
1 PML Petersen Matex Imp. e Exp. Ltda. 1 2 Safe Technical Supply Co. L.L.C. South Africa
Rua Branco de Morais P.O. Box 4832 1 2 Afrifil Manufacturing (PTY) LTD
489 - Chácara Santo Antônio UAE - Dubai 8 Pressberg Road Modderfontien
BR - 04718-010 - São Paulo / SP Tel.: +971/(0)4/32 43 24 0 ZA - Isando, 1600
Tel.: +55/(0)11 5186 2000 Fax: +971/(0)/4/32 43 78 6 Tel.: +27 11 452 5444
Fax: +55/(0)11 4082 8660 E-Mail: info@safetech.ae Fax: +27 11 609 9535
E-Mail: Luizcarlos.gomes@pml.com.br www.safetechnical.com E-Mail: sales@afrifil.co.za
www.pml.com.br www.afrifil.co.za
People's Republic of China
USA / Canada incl. Hong Kong / Macao
1 2 3 BOLL FILTER Corporation 1 Blohm & Voss Industries (China) Ltd.
9282 General Drive #180 Room 715-737, 7/F Sun Hung Kai Centre
Plymouth, MI 48170 - USA 30 Harbour Road, Wanchai
Tel.: +1/(0)734/451-4680 Hong Kong SAR, China
Fax: +1/(0)734/451-4681 Tel.: +852-31 81 78 30
E-Mail: latorre@bollfilterusa.com Fax: +852-25 41 21 71
www.bollfilterusa.com E-Mail: info@bvi-marine.com
www.bvi-marine.com.hk
2 3 Motor-Services Hugo Stamp, Inc.
USA - Ft. Lauderdale, Florida 33315 1 3 Blohm & Voss Industries (Shanghai) Ltd.
Tel.: +1/(0)954/763 3660 Xinzhuang Industry Park
Fax: +1/(0)954/763 2872 No. 318, Yuan Shan Rd.
CN - 201108 Shanghai
Asia Tel.: +86-21 64 42 22 11
India Fax: +86-21 64 42 20 66
1 2 3 BOLLFILTER India Pvt. Ltd. E-Mail: shanghai@bvi-marine.com
"Monarch Plaza", Office No. 106 www.bvi-marine.com.hk
Sector-11, CBD Belapur,
IN - Navi Mumbai 400614 Singapore / Malaysia / Indonesia
Tel.: +91/(0)22/27 56 01 47 1 2 3 MNM Corporation Pte. Ltd.
Fax: +91/(0)22/27 56 01 46 13 Joo Koon Crescent
E-Mail: info@bollfilterindia.com SGP - Singapur 629021
www.bollfilter.com Tel.: +65-68 61 42 22
Fax: +65-68 62 42 22
Japan E-Mail: mnmcorp@mnmcorp.com
1 2 3 BOLLFILTER Japan Ltd. www.mnmcorp.com
Toroa Kobe Bldg. 7F, 4-2-14 Hachiman-dori
651-0085 Chuo-ku South Korea
JP - Kobe 651-0085 1 2 3 Blohm + Voss (Korea) Ltd.
Tel.: +81/(0)78/242 8550 760-3, U-dong, Haeundae-gu
Fax: +81/(0)78/242 8515 ROK - 612-020 Pusan 1 Verkaufsbüro Agency
E-Mail: info@bollfilter.jp Tel.: +82-51-740 57 01/2/3 2 Lager Stockist
www.bollfilter.jp Fax: +82-51-740 57 04/5/6 3 Service Service
E-Mail: bvkorea@bvkorea.com
Januar 2010

Operating instructions for automatic filter
Type 6.72.1
Nominal diameter DN 40
Filter element Filter candle
Print document on both sides
NOTE:
50170 Kerpen
Germany
www.bollfilter.de
Date Version Language Order No. Item No.

08.2009 001 en - -
1/70
Table of Contents
1 Preamble. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Warranty and liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Basic safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.1 Proper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Warnings and symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.3 Target group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.4 Obligations of the user/operator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.5 Selection and qualifications of staff . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.6 Organisational measures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.6.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.6.2 Maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7.1 Filtered media . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.7.2 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Transportation and storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.1 Transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.2 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3.3 Packaging material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4 Scope of delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.1 Type plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
5.2 Overview of automatic filter assembly group . . . . . . . . . . . . . . . . . . 15
5.3 Overview of bypass filter and plug valve circuit assembly group. . . 19
6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 Filter installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2.1 Floor fastening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2.2 Installation diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2.3 Identifying the flow direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2.4 Filter inlet/outlet pipe connections . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2.5 Flushing oil outlet pipe connection. . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2.6 Filter heating (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.7 Connection of compressed air supply . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.8 Electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.9 Potential equalisation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1 Functional description of the automatic filter . . . . . . . . . . . . . . . . . . 27
7.1.1 Filter housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1.2 Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
7.1.3 Differential pressure monitoring system . . . . . . . . . . . . . . . . . . . . . 27
7.1.4 Air tank and flushing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
7.1.5 Pivoting actuator (pneumatic) with limit switch . . . . . . . . . . . . . . . . 30
7.1.6 Flushing valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

7.1.7 Filtration stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.1.8 Backflushing stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.2 Functional description of the plug valve switch-over circuit . . . . . . . 35
7.3 Functional description of the bypass filter . . . . . . . . . . . . . . . . . . . . 36
7.3.1 Housing cover safety device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
7.4 Automatic filter filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.4.1 Filter insert with filter candles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
7.4.2 Functional description of the filter insert with filter candles . . . . . . . 39
7.5 Bypass filter filter insert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.5.1 Star-pleated filter element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.5.2 Functional description of the star-pleated filter element . . . . . . . . . 41
7.6 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.6.1 Determination of time interval for time-controlled backflushing . . . . 43
7.7 Removal from service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.7.1 Short-term removal from service . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
7.7.2 Longer term removal from service / removal . . . . . . . . . . . . . . . . . . 44
7.7.3 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
8 Maintenance and servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
8.2 Cleaning agents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.3 Special tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
8.4 Maintenance intervals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
8.5 Cleaning/replacing the filter element on the automatic filter . . . . . . 49
8.5.2 Removing the filter insert with filter candles. . . . . . . . . . . . . . . . . . . 52
8.5.3 Cleaning the filter insert with filter candles. . . . . . . . . . . . . . . . . . . . 53
8.5.3.1 Cleaning the filter candles in case of stubborn soiling . . . . . . . . . . . 54
8.5.4 Installing the filter insert with filter candles. . . . . . . . . . . . . . . . . . . . 55
8.5.5 Concluding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.6 Cleaning/replacing the filter element on the bypass filter . . . . . . . . 57
8.6.2 Removing the star-pleated filter element . . . . . . . . . . . . . . . . . . . . . 58
8.6.3 Cleaning the star-pleated filter element . . . . . . . . . . . . . . . . . . . . . . 59
8.6.4 Installing the star-pleated filter element . . . . . . . . . . . . . . . . . . . . . . 60
8.6.5 Concluding work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.7 Manually backflushing the filter in the event of power failure. . . . . . 61
8.8 Remedying faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.8.1 Trouble shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
9 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9.1 Supplier's documentation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.2 Cleaning devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
9.3 BOLL CLEAN 2000 cleaning agent product information . . . . . . . . . 67
representatives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

1 Preamble
1.1 General
These operating instructions are designed to make it easier to get to know the
BOLL & KIRCH filter and make use of its proper intended uses.
The operating instructions contain all important instructions on how to operate
the filter safely, properly and economically. Adherence to the operating
instructions helps to prevent hazards, repair costs and reduce down times and
increase the reliability and even the serviceable life of the filter. Read the
operating instructions carefully and attentively.
Supplement the operating instructions with any instructions required due to
existing national and international regulations for the prevention of accidents and
environmental protection. Make sure that the operating instructions are always
available in the place of use for the filter. The operating instructions must be read
and applied by every person given the task of performing the following work:
• transportation,
• installation,
• operation,
• maintenance and servicing,
• Disposal.
1.2 Warranty and liability

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

1.3 Copyright
These operating instructions are a certified document as per the terms of the law
against unfair competition.
The copyright of the document is held by

BOLL & KIRCH Filterbau GmbH
50170 Kerpen
Germany
These operating instructions are for the user of the filter and the user's staff. They
contain text and drawings which, without the express permission of the
manufacturer must not be
• reproduced,
• distributed or
• otherwise made available to others, either in full or in part.
Failure to comply will require compensation.

2 Basic safety instructions
2.1 Proper use
The filter is constructed with state-of-the-art technology and according to the
recognised rules of safety. However, use of the filter may result in risks to the life
and limb of the user or third parties and/or damage to the filter or other objects of
material value.
Only use the filter if it is in a technically perfect condition and only use it properly;
paying due attention to safety and hazards, and in adherence to the operating
instructions. It is particularly important to remedy any faults (or have them
remedied), which may compromise safety.
The filter is designed for filtering liquid media only. The filter is designed for
installation in pipelines. The type of medium agreed in the order, and the limit
values for operating pressure and temperature as set out in the technical data
sheet, must be adhered to. Any other type of use or use going beyond this use,
is regarded as improper use. The manufacturer/supplier shall not be liable for
any damage caused as a result of improper use. The user bears the sole risk.
Proper use includes observance of the operating instructions and adherence to
the inspection and maintenance conditions.
Operationally safe function is only ensured if all the instructions, settings and
performance limits for the filter, are adhered to.
2.2 Warnings and symbols

The following designations and symbols are used in the operating instructions to
denote particularly important information:
DANGER!
Denotes immediate hazard with high risk which will cause death or serious
WARNING!
Denotes possible hazard with medium risk which may cause death or serious
CAUTION!
Denotes a hazard with low risk which could cause light or medium physical injury
or material damages if not avoided.
NOTE
Denotes special user tips and other particularly useful or important information.
DISPOSAL
Denotes special measures for environmental protection.
2.3 Target group

The operating instructions apply for use by qualified specialist staff only.

2.4 Obligations of the user/operator
• Always keep the operating instructions at hand at the place of use of the filter.
• Adhere to general legal and other binding regulations for the prevention of
accidents and environmental protection, and provide supplementary
instructions in the operating instructions accordingly. This type of obligation
can apply to the handling of hazardous substances or the provision/wearing
of personal safety clothing and equipment, for instance.
• Supplement the operating instructions with your own instructions, including
supervision and reporting obligations for specific operational matters, e.g.
with regard to organisation of work, working sequences and the appointed
staff.
• Observe all existing safety instructions and hazard warnings on the filter.
• Keep all existing safety instructions and danger signs on the filter complete
(in number) and in a legible condition.
• Do not make modifications of any kind to the filter which may compromise
safety, without the permission of the manufacturer.
• The spare parts which are used must comply with the technical requirements
set out by the manufacturer. This is always guaranteed by the use of original
spare parts.
• The user is responsible for the selection of materials and the chemical
resistance of the installed components, internal linings and coatings. The
user must specify the technical details when ordering the filter.
2.5 Selection and qualifications of staff

• All work on the filter must be performed exclusively by reliable staff. Staff
must not be under the influence of drugs or medication. Adhere to the legal
minimum age requirement.
• Only appoint trained staff or staff who have received appropriate instruction.
Clearly delegate the areas of responsibility of staff for installation, operation
and maintenance and servicing.

2.6 Organisational measures
2.6.1 General
• Follow the respective valid national and international regulations for the
prevention of accidents.
2.6.2 Maintenance and servicing
• Adhere to the maintenance tasks and intervals set out in the operating
instructions, including instructions on the replacement of parts/equipment.
• Only use original spare parts.
• If the filter is subject to a regular inspection by an inspection and testing
organisation, with regard to temperature, steam pressure and the
dangerousness of the medium, the inspection periods must be adhered to by
the user.
2.7 Consumables
• Observe the regulations for environmental protection. Make sure that
consumables are disposed of properly and in an environmentally friendly
manner.
2.7.1 Filtered media
• When handling media which are to be filtered, make sure you follow the
respective safety regulations for the media.
2.7.2 Cleaning agents
• When handling the cleaning agents, make sure you follow the respective
safety regulations for the cleaning agents.

3 Transportation and storage
3.1 Transportation
DANGER!
Risk of accidents from falling loads
During transportation of the filter, accidents may occur due to sizes and weights.
• Exercise extreme caution when transporting the filter in order to prevent
damage to or deformation of the filter.
• Only use suitable means of transport and lifting gear with sufficient load-
bearing capacity.
suspended loads.
3.2 Storage
CAUTION!
Improper storage will cause damage to the filter and filter elements
If stored incorrectly and improperly, moisture and contamination, for example,
may cause damage to the filter and the filter elements.
• Protect the filter and filter elements from moisture and contamination during
storage.
• Do not store the filter and filter elements below the frost line.
• If the filter and the filter elements have been stored for more than one year,
check that all seals are fully functional before installation.
3.3 Packaging material

CAUTION!
Risk of explosion from electrostatic charge
Packaging material, such as paper or plastic, can become statically charged and
generate sparks when discharged.
• Remove the packaging material before transportation into an explosion
protected zone.
DISPOSAL
Observe the regulations for environmental protection. Make sure that the
packaging material is disposed of properly and in an environmentally friendly
manner.

4 Scope of delivery
Immediately after receiving the delivery, check that the content is not damaged
and that it corresponds to the scope of the order. In case of discrepancies,
contact the manufacturer.

5 Technical data
NOTE
The filter described in these operating instructions is a combination of an
automatic filter and a bypass filter. The switchover between the two filters is
performed using a plug valve switch-over circuit.
NOTE
You will find the technical data in the appendix of these operating instructions.
5.1 Type plate

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

NOTE
The description of assembly groups can be found in the "Operation" chapter of
these operating instructions.

13 14 13 12
1
12
3
11
6
8
10
Fig. 5-1 Overview of assembly groups (exterior view I)
1 Air tank 8 Flushing valve

2 Pressure gauge 9 Draining
3 Safety valve 10 Type plate
4 Pressure controller 11 Terminal box (optional)
5 Solenoid valve (flushing valve) 12 Pressure gauge (optional)
6 Ball valve 13 3-way ball valve (optional)
7 One-way restrictor valve 14 Differential pressure
monitoring system
NOTE
Depending on the filter configuration, the differential pressure monitoring system
can be fitted to the bypass filter, see section 5.3.

1
Fig. 5-2 Overview of assembly groups (view II)
1 Filter housing 5 Pivoting actuator (pneumatic)

2 Cam disc 6 Upper section of housing
3 Limit switch 7 Lower section of housing
(optional)
4 Solenoid valve (pivoting 8 Shut-off valve
actuator)
NOTE
In conjunction with a bypass filter, the shut-off valve are positioned on the plug
valve switch-over circuit, see section 5.3.

1
6
3
4
N1
N2
N4
N3
N5
Fig. 5-3 Overview of assembly groups (cross sectional view)
1 Vent (automatic) 7 Spacer

2 Filter candle N1 Filter inlet
3 Valve tappet N2 Filter outlet
4 Candle holder N3 Flushing oil outlet
6 Change-over housing cover N5 Heating medium outlet

5.3 Overview of bypass filter and plug valve circuit assembly
group
1 2 3 4 5 6
9
15
N1
10
11
15 12
N2 N4
13
N5
14
1 Plug valve position sign 11 Filter element

2 Wrench 12 Draining
3 Seal (Tec-ring) 13 Filter heating (optional)
4 Cover (Plug valve switch-over 14 Plug valve
circuit)
5 Cover (Bypass filter) 15 Shut-off valve
6 Housing cover safety device N1 Inlet
including vent
7 Seal N2 Outlet
8 Vent N4 Heating medium inlet
9 Seal N5 Heating medium outlet

10 Housing
Fig. 5-5 Overview of assembly groups (view II, with differential pressure signal)
1 Differential pressure monitoring system

2 Shut-off valve

6 Installation
DANGER!
Risk of accidents from improper installation
Incorrect installation and failure to observe the listed safety instructions can lead
to accidents or damage to property.
Make sure of the following:
• The filter must be installed by qualified specialist staff or persons who have
received appropriate instruction.
• Only use suitable lifting gear with sufficient load-bearing capacity.
• Only use lifting gear on the provided suspension points (if available).
• Use lifting gear in such a way that the filter does not become damaged.
• Raise the filter evenly. Avoid tilting.
suspended loads.
• Additional devices to prevent maximum temperatures being exceeded and
temperatures dropping below the minimum and for compensation and relief
of overpressure, must be provided by the user throughout the entire system
of the plant. Observe the minimum and maximum permitted operating
temperatures and pressure values for the filter.
• Additional devices for monitoring the ambient temperature of the filter must
be provided by the user throughout the entire system of the plant.
• Install a ground cable with a cross section of at least 10 mm² as a potential
equalisation for the filter.
NOTE
Contact the manufacturer with any special questions you may have regarding
installation. The contact data for the respective national subsidiaries can be
found in the appendix of the operating instructions.

6.2 Filter installation
CAUTION!
Risk of damage to the filter housing
The filter housings are only designed for internal overpressure.
• The housing and connection flanges of the filter must not be exposed to any
external force or moment.
DANGER!
Combustible medium
When filtering combustible medium expelled medium may cause fires and
personal injuries.
• Adhere to the valid fire safety regulations when carrying out any work on the
filter.
6.2.1 Floor fastening
1 3 3
A B
Fig. 6-1 Automatic filter, floor fastening

2 Floor fastening B without filter heating
3 Fastening point
X Make sure the foundation has sufficient load bearing capacity.

X Make sure that there is sufficient space in the vicinity of the filter for
maintenance and servicing work.
X Align the filter.
X Screw the filter housing to the fastening points. When fastening the filter in
place, the filter housing must not be twisted.

6.2.2 Installation diagram
3
2
7 6
Fig. 6-2 Installation diagram
1 Filter 5 to the consumer

2 Scope of delivery (standard) 6 Pump
3 Vent (automatic) 7 Tank
4 Flushing oil line 8 Filter heating (optional)
6.2.3 Identifying the flow direction
NOTE
• The filter inlet/outlet and flushing oil outlet are indicated by the inscriptions
(Ein/In), (Aus/Out) and (Spülölaustritt/Flushing oil).
• The direction of flow is also shown in the technical data sheet which is
included in the appendix of these operating instructions.

6.2.4 Filter inlet/outlet pipe connections
X Establish the connections between the filter and piping.

X The pipes for the filter inlet and outlet may need to be provided with additional
supports, depending on the installation conditions. When installing the piping,
the filter housing must not be twisted.
NOTE
BOLL & KIRCH Filterbau GmbH recommends installing shut-off fittings in the
piping in front and in back of the filter.
6.2.5 Flushing oil outlet pipe connection
X Establish the connection between the flushing oil outlet and piping.
X Use the appropriate seal.
X Select a pipe cross section which is at least equal in size to the pipe cross
section shown in the technical data sheet. A cross section which is too small
may cause backpressure. The pipe must also be laid with an inclination and
bled.
X The pipe may need to be provided with additional supports, depending on the
installation conditions. When installing the piping, the filter housing must not
be twisted.

6.2.6 Filter heating (optional)
The filter heating is used during the filtering process to cover heat loss in the filter
and before starting up the plant in order to heat up the medium in the filter. The
filter can be heated with water vapour, hot water or thermal oil.
DANGER!
Risk of accidents from expelled hot medium
Too much pressure in the heating system can cause hot medium to be expelled
and lead to damage to the filter and accidents.
• Adhere to the maximum permitted operating temperature and operating
pressure for the filter heater.
X Connect the medium-carrying pipes to the filter heating on the plant side.
X The pipes for the heating medium inlet and outlet may need to be provided
with additional supports, depending on the installation conditions. When
installing the piping, the filter housing must not be twisted.
6.2.7 Connection of compressed air supply
2
3
Fig. 6-3 Connection of compressed air supply
1 Air tank
2 Ball valve
X Connect the plant's compressed air supply line to the one-way restrictor
valve on the ball valve.

6.2.8 Electrical connections
DANGER!
Risk of accidents from electric shock
When connecting to the power supply, the supply voltage can cause accidents
from electric shock.
• All the electrical connections on the filter must be made by a qualified
electrician and in line with the rules of electrical engineering.
Controller
NOTE
Differential pressure monitoring system, electrical
NOTE
You will find more detailed information on the differential pressure monitoring
system in the appendix of these operating instructions or in the manufacturer's
documentation.
NOTE
BOLL & KIRCH Filterbau GmbH differential pressure indicators have potential-
free contacts.
6.2.9 Potential equalisation
X For potential equalisation, install a ground cable with a cross section of at

least 10 mm² on the filter.
X Connect the ground cable to the fastening screw on the filter. If necessary,
prior to the installation of the ground cable, remove the paint from the
fastening point to ensure sufficient electrical contact.

7 Operation
7.1 Functional description of the automatic filter
The filter is used to filter particles from media in order to protect the downstream
parts of the plant.
The filter candles are cleaned automatically so that the plant does not have to be
switched off for cleaning.
7.1.1 Filter housing
The filter housing, comprising the lower housing section with the filter heating or
floor fastening without filter heating (optional), the upper housing section and
filter housings, contains all the pipe connections. The flushing valve is installed
on the upper section of housing.
The filter housings are arranged around the central drilled hole for fitting the plug
valve on the upper section of housing. A cover seals the plug valve off from the
outside, The pivoting actuator is fitted to it with a spacer.
7.1.2 Controller
The controller regulates and monitors all automatic filter functions.
NOTE
7.1.3 Differential pressure monitoring system
The differential pressure monitoring system measures the differential pressure

between the filter inlet and filter outlet. As the soiling increases, the differential
pressure in the filter also increases.
The controller processes the electrical signals from the differential pressure
monitoring system and triggers a backflushing process when the set maximum
value is reached.
NOTE
• You will find more detailed information on the differential pressure monitoring
system in the appendix of these operating instructions or in the
manufacturer's documentation.
• The differential pressure can also be displayed optically on the differential
pressure monitoring system.
• The control line for the differential pressure monitoring system is fitted with
shut-off valves (e.g. shut-off valves).

3 2 1 2 3
Fig. 7-1 Differential pressure monitoring system installation example
1 Differential pressure 4 Shut-off valve

monitoring system
2 3-way ball valve (optional) 5 Terminal box (optional)
3 Pressure gauge (optional)
The location for installation of the differential pressure monitoring system varies
depending on the filter configuration
Optional pressure gauges allow you to quantify the differential pressure.
The optional 3-way ball valves make it possible to check that the differential
pressure monitoring system is fully functional as and when required. The levers
have to point downwards when in operation.

7.1.4 Air tank and flushing valve
3 1
Fig. 7-2 Overview of the air tank
1 Air tank
2 Pressure gauge
3 Safety valve
4 Pressure controller
6 Ball valve
The compressed air in the air tank expands explosively when the solenoid valve
(flushing valve) is switched and opens the flushing valve. The flow which this
causes, pushes the medium on the clean side through the filter candles in the
counterflow direction at high speed. The pressure level in the air tank can be read
from the pressure gauge and set using a pressure controller. The air tank is
equipped with a safety valve to prevent the air tank from being damaged by
excessive positive pressure.

7.1.5 Pivoting actuator (pneumatic) with limit switch
If the pressure gradient between the dirty side and the clean side reaches a set
value due to the growing layer of dirt on the filter material, the automatic filter
chamber regeneration is triggered. The pivoting actuator turns the plug valve so
that the flow to the soiled filter chambers is shut off and, at the same time, the
stand-by filter chamber is activated. If the plug valve reaches the filter chamber
which is to be cleaned, the pivoting movement is stopped. The pivoting actuator
is actuated by a solenoid valve (pivoting actuator). The limit switch monitors the
position of the plug valve. If the plug valve is in the incorrect position, the flushing
process in the soiled filter chamber does not start.
7.1.6 Flushing valve
The pneumatically actuated flushing valve opens and closes the flushing oil
outlet at the start and end of the backflushing phases respectively. After a delay,
when the flushing valve is opened by the valve tappet, the compressed air supply
for backflushing flushing from the air tank is opened. A solenoid valve (flushing
valve) regulates the supply of compressed air for actuation of the flushing valve.

7.1.7 Filtration stage
N1
N2
3
Fig. 7-3 Filtration stage
1 Filter candle 5 Air tank

2 Plug valve N1 Filter inlet
3 Flushing valve N2 Filter outlet

The medium being filtered flows through the lower inlet flange into the housing,
from where it flows into the activated filter chamber and to the filter candles. The
medium flows through the filter candles from the outside to the inside and the
particles in the medium are held back on the filter medium of the filter candles.
The solenoid valve (flushing valve) is switched so that the flushing valve is
closed.
The plug valve isolates the cleaned filter chamber.
In the air tank, compressed air is available for the next backflushing.

7.1.8 Backflushing stage
11
5
10
6
N1 9
8
N2
N3
Fig. 7-4 Backflushing stage
1 Vent (automatic) 8 Flushing valve

2 Filter candle 9 Valve tappet
3 Limit switch and cam disc 10 Solenoid valve (flushing valve)
4 Solenoid valve (pivoting 11 Air tank
actuator)
5 Pivoting actuator (pneumatic) N1 Filter inlet
6 Differential pressure N2 Filter outlet
monitoring system
7 Plug valve N3 Flushing oil outlet

The foreign substances held back on the filter candles generate a growing
differential pressure between filter inlet and outlet.
Backflushing is triggered by the controller when the differential pressure reaches
a certain value.
When backflushing is triggered, the pneumatic pivoting actuator is switched over
by the solenoid valve (pivoting actuator) and the plug valve is pivoted from the
contaminated filter chamber to the filter chamber which is on stand-by.
The switch-over to the stand-by filter housing with a clean filter candles causes
immediate differential pressure relief. If the plug valve reaches the filter chamber
which is to be cleaned, the pneumatic pivoting movement is switched off. The
limit switch checks the position of the plug valve.
The solenoid valve (flushing valve) is then switched over electrically, causing the
flushing valve to open and the isolated filter chamber to depressurise.
Whilst the flushing valve is performing the opening movement (depending on the
depressurisation of the filter candles) the compressed air from the air tank enters
into the shut-off filter chamber and accelerates the medium in the filter chamber,
pressing it through the filter candles in the counterflow direction.
The drop in pressure which this creates causes the foreign substances deposited
on the filter material to be flushed off and flushed out of the filter housing via the
open flushing valve.
After the flushing time has elapsed, the solenoid valve (flushing valve) is
switched over electrically, causing the flushing oil outlet to close. At the same
time, the supply of stored backflushing air is ended. Once the flushing valve is
closed, the air tank is re-filled with compressed air.
The backflushed filter chamber is then filled with cleaned medium through a filling
hole until the correct operating pressure is achieved. In the process, the air in the
filter chamber is discharged by an automatic vent.
NOTE
The backflushing process is completed; the cleaned filter chamber remains shut
off from the filtration process until the next backflushing process.
CAUTION!
Risk of damage to the filter from improper flushing
Flushing an only partially filled filter causes increased strain on the filter candles.
• Never perform backflushing due to installation or control circumstances in an
only partially filled filter. A completely drained filter can be flushed for test
purposes without any restrictions.

7.2 Functional description of the plug valve switch-over circuit
The plug valve switch-over circuit is used to switch between the connected
automatic and bypass filter. The special shape of the plug valve prevents
interruptions in the flow of medium and pressure surges when switching over
and, at the same time, guarantees freedom of movement due to lower levels of
frictional force. The plug valve only requires seals in two positions; on the large
washer and on the plug valve neck.
The construction of the plug valve can compensate the pressure between the two
connected filters, depending on the position of the plug valve.
1 5
2 4
Fig. 7-5 Position of the plug valve circuit
1 Automatic filter in operation, pressure compensation valve to bypass

filter closed
2 Automatic filter in operation, pressure compensation valve to bypass
filter open
3 Automatic filter and bypass filter in operation
4 Bypass filter in operation, pressure compensation valve to automatic
filter open
5 Bypass filter in operation, pressure compensation valve to automatic
filter closed
The switch-over is performed manually using the attachable lever. The sign on
the cover, in conjunction with the marking on the plug valve neck, indicates the
direction of flow and thus shows which filter is in operation and whether the
pressure compensation valve is open or closed. The construction of the circuit
prevents both filters from being shut down at the same time.

NOTE
The measuring points for the differential pressure monitoring system are situated
at the inlet and outlet to the plug valve switch-over circuit.
CAUTION!
Risk of damage to the filter if the plug valve switch-over circuit is
positioned incorrectly
With a closed pressure compensation valve, the medium may be subject to heat
expansion and cause an increased build-up of pressure in the filter chamber
which is shut off.
• The pressure compensation valve must always remain open during
operation.
• The pressure compensation valve must only be closed when cleaning the
automatic filter or bypass filter.
7.3 Functional description of the bypass filter

The bypass filter is used to filter particles from media in order to protect the
downstream parts of the plant. The bypass filter is used in situations in which the
filtering process must not be stopped even whilst maintenance or repairs are
being performed on the automatic filter.
The medium being filter flows into the housing through the upper inlet flange and
from there into the filter chamber. The medium flows through the filter element
from the inside to the outside and the particles in the medium are held back on
the filter material of the filter element.

7.3.1 Housing cover safety device
1 2 3 4
Fig. 7-6 Housing cover safety device
1 Cover 3 Housing cover safety device

2 Vent 4 Threaded connector
The housing cover safety device has the task of preventing pressurised medium
from being expelled uncontrolledly in case of incorrect operation. The cover
sheet covers a minimum number of cover screws so that the cover cannot be
removed without opening the vent to bleed the system.
The filter chamber is relieved via the vent. When the filter is shut off, the operating
pressure is immediately relieved and hardly any medium is expelled. Otherwise,
close the vent immediately and the expulsion of medium is limited.

7.4 Automatic filter filter insert
7.4.1 Filter insert with filter candles
1 1
2 2
3 3
Fig. 7-7 Construction of the filter insert with filter candles
1 Filter candle
2 Candle holder
3 Seal

7.4.2 Functional description of the filter insert with filter candles
Filter inserts with filter candles are used for filtration. The flow runs from the
outside to the inside into the individual filter candles.
Particles of dirt in the flow are thus filtered off by the filter material in the filter
candles. The cleaned medium exits from the bottom of the filter candles and is
fed back into the plant.
The filter insert comprises several filter candles arranged in parallel. The filter
candles all have the same dimensions; they are interchangeable and can also be
removed separately. They are screwed into the candle holder.
The type, design and number of filter candles used depends on the medium
being filtered.
For media with a high ferrite content, the filter candle on the filter candle insert
can be replaced with an optional magnetic primary filter.
The candle holder secures the filter candles and thus protects the filter material
on the filter candles from damage during removal and installation.
The dirty side is sealed off from the clean side by a seal on the candle holder.

7.5 Bypass filter filter insert
7.5.1 Star-pleated filter element
1
2
5
6
Fig. 7-8 Construction of star-pleated filter element
1 Filter element clamp 5 Perforated sheet

2 Sieve ring 6 Magnetic insert (optional)
3 Seal 7 Filter bottom
4 Filter material
NOTE
The shape of the filter element clamp may vary depending on the nominal
diameter of the filter.

7.5.2 Functional description of the star-pleated filter element
Star-pleated filter elements are used for filtration. The direction of flow through
the star pleated-filter element is from the inside to the outside.
Particles of dirt in the flow are thus filtered off by the star-pleated filter element.
The cleaned medium then exits from the star-pleated filter element and is fed
back into the plant.
The bypass filter is fitted with a star-pleated filter element.
The filter element clamp fastens the star-pleated filter element in the filter
chamber.
The dirty side is sealed off from the clean side by a seal.
Construction and function of the magnetic insert (optional)

For media with a high ferrite content, it is recommendable to equip the star-
pleated filter element with a magnetic insert.
The magnetic insert comprises a cylinder-shaped magnet which is mounted on
a metal bar. The top end of the magnetic insert has a thread for connecting it to
the filter element clamp.
The magnetic insert is removed for cleaning and the collected dirt particles can
be easily wiped off.

7.6 Commissioning
CAUTION!
Risk of damage to the filter from improper filling
If the filter is filled improperly, the filter elements may be damaged.
not permitted.
NOTE
X Check whether all connections have been made properly.

X Open the shut-off valves in the control line to the differential pressure
monitoring system.
X Check the position of the 3-way ball valves (if fitted) on the differential
pressure monitoring system (levers must point downwards).
X Make sure that there is compressed air with sufficient operating pressure on
the filter's ball valve.
CAUTION!
Risk of damage to the filter if operated without compressed air supply
If the controller is switched on and the filter is commissioned without compressed
air supply, the solenoid valves may become damaged.
• Always open the filter's ball valve first when commissioning in order to ensure
that compressed air is supplied.
X Open the compressed air shut-off valve on the filter.

X Check the set pressure on the air tank's pressure gauge. If necessary, adjust
the pressure on the pressure controller.
operation, pressure compensation valve to bypass filter open" position.
X Put the filter heating (if fitted) into operation and wait until the filter has heated
up.
X Put the filter into operation using the controller. Backflushing is automatically
performed in one of the filter chambers.
NOTE
X Check that the controller is functioning by performing backflushing manually.

X Open the filter outlet shut-off valve
X Slowly open the filter inlet shut-off valve. Avoid pressure surges.

DANGER!
DISPOSAL
X Open the vent on the top of the housing of the bypass filter. The bypass filter
is filled via the open pressure compensation valve.
X Close the vent as soon as medium is expelled from a vent without any
bubbles.
X Carry out backflushing once more manually using the controller.
X The filter is ready for operation.
DISPOSAL
X After each time you commission the filter, check the filter for leaks and
eliminate them as necessary.
7.6.1 Determination of time interval for time-controlled backflushing
X Allow the filter to operate for 24 hours with differential pressure and record
the number of flushes from the flushing cycle counter or the controller. In
order to allow the filter to operate for 24 hours with differential pressure, you
have to deactivate the intervals for forced flushing on the controller.
X Calculate the average of all flushing intervals.
X Reset the flushing interval time (which should be 30 % shorter) on the
controller.

7.7 Removal from service
7.7.1 Short-term removal from service
NOTE
When using the filter in watery media, it is imperative to adhere to the following:
• Do not allow the filter to run to empty after switching off the supply pump. Dirt
may otherwise be allowed to harden.
• If the above condition cannot be met, set the controller so that backflushing
is triggered every 2 hours even if the supply pump is switched off.
7.7.2 Longer term removal from service / removal
NOTE
When removing the filter and taking it out of service for longer periods, pay
attention to the following points:
• The filter must be completely emptied.
• Disconnect all connections from the filter.
• The filter must be thoroughly cleaned.
• The filter must be sealed by applying an appropriate anticorrosive, if
necessary.
• The connection flange openings must be sealed with plastic (or similar)
dummy plugs.
7.7.3 Disposal
DISPOSAL
When the filter or individual components and consumables are finally disposed
of, make sure that they are disposed of in an environmentally friendly manner.

8 Maintenance and servicing
DANGER!
Risk of accidents from improper maintenance and servicing
Incorrect maintenance and servicing and failure to observe the listed safety
instructions can lead to accidents or damage to property. Make sure of the
following:
• Maintenance and servicing work must only be carried out by qualified
specialist staff or persons who have received appropriate instruction.
• When performing any work on the filter, always wear the appropriate safety
clothing.
• Only perform maintenance and servicing work when the filter is cooled,
depressurised and drained. Depending on the operating temperature, there
may be a risk of burns.
• Ensure the highest levels of cleanliness when opening the filter. No foreign
substances, e.g. tools, cleaning cloths, impurification etc., must be allowed
to remain in the filter.
• Visually inspect all seals during maintenance and replace them as
necessary.
• Clean all sealing surfaces thoroughly before assembly.
• On completion of the maintenance work, re-fit all available safety equipment
properly.
not permitted.
• Remove the filter from service if the inspection periods (if indicated) have
elapsed.
• Filter elements are sensitive to pressure and impact. Always exercise
extreme caution when installing and removing the filter elements. Before
installation, check all filter elements/seals and replace any damaged filter

8.2 Cleaning agents
CAUTION!
Risk of damage to the filter from incorrect use of cleaning agents
The components of the filter may become damaged if cleaning agents are used
incorrectly. The correct cleaning agent is selected in accordance with the type of
medium being filtered and the associated contaminations.
• BOLL & KIRCH Filterbau GmbH recommends BOLL CLEAN 2000 cleaning
instructions.
8.3 Special tool

The manufacturer provides the following special tools for the filter:
Wrench for removing the filter elements
Key for opening the controller
Key for fitting filter housings
Guide pins for filter housing removal

8.4 Maintenance intervals
Even automatic filters have to undergo regular checks and maintenance.
It is particularly important to note that the filter material on the filter elements may
become blocked over time despite regular backflushing. This depends largely on
the quality of medium and the available partial flow cleaning function. The soiling
can be removed by cleaning the filter elements by hand using a suitable cleaning
agent.
NOTE
instructions.
You can tell that the filter elements are becoming increasingly blocked because
the flushing intervals become shorter and shorter.
The number of backflushing cycles performed is recorded by the controller.
CAUTION!
Risk of damage to the filter and the plant from damaged filter elements
If the flushing intervals suddenly become longer, this may indicate that the filter
elements are damaged.
• In such an event, check all filter elements for damage immediately. Replace
any damaged filter elements as necessary.
In order to make sure the automatic filter continues to operate properly,

– the leak tightness of the automatic filter, especially all connections and
seals and
– the automatic filter for corrosion and other damage,
– the condition of the filter elements and
tightened.
• Check all filter elements for soiling after the first 500 flushes, then after a
further 5,000 and afterwards, every 10,000 flushes. To do so, remove the
filter inserts and clean the filter elements. If the backflushing intervals shorten
considerably beforehand, you must carry out checks and cleaning earlier.
• Check the flushing oil outlet for leaks every 10.000 flushes. No medium must
be expelled at the end of the flushing oil line during the filtration stage.
• The automatic filter must be inspected annually for leaks.
• Replace all seals at least every 2 years and when overhauling the automatic
filter.
NOTE
The filter elements are subject to wear from two-way strain. It is therefore
recommendable to keep a complete set of filter elements in stock.

In order to make sure the bypass filter continues to operate properly,
– the leak tightness of the bypass filter, especially all connections and seals
and
– the bypass filter for corrosion and other damage,
– the condition of the filter element and
tightened.
• The bypass filter must be inspected annually for leaks.
• Replace all seals at least every 2 years and when overhauling the bypass
filter.
In order to make sure the plug valve switch-over circuit continues to
operate properly, observe the following points for maintenance:
– the leak tightness of the complete plug valve circuit, especially all
connections and seals,
– the freedom of movement of the plug valve,
– the plug valve switch-over circuit for corrosion and other damage and
tightened.
• The plug valve circuit must be inspected annually for leaks.
• Replace all seals at least every 2 years and when overhauling the plug valve
circuit.

8.5 Cleaning/replacing the filter element on the automatic filter
NOTE
X Set the key on the plug valve circuit to the "Bypass filter in operation,
pressure compensation valve to automatic filter closed" position. The bypass
filter is thus in operation. The closed pressure compensation valve prevents
any medium from flowing into the automatic filter.
X Trigger backflushing on the controller.
X Afterwards, close the ball valve for the filter's compressed air supply.
X Then, carry out manual backflushing for the filter chamber which has not yet
been flushed.
X Switch off the controller.
DANGER!
Risk of accidents due to controller being switched on unintentionally
During maintenance accidents may be caused if the controller is switched on
unintentionally, e.g. by starting up the drives or from expelled medium.
• Secure the controller to prevent it from being switched on unintentionally, e.g.
by attaching a lock.
X Check the pressure gauge to establish whether the air tank is genuinely
depressurised.
X The filter chambers are now drained and depressurised.
CAUTION!
DANGER!
Hot medium may be expelled when opening the filter chamber.
• Depressurise and lower the level of medium before removing the filter insert.

1
Fig. 8-1 Removing the filter housing
1 Venting line
2 Filter housing
3 Screw
4 Upper section of housing
X Disconnect the venting lines from the filter housings.

X Unfasten the screw connection for the filter housings with the key included in
the scope of delivery.

A B
2
3
5
6
Fig. 8-2 Lifting off / setting down the filter housing
1 Filter housing 5 Change-over housing

2 Filter element 6 Seal
3 Guide pins A Inserting guide pins
4 Screw B Lifting off / setting down the
filter housing
CAUTION!
Risk of damage to the filter elements due to improper installation / removal
for the filter housings
• When installing / removing the filter housings, proceed with extreme care.
• Use the guide pins to install / remove the filter housings.
X Screw the guide pins into the change-over housing.

X Lift the filter housings off the upper section of housing.

8.5.2 Removing the filter insert with filter candles
Fig. 8-3 Removing the filter insert with filter candles
1 Filter element
2 Candle holder
3 Seal
X Remove the filter inserts from the housing by pulling vertically upwards.
X Allow the filter inserts to drip dry in a suitable container.

8.5.3 Cleaning the filter insert with filter candles
CAUTION!
Risk of damage to the filter insert from improper cleaning
If the filter insert is cleaned or handled improperly, the filter insert may become
damaged. Observe the following safety instructions:
• The soaking time in the "BOLL CLEAN 2000" cleaning agent must not
exceed 24 hours.
exceed 60 °C.
sufficient distance (at least 20 cm) from the filter material to prevent damage.
• When cleaning the filter insert using a cleaning gun and compressed air, the
pressure must not exceed a maximum of 4 bar.
element.
• Do not place the filter elements on top of each other as you may otherwise
cause damage.
NOTE
instructions.
the filter elements facing downwards. This way, particles detaching from the
filter elements can sink to the bottom.
the soaking stage.
X After soaking, remove the filter insert from the container and place it on a
suitable surface (e.g. perforated plate) with openings of the filter elements
facing downwards. Allow the cleaning agent to drip dry.
X Turn the filter insert around and place it down with the openings facing
upwards.
outside.
X Then dip the filter insert in the container with fresh cleaning agent again, with
the openings of the filter elements facing downwards. Rinse the filter insert
through again by turning it and moving it up and down in the cleaning agent.
X Allow the filter insert to drip dry again.
outside.
X Then check all filter elements for damage. Replace any damaged filter

NOTE
Sufficient cleaning results (approximately 60 %) have been achieved using the
described manual cleaning process for filter elements in similar applications.
In our experience, a cleaning effect of almost 100 % can only be achieved
manually by using the type 5.04 filter element cleaning unit with BOLL CLEAN
2000.
X In case of heavier soiling, you can clean using the high-pressure cleaner
procedure mentioned above. For cleaning, use water or water with cleaning
agent.
8.5.3.1 Cleaning the filter candles in case of stubborn soiling
In case the filter elements are heavily soiled (lacquer contamination, incrustation,
tar residue, fibres, chippings), the individual filter elements will have to be
removed and cleaned.
NOTE
If you do not have a filter element cleaning unit available, proceed as follows:
NOTE
instructions.
the filter elements facing upwards. The openings on the filter elements have
to protrude out of the cleaning agent. This prevents dirt from penetrating into
the clean side.
the soaking stage.
X Remove the filter insert from the cleaning agent. Allow the filter insert to drip
dry with the openings pointing downwards.
X Unscrew and remove the filter elements from the candle holder using the key
included in the scope of delivery.
X Then spray the filter elements through using the high-pressure cleaner with
suitable cleaning agent. First clean from the inside to the outside, then from
the outside to the inside. Repeat the process several times as necessary.
Finally, spray the filter elements from the inside to the out.
X Carefully rinse out the filter elements in fresh cleaning agent and allow the
filter elements to drip dry.
outside.
X Remove any particles collected on the magnetic candle (if fitted).
X Re-assembly is performed by carrying out the steps for disassembly in
reverse order. Clean the candle holder as necessary before assembly.

CAUTION!
Risk of damage to the filter elements from incorrect installation
Improper installation can cause damage to the filter elements.
• Adhere to the recommended tightening torque values for filter candles: 25
Nm for filter candles with a candle diameter of 28 mm or 50 mm.
8.5.4 Installing the filter insert with filter candles
X Clean any soiling which has collected on the inside of the filter.
X Check all the seals for damage. Replace any damaged seals as necessary.
X Insert the filter inserts vertically into the housing from above.
X Make sure that the seals are properly in place.

Fig. 8-4 Vent (automatic)
1 Double nipple
2 Float ball
3 Filter housing
X Check the condition of the vent (automatic) and check that it is functioning:
X Check the condition of the double nipple and
X the condition of the float ball and make sure it moves easily,
Replace any damaged components as necessary.
X Check the seals for damage. Replace any damaged seals as necessary.
X Place the filter housings on the upper section of housing. Make sure that the
seals are properly in place.
X Unscrew and remove the guide pins from the change-over housing.
X Screw the filter housings to the upper section of housing. Tighten the screw
connection evenly, gradually tightening opposite screws step-by-step.
X Connect the venting lines to the filter housings.

8.6 Cleaning/replacing the filter element on the bypass filter
operation, pressure compensation valve to bypass filter closed" position. The
automatic filter is thus in operation. The closed pressure compensation valve
prevents any medium from flowing into the bypass filter.
DANGER!
DANGER!
DISPOSAL
X Depressurise the filter. Carefully open the vent.
DANGER!
Hot medium may be expelled when opening the drain hole.
• Collect the expelled medium in a suitable container.
DISPOSAL
X Empty the filter. Carefully open the drain hole.

X Close the drain hole.
X Unscrew the vent screw far enough so that the securing plate on the cover
safety device can pivot to the side over the covered screws.
X Unfasten the screw connection on the cover.
X Lift the cover off the housing.

8.6.2 Removing the star-pleated filter element
X Remove the filter element from the housing by pulling it vertically upwards.
X Allow the filter element to drip dry in a suitable container.

8.6.3 Cleaning the star-pleated filter element
CAUTION!
Risk of damage to the filter element from improper cleaning
If the filter element is cleaned or handled improperly, the filter element wire mesh
may become damaged. Observe the following safety instructions:
• The soaking time in the cleaning agent is 1 - 4 hours, depending on the level
of contamination. Check the progress of cleaning whilst the element is
soaking.
exceed 60 °C.
sufficient distance (at least 20 cm) from the surface of the filter material to
prevent damage.
element.
X Shake the filter element to remove the coarsest dirt.
NOTE
instructions.
X Place the filter element in a container of suitable cleaning agent with the
opening pointing upwards.
X Allow the filter element to soak.
the soaking stage.
NOTE
X Then spray the filter element with a filter cleaning unit. Cleaning is performed
from the outside to the inside and from the inside to the outside. In the final
working step, the filter element has to be jet cleaned in the opposite direction
to the direction of filtration, i.e. from the outside to the inside.
X Rinse the filter element carefully and allow it to drip dry.
X Check the filter element for damage. Replace any damaged filter elements/
seals as necessary.

8.6.4 Installing the star-pleated filter element
X Clean any contamination which has collected on the inside of the filter
chamber.
X Insert the filter element into the housing from above.
X Make sure that the seal is properly in place.
X Place the cover on the housing. Make sure that the seal is properly in place.
X Screw the cover to the housing. Tighten the screw connection evenly,
gradually tightening opposite screws step-by-step.
X Pivot the securing plate on the housing cover safety device by the screws
which have to be secured, and screw the vent screw tight.

8.7 Manually backflushing the filter in the event of power failure
CAUTION!
Risk of accidents caused by the filter starting back up
The filter can start up again when electrical power returns and the movement of
the pivoting actuator may injure you.
• Before manually actuating the filter, first switch off the controller.
The manual backflushing process is performed in two steps:

• The plug valve pivots to the soiled filter chamber and
• backflushing is performed by opening the flushing valve.
Fig. 8-5 Manual actuation of the solenoid valve
1 Manual actuation on the solenoid valve

2 Solenoid valve (pivoting actuator)
X Check whether there is compressed air on the filter,

X Actuate the solenoid valve (pivoting actuator) manually with a screwdriver to
pivot the plug valve to the soiled filter chamber, Do not move the manual
actuator back into the initial position.
X Trigger backflushing directly by manually actuating the solenoid valve
(flushing valve) with a screwdriver. Manual actuation must last for at least 8 s.
X Move the solenoid valve's (flushing valve) manual actuator back into the
initial position.

X Move the solenoid valve's (pivoting actuator) manual actuator back into the
initial position.
X The automatic venting process in the filter chamber is not completed until the
filling time has elapsed.

8.8 Remedying faults
NOTE
In case of any faults or repairs which are not listed here, contact the BOLL &
KIRCH customer services department.
8.8.1 Trouble shooting

Differential pressure too Air pressure too low Check the compressed
high, no flushing air supply on the filter
connection (see
plant)
Flushing performed High level of soiling in Determine the cause of
often the medium soiling in the plant
elements
Air pressure too low Check the compressed
connection (see
plant)
Piping on the flushing oil Clean the piping (see
outlet blocked respective operating
plant)
(solenoid valve) or the valve (flushing valve) /
flushing valve is stuck check the flushing valve /
replace
Pivoting actuator not Plug valve is stuck Open the filter and
functioning remove the cause of the
blockage
The filling hole is Clean the filling hole in
blocked the filter housing
No pressure supply Check the compressed
connection (see
plant)
(pivoting actuator) or valve (pivoting actuator)
pivoting actuator are or pivoting actuator
stuck

Differential pressure will Piping on the flushing oil Clean the piping (see
not reduce outlet blocked respective operating
plant)
elements
No differential pressure Shut-off valves in Open shut-off valves
indicator control line closed
3-way ball valves (if Check the position of the
fitted) in the incorrect levers (the levers have to
switching position point down)
Differential pressure Check / replace the
monitoring system faulty differential pressure
monitoring system
No pressure display on Air pressure too low Check the compressed
the pressure gauge for air supply on the filter
the air tank connection (see
plant)
Set the air pressure on
the pressure controller
Ball valve on the filter Open the ball valve
closed
Pressure gauge faulty Replace the pressure
gauge

9 Appendix

9.1 Supplier's documentation
NOTE
Documentation for any components or assembly groups purchased externally by
BOLL & KIRCH Filterbau GmbH is enclosed with these operating instructions.
Adhere to the information contained, in particular information on the subject of
safety.
9.2 Cleaning devices

For particularly good cleaning results, BOLL & KIRCH Filterbau GmbH
recommends the filter element cleaning unit type 5.04 with rotating nozzle and
flat jet nozzle or optionally, the type 5.05 ultrasonic cleaning unit.

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

representatives
If you require service or spare parts, please contact the main site or our
subsidiaries, representatives or service points.
Deutschland Croatia Poland

1 2 3 BOLL & KIRCH Filterbau GmbH 1 Marine Trade d.o.o. 1 TRIMOR sp. z o. o.
Postfach 1420, D-50143 Kerpen Vladimira Nazora 6 ul. Andersa 17
Siemensstr. 10-14, D-50170 Kerpen HR - 47000 Karlovac PL-81-831 Sopot
Tel.: +49/(0)2273/562-0 Tel.: +385/(0)47/ 61 19 07 Tel.: +48/(0)58 551 66 40
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E-Mail: info@bollfilter.de E-Mail: marine-trade@ka.t-com.hr E-Mail: trimor@trimor.com.pl
www.bollfilter.de www.trimor.com.pl
Cyprus
1 3 BOLL & KIRCH Filterbau GmbH 1 M.I.E. Services Ltd. Russia / Ukraine / Belarus
Geschäftsstelle Nord The Hawk Building 1 2 3 000 BOLLFILTER Russland
An der Strusbek 34 124 Gladstonos Street Datschnyi prospekt, 2
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Fax: +30/(0)210/92 42 242 E-Mail: info@bollfilter.es
Europe E-Mail: filterkon@filterkon.com www.bollfilter.com
Austria / www.filterkon.com
Czech Republic / 1 2 3 The Netherlands
Slovakia / Slovenia Great Britain and Ireland Lubrafil B.V.
1 2 3 Schmachtl GmbH 1 2 3 BOLLFILTER UK Limited Aalborg 2
Pummererstrasse 36 Unit 9 Station Way NL - 2993 LP Barendrecht
A - 4020 Linz UK - Tolleshunt D'arcy, Essex CM9 8TY Tel.: +31/(0)180/55 62 55
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E-Mail: g.oehler@schmachtl.at E-Mail: sales@bollfilter.co.uk www.lubrafil.nl
www.schmachtl.at www.bollfilteruk.co.uk
1 Turkey
Belgium/Luxembourg Italy ARES MAKíNA LTD. STI.
1 2 3 AUXIMECA N.V. 1 2 DECOSTA S.r.l. Ataúehir Bulvari 48.
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E-Mail: info@auximeca.be E-Mail: sales@decosta.it E-Mail: sami.uygurer@aresmakina.com
www.auximeca.com www.decosta.it www.aresmakina.com

America Africa
Brazil Middle East
1 PML Petersen Matex Imp. e Exp. Ltda. 1 2 Safe Technical Supply Co. L.L.C. South Africa
Rua Branco de Morais P.O. Box 4832 1 2 Afrifil Manufacturing (PTY) LTD
489 - Chácara Santo Antônio UAE - Dubai 8 Pressberg Road Modderfontien
BR - 04718-010 - São Paulo / SP Tel.: +971/(0)4/32 43 24 0 ZA - Isando, 1600
Tel.: +55/(0)11 5186 2000 Fax: +971/(0)/4/32 43 78 6 Tel.: +27 11 452 5444
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E-Mail: Luizcarlos.gomes@pml.com.br www.safetechnical.com E-Mail: sales@afrifil.co.za
www.pml.com.br www.afrifil.co.za
People's Republic of China
USA / Canada incl. Hong Kong / Macao
1 2 3 BOLL FILTER Corporation 1 Blohm & Voss Industries (China) Ltd.
9282 General Drive #180 Room 715-737, 7/F Sun Hung Kai Centre
Plymouth, MI 48170 - USA 30 Harbour Road, Wanchai
Tel.: +1/(0)734/451-4680 Hong Kong SAR, China
Fax: +1/(0)734/451-4681 Tel.: +852-31 81 78 30
E-Mail: latorre@bollfilterusa.com Fax: +852-25 41 21 71
www.bollfilterusa.com E-Mail: info@bvi-marine.com
www.bvi-marine.com.hk
2 3 Motor-Services Hugo Stamp, Inc.
USA - Ft. Lauderdale, Florida 33315 1 3 Blohm & Voss Industries (Shanghai) Ltd.
Tel.: +1/(0)954/763 3660 Xinzhuang Industry Park
Fax: +1/(0)954/763 2872 No. 318, Yuan Shan Rd.
CN - 201108 Shanghai
Asia Tel.: +86-21 64 42 22 11
India Fax: +86-21 64 42 20 66
1 2 3 BOLLFILTER India Pvt. Ltd. E-Mail: shanghai@bvi-marine.com
"Monarch Plaza", Office No. 106 www.bvi-marine.com.hk
Sector-11, CBD Belapur,
IN - Navi Mumbai 400614 Singapore / Malaysia / Indonesia
Tel.: +91/(0)22/27 56 01 47 1 2 3 MNM Corporation Pte. Ltd.
Fax: +91/(0)22/27 56 01 46 13 Joo Koon Crescent
E-Mail: info@bollfilterindia.com SGP - Singapur 629021
www.bollfilter.com Tel.: +65-68 61 42 22
Fax: +65-68 62 42 22
Japan E-Mail: mnmcorp@mnmcorp.com
1 2 3 BOLLFILTER Japan Ltd. www.mnmcorp.com
Toroa Kobe Bldg. 7F, 4-2-14 Hachiman-dori
651-0085 Chuo-ku South Korea
JP - Kobe 651-0085 1 2 3 Blohm + Voss (Korea) Ltd.
Tel.: +81/(0)78/242 8550 760-3, U-dong, Haeundae-gu
Fax: +81/(0)78/242 8515 ROK - 612-020 Pusan 1 Verkaufsbüro Agency
E-Mail: info@bollfilter.jp Tel.: +82-51-740 57 01/2/3 2 Lager Stockist
www.bollfilter.jp Fax: +82-51-740 57 04/5/6 3 Service Service
E-Mail: bvkorea@bvkorea.com
Januar 2010

industry controller KFM 92 / KFM 93 B 9200 E
operating instructions Page 1 of 8
1
1 Digital display actual value
2 2nd digital display (if aktive) 3
2
3 LED-display relais function
4 Key for setpoint and parameter mode
5 Setpoint adjustment 6
6 Parameter mode lock switch (back face)
4 5
DIN-certificate: TR (TW) 949 ..
Brief description:
KFM 92 is a microprozessor based industry controller series in panel mounting- format 96 x 96 mm.
Design and operating elements are especially devised for easy and convenient handling and operation.
An assembly system renders possible the simple basic version as well as a plurality of variants with
up to 8 relays, several digital and analog out- and inputs and other additional devices.
Types: Inputs:
(depending on configuration*): type: max. 4 measuring inputs, type suffix
indicator 9201. acc. to sub-type:
one stage controller 9210. Pt100 DIN, 0...400°C none (or 0)
two stage controller 9220. Pt100 DIN, 0...100°C 1.
heating / cooling controller 9230. thermo couple Ni Cr NI (type K)0...1200°C n.
positioner / follow-up controller 9240. thermo couple Fe Cu NI (type J)0... 900°C f.
two- point- PID controller 9250. thermo couple Pt Rh Pt (type S)0...1700°C p.
three- point- PID controller 9260. feedback device 0...100 up to 1000 Ω w.
three- point- step controller 9270. standard signal 0(4)...20mA, 0(2)...10V e.
continuous controller 9280. combined input Pt100 / standard signal q.
continuous controller, 2 outputs 9281. Ranges:
Sub-types: suffix (*) Pt 100: 0...400°C, switchable to °F, optional: other
basic function .0 ranges; for standard signal range adjustable -999 to
basic function + 1 additional contact .1 4000. Setpoint ranges can be limited by menu
basic function + 2 additional contacts .2 Displays:
2 x basic function .3 2 four- figured digital displays, decimal point
extension: logik output ..L adjustable, upper display: actual value, lower
function extensions suffix (*) display: other selectable data,
cascade controller 991k up to 8 LEDs for relays function display.
program controller 991p Display of function:
ramp set point value 991r Hold down the P-key for more than 5 sec
step controller 991t to get a short-cut message of the configured function on
the display (=position 3-5 of list number)
Additional devices: (*) (in case of locked parameter mode only ).
additional analog inputs (99) a Measuring line monitoring:
external set value incl. switch-over (99) bwa Display "Err 1...4" in case of measuring line fault
second set value incl. switch-over (99) bwz and adjustable safety shut down of all outputs
binary input to switch special functions (99) b..
additional switching contacts (99) f.. Outputs:
analog signal outputs (99) o. up to 8 relays with potential free change over switch,
serial interface RS 232/485 (99) s. as control outputs or as additional contacts,
interface Profibus, Interbus S, other (99) sp/si. capacity: 250V 2A,
incl. spark extinction (for normally open contacts)
* In case of more than 1 extension there is at the 1-2 continuous outputs 0/4...20mA, 0/2...10V as
data plate only once '99' , f.e. 92700-99aw-ogx-rü. control or signal outputs(apparent ohmic load 500 Ω)
For more information see corresponding data sheets.'
data subjects to alteration 9200e1.doc / 0510208
Industry controller type KFM 9... B 9... E
Installation and connection Page 2 of 8
Installation:
Before installation inspect the controller for any visible signs of damage caused during transport
Check power supply acc. to name plate.
Push the housing from the front into the DIN- panel cut-out and secure from behind with the
fastening devices supplied.
Electrical wiring:
Plug bar on the back face of the controller; connect up the controller at the rear following the
wiring diagram; wire cross section max. 1,5 mm2
- To avoid cross interference all low voltage measuring lines and pilot wires must be encased
in a shielded cable (the shielding must be earthed one-sided).
- The control leads must be fused externally to protect the output relays.
- Phase wire and neutral wire must not be transposed.
Putting into operation:

Switch on power supply. Digital display and control lamps will light up according to
the setpoint after some seconds. If nothing happens check the fine-wire fuse on the back panel
of the controller and the electrical wiring. Adjust set value and check other adjustments.
Maintenance:
All electronic controllers in the KFM range are virtually maintenance-free. Provided that the
controller is correctly installed and put into operation and is protected against mechanical
damage and inadmissible operating conditions, it should give years of trouble-free service.
In case of faults repair work by the customer should be restricted to the externally accessible
leads and connections and components the customer is expressly permitted to deal with himself.
(bridge circuits, fuses).
All further work, especially on internal components will terminate warranty, makes subsequent
inspection and fault repair more difficult and can cause considerable damage to the circuitry.
For repair remittance remove plug board with connected leads on the rear side,
loosen fastening devices and remove controller from the panel.
In case of remittance please give precise details of the fault to reduce time and cost of repair.
Error messages:
Err 1...6 Fault on measuring input nr. ...
check measuring lines for short circuit or breakage
check measuring input by connecting a RTD
Err 55 Fault on loading the parameter;
press any key, the controller starts in emergency operation mode,
configuration of the parameters has to be checked
Err 50 Hardware error in program section
Err 52 Hardware error in data section
no further operation possible, remit controller for repair
Error messages during self adaptation:

Err 202 Ambient conditions are not suitable for self adaptation;
adjust parameter manually
Err 205 routine exceeded the setpoint
raise setpoint or lower actual value and start adaptation again
Err 206 Fault on measuring input during adaptation;
check the wiring and start adaptation again
data subjects to alteration 9_E2.DOC /0010803

Operation Page 3 of 8
Operating status:
The upper display shows the actual value (channel / measuring input 1),
the lower display remains empty or (depending on the version and settings) shows
- the attendant unit of measure (°C, °F, %...)
- an additional actual value, the setpoint value or the controller output value Y
- or the additional actual value only when the key is pressed.
Alternative type:
switch over the upper display to the several actual values by pressing the key,,
the lower display shows the number of the attendant measuring input.
Setpoint value setting:
press - key shortly (do not hold down)
The upper display shows the abbreviation of

the activated setpoint adjustment mode,
the lower display shows the adjusted value.
The indicated value can now be changed by the (lower) and (higher) -keys..
Each variation of the set value is immediately active, without any more operating steps.
The arrow keys have a built-in accelerator mode:
longer pressing causes faster alterations.
Return to operating level:

Press - key shortly (or automatically after 30 seconds without any key-action)
optional: Press - key shortly again: *SP =set values of further control loops (*=no.) /
SP* =further set values of the control loop / SPE =external setpoint (display mode only);
flashing display signifies that the function is not active at the moment.
Manual operation: (optional)
Hold down - key and press - key, then release both keys..
(optional: switch on and off using separate - key)
(for multi-channel controllers first enter the channel number*,
and press - key, then:)
The lower diplay shows „H *“ and - if activated - the output position.

The upper display still shows the actual value. The automatic control is interrupted.
Manual control is now possible using the ... - keys..
Return to operating level only by pressing the - key (if present: the - key) .
(no automatic return from the manual mode)
optional: starting the self adaptation (ref. to chapter Optimization):

On manual operation level - key >5 sec ;
the lower display indicates „-Ad-“.
Cancel: - key >5 sec again
data subjects to alteration 9_E2.DOC /0010803

Parameter level Page 4 of 8
Access from operating level.
Unlock the access first:

Turn the switch on the rear panel of the controller to position „U“ = unlocked
(Lock access after the adjustments: Switch position to „L“ = locked).
After the parameter level (refer to the instructions to each level ) has been invoked,
the first setting is shown and can be modified.
It is not possible to invoke the parameter level when the switch is locked .
In this case the display shows the abbreviation of the configured controller type.
Confirm the entry and / or move on to next parameter:

press the -key briefly
Settings in detail:
(not available on all types)
Level 1: Invoke: Hold down the - key for more than 5 sec.
until the display changes factory setting: notes:
CH channel selection (no.) for multi-channel controller (only)

*P proportional range Xp (%) (ref. to chapter „Optimization“) 25,0 ___
*I integral action time Tn (min) (ref. to chapter „Optimization“) 7,0 ___
*d rate time Tv (min) (ref. to chapter „Optimization“) 0,2 ___
*Sh sensitivity of response Xsh (%) 0,1 ___
*SA.. switching interval (absolut value) for following (additional) contact no... 5,0* ___
SP.. set point for independent additional contact no... 0,0 ___
*Sd.. switching difference for additional contact no... 3,0 ___
(*201,701/SA3:10,0)
Return to operating status:
Briefly press the - key (or automatically after 30 sec.)
Level 2: Invoke: Hold down - key and press - key,

y,
hold down both keys for more than 5 sec. until display changes.
Unit switch-over the displayunit (°C / °F) C ___
*bLo/*bHI start / end of display range for voltage- / current -input (only) # ___
*ELo/*EHI start / end of range for external setpoint (only), referring to signal # ___
*SLo/*SHI start / end of range for signal output (only), referring to signal # ___
nSt modification of decimal point characters (0 / 1 / 2) 0 ___
*Lo / *HI start / end of setpoint range (°C /°F or value) # ___
dSPL select display function for lower display (AUS / SP / Y / IST2) AUS ___
(AUS = off, SP = setpoint, Y = output, Ist2 = actual value of channel / measuring input 2)
Return to operating status:
Briefly press the - key (or automatically after 30 sec.)
* = channel no. in case of multiple measuring inputs or control loops. # = acc. to range
data subjects to alteration 9_E4.DOC / 9910414

Optimization Page 5 of 8
1. manual optimization
An optimum adaptation of the control parameters (P,I,D) is necessary in order to balance
an appearing deviation as quickly, non-oscillating and exactly as possible,
according to the given operating conditions.
Generally these adjustments require a lot of professional knowledge that cannot be replaced
by this brief information.
The following informations are for help purpose only:
P = proportional band Xp (%):
lower value = longer impulses, more sensitive reaction
higher value = shorter impulses, less sensitive reaction
Examples: - Oscillating temperature without distinct initial overshot: Xp too low;
- The setpoint is reached very slowly after initial exceeding: Xp too high.
I = integral action time Tn (min):
lower value= shorter impulse gaps, faster balancing
higher value= longer impulse gaps, slower balancing
Examples: - the set value is reached very slowly without overshooting: Tn too high;
- high initial overshot followed by fading oscillation: Tn too low.
D = rate time Tv (min):
increases the controller reaction in case of fast actual value or setpoint alterations
(adjust only if necessary). Higher values cause higher increase.
2. Self-adaptation
The self-adaptation is an automatic procedure that determines and self-adjusts
the optimum control parameters Xp, Tn and Tv.
Operation, if contained in supply schedule:
(Parameter-safety-switch on the rear panel of the controller has to be unlocked: position „u“)
Check starting assumptions:
Actual value at least 20% below the adjusted set value,(e.g.:heating phase), otherwise first:
Lower actual value adequately by manual operation (position of final control element) (quick circuits)
or increase setpoint adequately, if admissible. (faster procedure for slower circuits)
Call manual operation level: Press - key plus - key (optional: seperate key).
Check controller output: must not be higher than 85% , reduce if necessary.
Start self-adaptation: Hold down - key for more than 5 sec. on manual operation level.
During operation the lower display shows: „-Ad-“,
the upper display still shows permanently the actual value.
Information about computer operation: First the self-adaptation program waits for stabilization
of the actual value according to the given controller output (actual value alteration < 0,1% / min),
then it increases the output signal about 10% or, in case of three- point- step controller operation,
it triggers an output impulse with about 10% of the adjusted regulating time.
The optimum parameters are computed according to the unit- step response.
Cancel: Press - key for more than 5 sec. = return to manual operation level
After successfully finishing the procedure the controller will return automatically
to operating level.
Unsuccessful adaptation ( Display shows error code, ref.to chapter error messages):
Press - key again: Return to manual operation level
eliminate the indicated error
start adaptation again: - key > 5 sec.
or return to operating level: - key shortly

Configuration Page 6 of 8
Access from the operating level.

Unlock the access first: Turn the switch on the rear panel of the controller to position „U“
(= unlocked). It is not possible to configure the controller with locked switch.
(Lock access after the adjustments: Switch position to „L“= locked)
Hold down the - key and press the - key,
y,
hold down both keys for more than 5 sec. until the display changes
Enter the code number (password) ... (1...9999), factory setting: 1

move on to next input: briefly press - key
y
Alternatively: Hold down key after entering code for more than 10 sec.
Possibility to modify code number (optional)
Select control function (type dependent): the displayed ID number for the configured
control function can be changed by pressing the - key..
(Example Type 930K31: choose (92..) 200, 201, 700, 701)
Return to operating level: briefly press the - key

y
or
move on to following adjustments: hold down - key for more than 5 sec.
Note: when switching is continued after a function has been changed, the display will first
flash for several seconds, only then will the controller return to the selected level.
Configurations are displayed in succession (type and design dependent)
and can be changed: ...
(move on to next input: press - key shortly)
factory setting
Ist* correction value to change the controller display (+ / -) 0.0
EinG type of measuring input Pt 100 / DC-signal: „rtd / Iu“ rtd
Ain* type of DC signal for input No.*:rtd/ 0/4-20mA/ 0/2...10V 4...20 mA
(observe different terminal connection I/U) (91..:rtd)
SP 2/E kind of 2nd/ external setpoint: Add/ Sub/ AbS AbS
(adding / subtracting / absolute)
*Y’ ‘ travel time of the actuator „6...600“ (sec.) 60 sec.
*cy’ ‘ switching frequency for 2-point controllers: „2...120“ (sec.) 20 sec.
*out adjusting kind of output signal „0...20/ 4...20(mA)/ 0...10/ 2..10(V)” 4...20 mA
*out adjusting output characteristics direct / inverted „di / in“ in
(for 2 output signals:“in in / in di / di in / di di“)
*td for 2 output signals: deadpoint between output 1 and 2 „0...10%“ 0
AP correction of the output signal operation position 50%
FG A/E automatical adjustment for teletransmitter input (ref. sheet 99ar)
Sou* adjusting type of information signal „0..20/4..20(mA)/0..10/2..10(V)“ 4...20 mA
Sou* adjusting kind of information signal „Ist/Soll..“ (actual/ setp.value) 4...20 mA
(*Sout= signal 1, Sou2= signal 2)
*Y_S behaviour of the output in case of measuring line fault:
relay position:“rel1 / rel2 / AUS“ ( AUS = relays off) rel2(70.),rel1(20.)
continuous output position: „0...100“ (%) 0
reL.. function selection for add. switching contacts :
add. contact 1 (relay-no.*) SoA(701),StA(201)
add. contact 2 (relay-no.*) Su A
select the corresponding measuring input / control circuit CH 1
relay condition in case of measuring line fault: „SiE/SiA“(on/off) Si A
Adr bus adress (adress no.) (for interface equipment only) 5
Return to operating level: briefly press the - key
y again
* = In case of multiple measuring inputs or control loops: relay- or channel number

Facilities for Setting Supplementary Contacts Page 7 of 8
Selectable switching functions (depending on version):

For setting please refer to configuration level under „reL...“
Switching functions for trailing contacts: on
off
Sd Sd
LC A Break contact on either side of setpoint SA SA
(Limit comparator). Relay drops out as
deviation increases (Aus = off) on
of f
LC E Make contact on either side of setpoint Sd
SA SA
Sd
(Limit comparator). Relay picks up as

deviation increases (Ein = on) on
of f
Su A Break contact below setpoint. Relay drops Sd
SA
out as actual value decreases (Aus = off)
on
Su E Make contact below setpoint. Relay picks of f

Sd
SA
up as actual value decreases (Ein = on)
on
So A Break contact above setpoint. Relay drops of f
Sd
out as actual value increases (Aus = off) SA
on
So E Make contact above setpoint. Relay picks
of f
up as actual value increases (Ein = on) SA
Sd
St A Heating stage below setpoint. Relay on
drops out actual value increases (Aus = of f

Sd
SA actual v alue
off) SP
(s etpoint)
Switching functions for independent contacts: on
of f
US A Relay drops out with increasing actual Sd
value (Aus = off) on
of f
US E Relay picks up with increasing actual Sd
actual value
value (Ein = on) SP
Switching point
Service function:
Ein/Aus contact is constantly switched on (Ein) or
off (Aus) respectively
Only for units with program option

Pr A Relay switched off (aus) during SP program level, otherwise switched on
Pr E Relay switched on (ein) during SP program level, otherwise switched off
Special function:
SF6 as SoA but switching point at setpoint, control output around SA below
In each case additional settings follow under "rEL." after the selection is acknowledged (P key)
(depending on version):
Ist./ Y assigned value: actual value no. ... or Y (actuating signal)
CH../.SP.(only) for trailing contacts: assigned control circuit / channel (no.) or
assigned setpoint (1SP., rSP, SP.1, ..)
for independent contacts: assignment of parameter input (channel no..)
"Safety" shut down (in case of measuring line fault):
SI E Relay for "Safety" behaviour in event of measuring circuit error: relay on
SI A Relay for "Safety" behaviour in event of measuring circuit error: relay off

Industry controller 92 E
Technical data Page 8 of 8
Characteristics: stage controller (invers)

Adjustment on parameter level, with lock switch, K2 K1
on
pre adjusted on customer´s demand.
off Sd2 Sd1 actual value
(parameters depending on sub type:)
SA2
Proportional band Xp: 0,1...999,9 % SP
Integral action time Tn: 0,0...999,9 min three- point- step- controller (invers)
Rate time Tv: 0,0...99,9 min K1(+) K2(-)
Sensitivity of response Xsh: 0,1...1,0 % on
Travel time of the actuator Tm: 6...600 sec off actual value
Sh
Switching frequency cy: 2...120 sec
SP
Function characteristics: direct / inverted
Switching interval SA (add. contacts): 0..100,0 K continuous controller
Switching difference Sd: 0,1...100,0 K single output double output
100% Y1
Additional contact functions: AP
in in..
Y2
di di..
As switching interval above and below setpoint or 0%
P ..di
independent adjustable with own setpoint and -100% P1 td td P2
..in
measuring input, switching function adjustable l92-d4990419

(ref. to chapter additional switching contacts)
Other data:
Installation dimensions:
Housing for panel mounting, 96 x 96 mm (type 92..,
93..) or 72 x 144 mm (type 94)
L Power supply: 230VAC +/- 10 %, 48...62Hz
alternative 115 VAC, 48 VAC, 24 VAC, 24 VDC
B +0,8
Power consumption: approx. 14 VA
Protective system DIN 40050: IP54 (terminals IP20)
H +0,8
Permissible ambient temperature: 0...60°C
Nominal temperature: 20°C
Climatic category: KUF to DIN 40050
Relative humidity <= 75 % yearly average,
Form 96x96: L= 150mm, B= 92mm H=92mm no condensation
Form 72x144: L= 170mm, B=168mm H=139mm EMC: refer to EN 50081-2 and EN 50082-2
Wiring diagram:
(Example, depending on sub type some details can be missed
valid for each delivered controller is the wiring diagram on its casing only)
A927_e59710718
controller electronics
fu se: (+) (-)
2 4 V :T 0 ,5 A
1 1 5 V :T 0 ,2 A
2 3 0 V :T 0 ,1 A
18V / external digital power control logic signal
40mA analog inputs set value inputs supply output outp. output relay outputs
Ist 3 Ist 4 dig 3 dig 4 Y 2 log 2 Sout 2 Rel 5 Rel 6 Rel 7 Rel 8
7 8 9 10 11 12 23 24 25 26 32 31 37 36 41 31 62 63 64 65 66 67 68 69 70 71 72 73
U+ Ist 1 Ist 2 SPE dig 1 dig 2 Y 1 log 1 Sout 1 Rel 1 Rel 2 Rel 3 Rel 4
99 1 2 3 4 5 6 13 14 15 19 20 21 22 27 28 29 30 31 35 36 40 31 50 51 52 53 54 55 56 57 58 59 60 61
I U L N + + + (protect relay outputs py external fuse 2A)
(L+) (L-)
wiring examples (for input 1 each)

Pt100 Pt100 standard signal "e" standard signal "q" external set value connecting-example
3 wire 2 wire 0/4..20mA 0/2..10V 0/4..20mA 0/2..10V 0/4..20mA 0/2..10V actuator
a92zu_60311202
1 2 3 1 2 3 1 3 2 3 10 3 11 3 13 15 14 15 50 51 52 53 54 55
L
+ - + - + - + - + - + - M
~
open close N
thermo- feedback standard signal incl. feed voltage switch-over optional:

"e" "q" SP active SP2/SPE
couple device power selection 6 7 8 9
1 2 3 1 2 3 99 1 99 10 19 20 19 20 a b c d
- + A S E
230V 1 2 3 4 5
+ - + -
115V RS 232 / 485
data subjects to alteration 9_e8.doc / 0510422

January 2007
VISCOMASTER DYNAMIC
Technical Manual
VISCOMASTER DYNAMIC – Technical Manual Page 1 of 32

VERY IMPORTANT
HANDLE THE VISCOMASTER DYNAMIC WITH CARE
DO NOT …drop the transmitter.
DO NOT …use liquids incompatible with materials of construction.
DO NOT …operate the VISCOMASTER DYNAMIC above its rated

pressure.
DO NOT …pressure test beyond the specified Test pressure.
ENSURE …all explosion proof requirements are applied
ENSURE …transmitter and associated pipework are pressure

tested to 1½ times the maximum operating pressure
after installation.
ALWAYS …store and transport the VISCOMASTER DYNAMIC in its

original packaging.

Contents
CHAPTER 1 - INTRODUCTION
1.1 ABOUT THE VISCOMASTER DYNAMIC .............................................. 5

1.1.1 What is it? ........................................................................................................ 5
1.1.2 ViscoMaster Dynamic measurements.............................................................. 5
1.1.4 What is it used for ? ......................................................................................... 6
CHAPTER 2 - MECHANICAL INSTALLATION
2.1 INTRODUCTION ..................................................................................... 7
2.2 INSTALLATION EFFECTS ..................................................................... 8

2.2.1 Boundary effects .............................................................................................. 8
2.2.2 Fluid conditioning ........................................................................................... 10
2.2.3 Temperature and thermal insulation .............................................................. 10
2.2.4 Entrained gas ................................................................................................. 10
2.2.5 Solids contamination ...................................................................................... 11
2.2.6 Vibration effects ............................................................................................. 11
2.3 GENERAL FITTING NOTES ................................................................. 11
2.4 VISCOMASTER IN-LINE ADAPTER .................................................... 12
2.5 COMMISSIONING ................................................................................. 13
2.6 DURING NORMAL RUNNING .............................................................. 13
2.7 REMOVAL AND REFITTING PROCEDURE ........................................ 13
CHAPTER 3 - ELECTRICAL INSTALLATION
3.1 INTRODUCTION ................................................................................... 15
3.2 INSTALLATION CONSIDERATIONS ................................................... 16

3.2.1 Power supply ................................................................................................. 16
3.2.2 EMC ............................................................................................................... 16
3.2.3 Ground connections ....................................................................................... 16
3.2.4 Cabling........................................................................................................... 17
3.2.5 Surge protection............................................................................................. 17
3.3 WIRING THE VISCOMASTER SERIES TRANSMITTER ..................... 18
3.4 POWER SUPPLY INPUT ...................................................................... 18

3.5 MODBUS (RS-485) ................................................................................ 19
3.6 4-20mA OUTPUT .................................................................................. 20
3.7 WIRING PROCEDURE .......................................................................... 21
CHAPTER 4 - MAINTENANCE
4.1 GENERAL .............................................................................................. 23
4.2 GENERAL MAINTENANCE .................................................................. 24

4.2.1 Physical checks ............................................................................................. 24
4.2.2 Electrical checks ............................................................................................ 24
4.2.3 Performance checks ...................................................................................... 24
4.2.4 Calibration check ........................................................................................... 24
4.3 FAULT ANALYSIS AND REMEDIAL ACTION ..................................... 25

4.3.1 Mechanical servicing ..................................................................................... 27
4.3.2 Time Period Trap ........................................................................................... 27
CHAPTER 5 - SPECIFICATION
5.1 GENERAL .............................................................................................. 28
5.2 SPECIFICATION ................................................................................... 28

5.2.1 Sensor performance ...................................................................................... 28
5.2.2 Environmental................................................................................................ 29
5.2.3 Transmitter power supply .............................................................................. 29
5.2.4 Analog output ................................................................................................ 29
5.2.5 RS485 Interface ............................................................................................. 30
5.2.6 Approvals....................................................................................................... 30
5.3 FACTORY DEFAULT CONFIGURATION ............................................. 31

1
Introduction
1.1 ABOUT THE VISCOMASTER DYNAMIC
1.1.1 WHAT IS IT?
The Viscomaster Dynamic is a digital viscosity transmitter, designed for use with Heavy Fuel Oils (HFOs). Based on
proven tuning fork technology, it is an all-welded sensor designed to be mounted directly in-line or into a tank.
Viscosity are determined from the resonance of the tuning fork immersed in the fluid. A temperature sensor (PRT) is
also fitted within the transmitter, which is used to measure the transmitter’s temperature. The wetted parts of the
transmitter are available in stainless steel (type 316) and the immersed tines are coated with PTFE to inhibit the build
up of asphaltenes.
The transmitter contains integral electronics that allow sensor and calculation configuration, enabling it to perform a
variety of calculations. Two forms of output are available:
1. Two 4-20mA analog outputs, factory set but have individually configurable span, bias, limits and
filter options. The standard factory settings for these outputs are Line Kinematic Viscosity on
Analog Output 1 and Temperature on Analog Output 2.
Alternatively, each output may be controlled by one of the following:

x Line dynamic viscosity.
x Line temperature.
Note: The Viscomaster Dynamic’s analog output 2 is factory set to Temperature and only the span,
bias and limits can be changed.
2. An RS485 (Modbus) interface, giving access to other measurement results, system information
and configuration parameters.
No signal converter is required, which simplifies wiring and enables the Viscomaster to be connected directly to a
plant monitoring / control systems or a local indicator.
Re-configuration of the transmitter’s default settings (see chapter 5) is achieved by linking a PC to the Modbus
(RS485) connection and running ADView software. Once configured, the PC can be removed.
1.1.2 VISCOMASTER DYNAMIC MEASUREMENTS

The Viscomaster Dynamic directly measures the following fluid properties:
x Line dynamic viscosity (measured in centiPoise - cP).
x Temperature (measured in °C or °F).

From these measurements, Viscomaster Dynamic calculates:
x Line kinematic viscosity (measured in centiStokes - cSt).
Note: The Line Kinematic Viscosity calculation requires the user input of a base (or reference) density value and a
temperature (at which the base density value is valid).
1.1.3 WHAT IS IT USED FOR?

The Viscomaster is designed specifically to control the viscosity of Heavy Fuel Oil (HFO) used by large diesel engines.
This is typically achieved by adjusting the heating of incoming HFO to maintain the viscosity within the limits set by
the engine manufacturer.
HFO is a low cost, high viscosity fuel derived from refinery wastes. The quality of the oil and its viscosity/temperature
characteristics can vary due to:
x Stratification within storage tanks.

x Contamination in transit storage.
x Variations in the production process at the refinery or at the blending plant.
HFO heating is usually required to ensure that the viscosity of the oil at the injectors of a large diesel engine or burner
nozzle is maintained at the optimum value (typically between 10 and 20cSt). Failure to observe the viscosity limits
results in inefficient combustion, pollution problems and higher operating costs (either due to excessive fuel being burnt
or premature wear to engine components).
Since simple temperature control has been shown to be ineffective due to the variability of oil quality in HFO, viscosity
control is usually performed.
A typical HFO fuel circuit is shown in figure 1.
Note: In some installations, equipment may be installed in between the viscosity transmitter and the burner
/ engine to remove contaminants from the fuel; the efficient operation of this equipment may also depend
on the viscosity of the HFO.
1
2
Relay Viscosity alarm (to AMS)
* *
*
3
* *
*
* Not supplied by Aquametro
Figure 1

2
Mechanical Installation
2.1 INTRODUCTION
There are a variety of external factors which affect the ability of the Viscomaster to operate successfully. In order to
ensure that your system works correctly, the effects of these factors must be taken into consideration when designing
your installation.
There are two main aspects to consider:

1. The accuracy and repeatability of the measurements;
2. The relevance of the measurements to the overall purpose of the system.
Factors which may adversely affect accuracy and repeatability include:

x The presence of gas or bubbles within the fluid being measured.
x Non-uniformity of the fluid.
x The presence of solids as contaminants.
x Fouling of the transducer.
x Temperature gradients – thermal insulation must be placed near the sensor chamber and body.
x Cavitations and swirls caused by valves or discontinuities in the pipework.
x Operating at temperatures below the wax point of heavy fuel oil (HFO).
x The correct pipe diameter that corresponds to the calibration of the Viscomaster.
In some applications, absolute accuracy is less important than repeatability. For example, in a system where the control
parameters are initially adjusted for optimum performance, and thereafter only checked periodically.
The term achievable accuracy can be used to describe a measure of the product quality that can be realistically obtained
from a process system. It is a function of measurement accuracy, stability and system response. High accuracy alone is no
guarantee of good product quality if the response time of the system is measured in tens of minutes, or if the measurement
bears little relevance to the operation of the system. Similarly, systems which require constant calibration and maintenance
cannot achieve good achievable accuracy.
Factors which may adversely affect the relevance of the measurements could include:
x Measurement used for control purposes being made too far away from the point of control, so that the
system cannot respond properly to changes.
x Measurements made on fluid which is unrepresentative of the main flow.
This chapter has the following sections:

x Section 2.2 – The importance of installation effects.
x Section 2.3 – General fitting notes.
x Section 2.4 – Mechanical details for mounting and installing Viscomaster.
x Section 2.5 – Commissioning the system.
x Section 2.6 – During normal running.
x Section 2.7 – Removal and refitting procedure.

2.2 INSTALLATION EFFECTS
Unlike other Mobrey’s sensors, the vibrating tines of the Viscomaster are not totally enclosed. The walls of the pipe or
tank in which the transmitter is installed will introduce boundaries to the fluid flow, and this will have an effect on the
calibration of the sensor. To overcome this, Mobrey calibrates the Viscomaster under a variety of pre-defined
conditions corresponding to the installation and pipe schedule. This condition is selected when ordering the
Viscomaster, so that by calibrating the sensor under the same boundary conditions as the installation, the need for
additional on-site calibration is eliminated.
2.2.1 BOUNDARY EFFECTS

Any insertion device or transducer can only measure the properties of the fluid within the region of fluid to which it is
sensitive.
For practical reasons it is helpful to consider the sensitive or effective region for the transmitter as an three-
dimensional ellipse centred on the tips of the tines with its long axis aligned with the direction in which the tines
vibrate, as shown below. The Viscomaster is insensitive to the properties of the fluid outside this region.
long axis
short
axis
If part of this volume is taken up by the pipework or fittings there is said to be a boundary effect; i.e. the intrusion of
the pipe walls will alter the calibration.
The diagram below illustrates the Viscomaster installed in a pocket on the side of a 4” (100mm) horizontal pipe line
(viewed from above). The effective region is completely enclosed within the pipe line and thus is completely fluid.

This next view shows other pipe outlines superimposed:
The smaller circle represents a 4” vertical pipe, which intersects the effective region. The 6” (150mm) pipe is the
smallest pipe diameter to completely enclose the effective region when the pipe is vertical. Thus smaller pipe
diameters can lead to a variety of different geometries which would each require a separate calibration.
An alternative condition is shown in the next diagram where the side pocket is extended until it passes completely
through the effective region producing a “core”:
From this, it would appear that almost every installation requires a separate in situ calibration - a very undesirable
situation. The problem is resolved by providing standard calibration geometries which can be used in all pipe work
configurations and thereby allow the factory calibration conditions to be reproduced in the process. These standard
geometries are described in Section.

2.2.2 FLUID CONDITIONING
The fluid in at the Viscomaster must be of uniform composition and at uniform temperature, and it must be
representative of the fluid flow as a whole. This is achieved either by mixing of the fluid either using a static inline
mixer or taking advantage of any natural pipe condition that tends to cause mixing, such as pump discharge, partially
open valves etc.
2.2.3 TEMPERATURE AND THERMAL INSULATION

Always insulate the Viscomaster and surrounding pipework thoroughly (see photograph below). Insulation should
completely cover installation kit / flow-through chamber and Viscomaster assembly, up to the electronics housing.
Insulation must be a minimum of 25mm (1”) thick rockwool / calcium silicate and enclosed in a sealed protective casing.
Avoid direct heating or cooling of the Viscomaster and associated pipework upstream and downstream that is likely to
create temperature gradients. If it is necessary to provide protection against cooling due to loss of flow, electrical
trace heating may be applied, provided it is thermostatically controlled and the thermostat is set to operate below the
minimum operating temperature of the system.
2.2.4 ENTRAINED GAS

Gas pockets can disrupt the measurement. A brief disruption in the signal caused by transient gas pockets can
be negated in the internal signal conditioning software, but more frequent disruptions or serious gas
entrainment must be avoided. This can be achieved by observing the following conditions:
x Keep pipe lines fully flooded at all times.
x Vent any gas prior to the Viscomaster.
x Avoid sudden pressure drops or temperature changes which may cause dissolved gases to break out
of the fluid.
x Maintain a back pressure on the system sufficient to prevent gas break out. (E.g. back pressure
equivalent to twice the head-loss plus twice vapour pressure).
x Maintain flow velocity at the sensor within the specified limits.

2.2.5 SOLIDS CONTAMINATION
x Avoid sudden changes of velocity that may cause sedimentation.
x Install the transmitter far enough downstream from any pipework configuration which may cause
centrifuging of solids (e.g. bends).
x Maintain flow velocity at the sensor within the specified limits.
x If necessary, use a suitable screen or filter to trap objects or lumps which may block or damage the
sensor or flow chamber. (Viscomaster can handle normal slurries.)
2.2.6 VIBRATION EFFECTS

The Viscomaster series transmitters have been extensively tested under severe vibration conditions, both in the test
laboratory and Marine/Power Station/Burner applications. The Viscomaster transmitters are approved according to
the Lloyds Register standard, levels ENV 1,2 and 3 and operate correctly up to the classification level of ENV4
(vibration test 2). This vibration level, ENV 4 includes correct operation at vibration levels of 4g rms between
frequencies of 5-100Hz, and is used to describe the requirements for engine mounted equipment.
If vibration levels exceed these limits, or the Viscomaster series transmitters are not installed as recommended by
Mobrey, Mobrey cannot take responsibility for the correct operation of these units.
2.3 GENERAL FITTING NOTES

The Viscomaster uses a 1.5” Swagelok style of fitting which requires no seals, minimising maintenance and spares.
These fittings are leak proof over a wide range of pressure and temperature conditions, and during rapid temperature
cycling, which may occur during the transfer from HFO to distillate fuel.
The Viscomaster should normally be installed horizontally, with the slot between the tines vertical; this ensures that,
for low flow rates, any solids or gas bubbles are not trapped. When installed in a flow-through chamber, however,
provided that the flow rate is within the recommended range, the transmitter can be mounted horizontally or vertically.
Allow at least 200mm (7.8”) clearance to enable the Viscomaster to be removed from the fitting.

2.4 VISCOMASTER IN-LINE ADAPTER
Conditions:
Temperature: -50 to +200qC
Flow: 10 to 330 l/min (0.6 to 20 m3/hr) (2.6 to 87 US gal./min)
Viscosity limit: Up to 100cSt
Pressure: As defined by process flanges.
Viscometer
calibration boundary: 2½“ Schedule 40
This adapter has been specifically designed to provide a simple, direct replacement for existing vibration-type
viscometers. Typically, the flange-to-flange distance is 150mm. Usually, no pipework changes are necessary.
The viscometer is mounted 25mm away from the main flow line, allowing good product mixing, sensor protection and
stable measurement conditions.
Typical dimensions are shown in the drawing.
Note: The schematic shown may vary without notice, although overall dimensions will remain unchanged.

2.5 COMMISSIONING
1. Once the pipework installation has been prepared, and before installing the Viscomaster and thermal
insulation, fit a blanking compression nut to the Viscomaster mounting, and pressurise and flush the
system.
2. Isolate the system, depressurise and remove the blanking compression nut.
3. Install the Viscomaster, and tighten the fitting nut, but do not fit the thermal insulation.
4. Slowly pressurise the system and check for leaks, particularly if the normal operating temperature is
high, or the Viscomaster has been fitted cold; tighten as necessary.
5. Now tighten the nut again, if necessary. Once you are satisfied with the integrity of the seal, the
insulation can be fitted.
6. Once the system has stabilised and is leak free, fit the insulation material.
2.6 DURING NORMAL RUNNING

Observe and record the normal operating temperatures and viscosity readings.
When several systems are run in parallel and use the same fuel source, comparison of the readings between
installations can be a useful indicator of possible system faults. Differences between readings or changes from the
normally observed conditions should always be investigated to confirm that instrumentation is functioning correctly.
Particular attention should be paid to the conditions before and after engine shutdowns in order to detect any
possibility of asphaltenes coating (precipitation of asphaltenes from the HFO caused by dilution with distillate fuel)
which may cause the instrument to read high. If the re-circulation flow is high enough or the instruments have been
supplied with PTFE coating, asphaltenes or any other deposits should quickly be removed and the expected
operating temperatures should be restored.
If Viscomaster is still reading high and the oil quality is known not to have changed, then the instrument should be
removed and cleaned with a rag. Removal should only be performed in accordance with the engine or burner
manufacturers’ recommendations or in accordance with safe site practice. This must include isolation and
depressurisation, as detailed below.
2.7 REMOVAL AND REFITTING PROCEDURE

All national and international safety regulations should be observed.
Observe safe working practice, wear protective clothing and safety glasses, and use suitable gloves to prevent burns
or absorption of hot oil.
Check that the isolation valves have been fully closed, remove insulation and allow to cool to a safe level (cooling will
tend to reduce any retained pressure) and de-pressurise the system if a drain valve or pressure relieving valve is
fitted.
When the above conditions are satisfied, slacken the lock nut by 1½ to 2 turns, sufficient for the sensor to be rocked.
(If necessary, jolt the Viscomaster loose with a blow of the hand to the amplifier housing.) This will allow the seal between
the sensor and the chamber retro-fit kit to be broken. Do not slacken the lock nut further unless the seal is broken and
the sensor is definitely loose in the fitting.

Note: If the system is still pressurised, the Viscomaster may lift and be held against the retaining nut. Rocking and
alternately pushing the sensor in and out of the pocket within the limits allowed by the slackened nut will break any
seal and allow oil under pressure to seep past the lock nut. If this leakage is excessive, re-tighten the lock nut and
take further action to de-pressurise the system.
When the Viscomaster can be rocked in the flow chamber and there is no serious or continuous escape of oil, it is
safe to remove the lock nut.
Always keep all parts of your body away from the axis of the sensor (i.e., the direction in which the sensor
will be withdrawn). If the system is under pressure or suddenly comes under pressure (e.g., due to valve
failure or pump start), and the lock nut is not in place, the instrument may be forcibly ejected from the flow
chamber and cause serious injury.
Clean and maintain the Viscomaster as directed and then refit it, as described in Section 2.5

3
Electrical Installation
3.1 INTRODUCTION
The Viscomaster Series transmitter has two types of output:
x Two 4-20mA analog outputs:

The Viscomaster Dynamic has a single fully configurable output proportional to a user-specified
parameter.
The parameters that can be output on each analog output are as follows:
Viscomaster Dynamic
Analog Output 1 Analog Output 2
Dynamic viscosity (cP) Temperature *
Kinematic viscosity (cSt)*

Line density
Temperature
* Factory default selection.
Note: In all cases, the Limit values of each analog output are configurable.
x A Modbus (RS485) interface, giving access to other measurement results, system information and
configuration parameters. The Modbus interface is also used to configure the Viscomaster Series
transmitter, using a PC running Mobrey’s ADView software (see separate manual)
It is recommended that both outputs are installed, requiring a minimum of eight wires (two for each output, and two
for power). Although you may not immediately require the Modbus connection, it may be required for in-situ
calibration adjustment and future system enhancements, and the cost of the additional wires is trivial compared to the
expense of installing them retrospectively.
A number of factors must be taken into account when planning the electrical installation. These include:
x Power supply (Section 3.2.1 and Section 3.4)

x EMC (Section 3.2.2)

x Ground connections (Section 3.2.3)
x Cables (Section 3.2.4)
x Surge protection (Section 3.2.5)
x Modbus connections (Section 3.5)
x Analog Output connections (Section 3.6)
3.2 INSTALLATION CONSIDERATIONS

3.2.1 POWER SUPPLY
The power supply to Viscomaster Series transmitters must have the following specification:
Voltage: Nominally 24V dc, but in the range 20 to 28V dc.

Current: >50mA.
If several Viscomaster Series transmitters are to be used within a local area, one power supply can be used to power
them all; where the transmitters are distributed over a wide area and cabling costs are high, it may be more cost
effective to use several smaller, local power supplies.
Upon leaving the factory, the two 4-20mA analog outputs are non-isolated as they are powered through internal links
to the power supply input. However, if split-pads “LNK A” (Analog Output 1) and “LNK B” (Analog Output 2) by the
terminal block are ‘broken’, they become isolated and require a separate 20-28V dc power supply. (See section 3.6
for further details).
Care should be taken where there is the possibility of significant common-mode voltages between different parts of
the system. For example, if the Viscomaster Series transmitter is local powered from a power supply which is at a
different potential to the RS485 ground connection (if used).
3.2.2 EMC
To meet the EC Directive for EMC (Electromagnetic Compatibility), it is recommended that the transmitter be
connected using a suitable instrumentation cable containing an overall screen. This should be earthed at both ends
of the cable. At the transmitter, the screen can be earthed to the transmitter body (and therefore to the pipework),
using a conductive cable gland.
3.2.3 GROUND CONNECTIONS

It is not necessary to earth the transmitter through a separate connection; this is usually achieved directly through the
metalwork of the installation.
The electronics and communications connections (RS485/Modbus and 4-20mA analog outputs) of a Viscomaster
Series transmitter are not connected to the body of the transmitter. This means that the negative terminal of the
power supply can be at a different potential to the earthed bodywork.
In the majority of applications, it is not necessary to connect the RS485 ground connection. In areas where there is a
significant amount of electrical noise, higher communications integrity may be obtained by connecting the negative
power terminal (pin 2) of the Viscomaster Series transmitter to the communications ground. If this is done, it is
important to ensure that the possibility of ground loops (caused by differences in earth potential) is eliminated.

3.2.4 CABLING
Although it is possible to connect separate cables to the Viscomaster Series transmitter for power, RS485 and the 4-
20mA analogue output, it is recommended that all connections are made through one instrumentation-grade cable.
Connections for the Analog and Modbus signals should be individually screened twisted-pairs with an overall screen,
foil or braid for the cable. Where permissible, the screen should be connected to earth at both ends. (At the
Viscomaster Series transmitter, this is best done using a conductive cable gland.)
Cables should conform to BS2538. In the USA, use Belden 9402 (two-pair) or Beldon 85220 (single-pair). Other
cables that are suitable are those that meet BS5308 Multi-pair Instrumentation Types 1 and 2, Belden Types 9500,
9873, 9874, 9773, 9774 etc.
The typical maximum recommended cable length for the above cable types is 1000m (3200ft.), but care must be
taken to ensure that the power supply at the transmitter is at least 20V. Thus, for 24V power supply, the overall
resistance for the power supply connections (both wires in series) must be less than 100 ohms.
In order to complete the wiring, you will need the following parts:
x ½” NPT to M20 gland adapter.
x ½” NPT blanking plug.
x M20 x 1 cable gland (not supplied).
The gland adapter and blanking plug are supplied with each Viscomaster Series transmitter. These two parts
are “EExd” rated. However, you will need to get a suitably rated cable gland. Alternative parts may be required
in order to meet local electrical installation regulations.
In hazardous areas, all parts must be explosion-proof.
3.2.5 SURGE PROTECTION

Careful consideration should be given to the likelihood of power supply surges or lightning strikes. The power supply
connections of the Viscomaster Series transmitter have a surge arrestor fitted that gives protection against power
supply transients.
If there is a possibility of lightning strikes, external surge protection devices - one for each pair of signals and the
power supply - should be installed as close to the Viscomaster Series transmitter as possible.
Another method of surge protection is to connect an MOV (Metal Oxide Varistor) (breakdown voltage >30V)
with an NE-2 neon bulb in parallel across each wire and ground. These can be mounted in a junction box close
to the Viscomaster Series transmitter.

3.3 WIRING THE VISCOMASTER SERIES TRANSMITTER
Figure 3.1 shows the terminal board of the Viscomaster Series transmitter. To reveal the terminal board, it is
necessary to unscrew the housing cap; the procedure is described in Section 3.7.
Note: If the Viscomaster Series transmitter is to be used in hazardous areas, the electrical installation
must strictly adhere to the safety information given in safety instruction booklet 78265061/SI, which
will have accompanied this manual.
The connections to the Viscomaster Series transmitter are:

x Power.
x Modbus (RS485) communications.
x Analog output (4-20mA).
It is recommended that you install all three connections (six cores) at installation, to avoid the possibility of expensive
alterations to the cabling at a later date. Typically, three pairs of shielded 19/0.30mm2 (#16 AWG) to 19/0.15mm2
(#22 AWG) wire are used for wiring.
Figure 3.1: View of the terminal board
3.4 POWER SUPPLY INPUT

Terminals 1 and 2 are for connecting an external 24V dc power supply, as guided in Figure 3.2.
Ensure that the loop resistance of the cable(s) is such that the voltage at the transmitter terminals is greater than 20
volts. (The maximum voltage at the terminals is 28V dc.)
Figure 3.2: Power supply connections

3.5 MODBUS (RS485)
Terminals 3 and 4 are for RS485/Modbus connections to a PC, as shown in Figure 3.3.
Note: The PC and converter are always located in a non-hazardous (safe) area.
The RS485/232 converter and PC are not normally installed permanently. However it is strongly recommended that
the wiring to the Viscomaster Series is made at the time of installation.
For detailed information on RS485, see separate manual.
Note: If you encounter communication difficulties with RS485, swap over the ‘A’ and ‘B’ signal
connections at one end of the network.
TERMINAL BLOCK VERSION:
OR
9-PIN DIN CONNECTOR VERSION:
Figure 3.3: Modbus connections < 100 metres

3.6 4-20mA OUTPUTS
Terminals 5, 6, 7 and 8 are for connecting the two 4-20mA analog outputs to external devices, such as a signal
converter.
Upon leaving the factory, the two 4-20mA analog outputs are non-isolated as they are powered through internal links
to the Power Supply Input.
However, if split-pads “LNK A” (Analog Output 1) and “LNK B” (Analog Output 2) by the terminal block are ‘broken’,
they become isolated and require direct connections to another external 20-28V dc power supply. A second or third
external 20-28V dc supply can be used.
Figure 3.4: 4-20mA Outputs (Isolated)
Note: The external device must be located in a non-hazardous (safe) area unless it is explosion proof and
suitably certified.
The 4-20mA analog outputs can be configured to be proportional to a user-defined base density, referred density,
temperature, or one of the special functions. Fault conditions within the Viscomaster Series are indicated by a 2mA
output. If this is detected, the Modbus link can be used to interrogate the transmitter to establish the likely cause of
the problem.

3.7 WIRING PROCEDURE
1. Open the Terminal Board side of the

VIEW FROM TOP OF 7829:
Viscomaster Series’s electronics housing by
UNDO THIS CAP
undoing the 2.5mm AF grub screw and
unscrewing the lid anticlockwise. GRUB
SCREW
2. Fit the M20 gland adaptor into the most

convenient ½” NPT hole. Then, fit the M20 x 1
cable gland to the adapter.
Fit a ½” NPT blanking plug to the unused hole.
(1) ½” NPT Blanking Plug.
(2) ½” NPT to M20 adaptor.
(3) M20 cable gland.
3. Insert the cable through the cable gland and

adaptor so that the multi-core cable is gripped
leaving 200mm of free, unscreened wire to
connect to the terminal blocks.

4. Wire up the cable cores as shown:
6. When you have screwed the wires into the

correct terminals, carefully tuck the wires
around the electronics, and tighten the
cable gland
7. Finally, screw the housing cap on fully and VIEW FROM UNDERNEATH THE ELECTRONICS:
tighten the locking grub screw using the

2.5mm AF hex drive.
TIGHTEN
CAP
TIGHTEN
GRUB

4
Maintenance
WARNING: If the transmitter being serviced is to be used in a hazardous
area, the rules of compliance with current standards
concerning flameproof equipment must be strictly adhered to.
4.1 GENERAL
The Viscomaster Series transmitter has no moving parts and maintenance is limited to simple visual checks for
leaks and physical damage. ADView’s Data Logging facility can be used whenever necessary to verify that the
transmitter is functioning correctly (See sperate manual).
Check calibrations should be carried out at specified intervals in order to identify a malfunction or deterioration in
transmitter performance. If a fault or a drop in performance is detected, further tests are required to identify the cause
of the fault. Remedial action is limited to cleaning the tines, making good any poor connections and replacing the
internal electronics. In extreme cases, the complete Viscomaster Series transmitter may need to be replaced.
Note: The electronics within the transmitter contain calibration information relevant to that particular transmitter only.
The circuit boards operate as a pair, and therefore both boards must be changed together. Contact Aquametro for
more details if you need to change the boards.
CAUTION: Care is essential in handling of the Viscomaster Series transmitter

during removal from and fitment to the tank, and during
transportation. Wherever possible, retain and use the original
packaging.

4.2 GENERAL MAINTENANCE
This procedure is recommended for periodic maintenance and can also be used when fault finding.
4.2.1 PHYSICAL CHECKS

a. Examine the transmitter, its electronics housing and cables for any signs of damage and corrosion.
b. Make sure that the spigot connection is tight.
c. Check the transmitter for sign of leakage.
d. Check that there is no ingress of water/fluid into the electronics housing.
e. Ensure that the threads on the covers are well greased (graphite grease) and that the ‘O’ rings are in
good condition.
Note: The covers MUST be completely screwed down and, in the case of an explosion-proof enclosure
application, DO NOT FAIL to tighten the locking screws.
4.2.2 ELECTRICAL CHECK

Check the power supply and current consumption at the transmitter terminals 1 and 2.
These should give:
35mA to 42mA (at 22.8V to 25.2V)

If the current consumption is outside this range, contact Aquametro for advice.
4.2.3 PERFORMANCE CHECK

When several systems are run in parallel and use the same fluid source, comparison of the line viscosity,
base density and temperature readings between installations can be a useful indicator of possible system
faults. Differences between readings, or changes from the normally observed conditions should always be
investigated to confirm that instrumentation is functioning correctly.
4.2.4 CALIBRATION CHECK

a. Carry out a check calibration as detailed in sperate manual.
b. Compare the results obtained with the previous calibration figures to identify any substantial
deterioration in transducer performance or any malfunction.
Notes:
1. A drop in performance is likely due to a build-up of deposition on the tines, which can be removed by
the application of a suitable solvent. See section 4.3.1 for further details.
2. Malfunctions generally could be the result of electrical/electronic faults in either the Viscomaster Series
transmitter or the readout equipment. Always check the readout equipment first before attention is
directed to the Viscomaster Series transmitter.

4.3 FAULT ANALYSIS AND REMEDIAL ACTION
A fault may be categorised as either an erratic reading or a reading that is outside limits.
Electrical faults can also cause symptoms that appear to affect the readings and it is recommended that the electrical
system be checked first, before removing the transmitter for servicing.
Fault Possible causes Remedies
Readings fluctuate Analog output averaging Increase the averaging time using
slightly, i.e., are noisy time not long enough ADView’s Board Configuration facility
(see separate manual).
Erratic readings Gas bubbles around tines Remove primary cause; e.g.:
Cavitations - install air release units to release
gas; apply back pressure to
Severe vibration discourage bubble formation.
Severe electrical - remove cause of vibration
interference
Alternatively, it may be necessary to
Large amount of adjust the Time Period Trap
contaminants
Readings outside limits Deposition and/or Clean tines

corrosion on the tines.
Analog output = 0mA No power to analogue If voltage across pins 5 and 6 is not 15
output to 28V, replace power supply.
Analog output circuit Use ADView’s facility to set the
failure analogue output to 4, 12 or 20mA (in
Board Configuration) to check whether
the output is functioning. If not, replace
circuit boards.
Analog output is 2mA Alarm condition caused by If voltage across pins 1 and 2 is not 20
lack of power to to 28V, check and replace main power
Viscomaster Series supply.
transmitter
Alarm condition caused by Use ADView Diagnostics to check that
other internal failure phase locked loop is in lock.
Temperature readings If other readings from Return the transmitter to Mobrey for
incorrect transmitter are correct (i.e. servicing. Re-fit the transit cover to the
analog output and Modbus transmitter and secure it with 2 grub
appear to be functioning screws.
correctly), the temperature
sensor has probably failed.

Transmitter does not Power failure to Check power supply to transmitter and
communicate with transmitter. converter; replace if necessary.
ADView:
Power supply to Check wiring.
RS485/232 converter
failed.
A and B Modbus Check wiring.
connections reversed.
RS485/232 converter Try another converter.
failed, wired incorrectly,
or connected the wrong
way round.
ADView incorrectly Re-install ADView.

installed on PC.
Incorrect Slave address Check slave address.

chosen for transmitter.
RS232 port on PC failed. Connect to another free RS232 port on

the PC, if available.
Alternatively connect a known working

RS232 device to the PC to check that the
port is working.
Viscosity reads high Thermal insulation is Repair or replace thermal insulation.

during normal running defective.
PTFE laminate damaged, Remove transmitter for visual check;

leading to coating of fork return to Mobrey for servicing.
tines.
Calibration data is Compare calibration data to certificate or
corrupted. stored configuration. Re-program as
necessary.
Viscosity reads high Pump coated with Check pump delivery; service pump.
after engine shutdown asphaltenes.
and restart
Bypass not fully closed. Close bypass
PTFE laminate damaged, Remove transmitter for visual check;

leading to coating of fork return to Mobrey for servicing.
tines.
Calibration data is Compare calibration data to certificate or

corrupted. stored configuration. Reprogram as
necessary.
Return transmitter to Mobrey for

servicing.

4.3.1 MECHANICAL SERVICING
This mainly comprises the cleaning of any deposition or corrosion from the tines. Deposition is removed by the use of
a suitable solvent. Take care not to damage the PTFE coating. Where extensive corrosion has been treated, it is
highly recommended that a full calibration is carried out to check the transmitter characteristics.
CAUTION: Care is essential in handling the transducer during transit,

installation, and removal from the installation.
4.3.2 TIME PERIOD TRAP

Disturbances in the fluid caused by bubbles, cavitations or contaminants can cause sudden changes in the measured
output, which may, under some circumstances, give rise to instability (i.e. hunting) in a control system relying on the
measurement. The Viscomaster Series transmitter can maintain the analogue output during such perturbations by
ignoring the aberrant measurement, and maintaining the output at the last good measured value. This facility is known
as the Time Period Trap (TPT).
Under all normal circumstances, the factory settings for the TPT should be used. However, in extreme cases it may be
necessary to alter the settings to meet the demands of a particular system. This should only be done after monitoring
the behaviour of the system for some time, to establish the normal running conditions.
Great care must be taken not to reduce the sensitivity of the transmitter so that normal response to fluctuations in the
fluid is impaired.
The time period trap facility works as follows:
After each measurement of the time period (of the Viscomaster Series transmitter’s vibrating tines), the new value is
compared with the previous value. If the difference between them is smaller than the allowable tolerance, the output is
updated to correspond to the new measured value, and the TPT remains inoperative; i.e., operation is normal. If the
difference exceeds the allowable tolerance, the output remains at the previous level, and does not follow the apparent
sudden change in value.
This process is repeated until either:

(a) The latest measured value falls back to the level of the original value, indicating that the transient has
passed; or
(b) The TPT count is reached. At this point, it is assumed that the change in value is not due to a random
disturbance, and the output adopts the value of the latest reading.
Two Modbus Registers control the operation of the Time Period Trap facility. These can be changed, if necessary,
using ADView’s Register Read/Write facility (see separate manual).
Modbus Register 138: contains the maximum allowable change in the time period between readings, specified in Ps.
The preset value is 10.
Modbus Register 137: contains the Time period count, which is the maximum number of measurements to be
rejected before resuming normal operation; the preset value is 2. If the value is set to 0, TPT is disabled, and the
output will always follow the time period measurement. If you want to program another value, it should be determined
experimentally, and be equal to the length of the longest undesirable transients which are likely to arise. If the value
is set too high, the Viscomaster Series transmitter will be slow to respond to genuine changes in the fluid properties.

5
Specification
5.1 GENERAL
The Viscomaster Series transmitter comprises a vibrating fork sensor, with processing electronics within a housing which
allows full configuration; all signal processing, calculations, and calibration adjustments are made without the need for
external electronics.
Two 4-20mA analog outputs are available:

x On the Viscomaster Dynamic, Analogue Output 1 is configurable to output a user-specified parameter,
such as Kinematic Viscosity. Analogue Output 2 is fixed to output Temperature. The zero and span are
configurable. (For further details, see Chapter 3.)
An RS485 serial communications link is also available, which utilises the Modbus protocol to provide a means of
configuring the device, retrieving data measurements, and performing diagnostics.
ADView, a PC software application running under Windows 98, NT, 2000 or XP, is available for data logging,
configuration and diagnostics purposes (see separate manual)
5.2 SPECIFICATION
5.2.1 SENSOR PERFORMANCE
Viscosity measurement
Measurement technology: Tuning Fork driven and sensed by piezoelectric
crystals.
Operating range: 0.5 to 100cSt
Accuracy: ± 1% operating range

(0.5 to 100cSt: ± 0.2%)
Repeatability: ± 0.5% reading
Pressure effect: Negligible

Temperature
Temperature Technology: PT100 platinum resistance thermometer in tuning fork
Integral PRT Temperature Range: -50° to +200qC
Integral PRT Temperature Accuracy: BS1904 Class B , DIN 43760 Class B
5.2.2 ENVIRONMENTAL
Fluid temperature range: -50qC to +200qC (-58qF to +392qF)
Max. operating pressure: 207 Bar (3000psi)
Enclosure Type: Die cast low copper alloy.

Polyurethane paint finish.
Protection: IP66
Max. weight: 6.7kg.
Max. vibration: 4g rms 5-100Hz

(as specified by Lloyds Register ENV4 specification)
5.2.3 TRANSMITTER POWER SUPPLY

Minimum Input Voltage: 20V
Maximum Input Voltage: 28V
Current Consumption: 35 to 45mA
5.2.4 ANALOG OUTPUT

Note: See Chapter 3 for details of powering the analog outputs.
Number of channels: 2
Range: 3.9mA to 20.8mA
Alarm Condition: 2mA
Nominal Power Supply: 24V
Maximum Terminal voltage: 28V
Minimum Terminal voltage: 15V
Isolation to Main Power Supply: 75Vdc rated
Accuracy @20qC: r0.1% reading r0.05% FS
Repeatability: r0.05% FS
(-40qC to +85qC)

5.2.5 RS485 INTERFACE
Connections: A and B signals (screw terminals)
Communications protocol: Modbus RTU
Isolation: None (RS485 in same circuit as main power supply)
Baud rate: 9600 (fixed)
Termination: Not required
5.2.6 APPROVALS
EMC: EN 61326:1997 +A1
Approvals: EEx d IIC T4 (ATEX)
CSA Class 1, Division 1, Group C.

5.3 FACTORY DEFAULT CONFIGURATION
The Viscomaster Series transmitters are supplied in a standard configuration.
Analog outputs are set to provide line kinematic viscosity (in cSt) and temperature (in qC). Units are kg/m3 for the density
parameter.
The complete set of default values are shown below.
Viscomaster Dynamic
Parameter
Factory default value
Analog output 1: Variable Line kinematic viscosity

Units cSt
4mA setting 0
20mA setting As ordered.
Analog output 2: Variable Temperature

Units qC
4mA setting 0
20mA setting 150qC
Alarms: Coverage General system

Analog output
User range
Hysteresis 2%
Alarm user range: Variable Line kinematic viscosity

Units cSt
Low setting 0
High setting 100
Density calculations: Temperature units qC

Temperature offset 0
Pressure units bar
Pressure set value 1.013
Line density units kg/m3
Line density scale factor (Not Applicable)
Line density offset (Not Applicable)
API referral: Product type (Not Applicable)

User K0 (Not Applicable)
User K1 (Not Applicable)
Base temperature (Not Applicable)
Base pressure (Not Applicable)
Output averaging 5s
time:

Modbus: Slave address 1
Byte order Big Endian
Register size 32 bit
Hardware type: Advanced fork
Head Office:
Switzerland: Aquametro AG, Ringstrasse 75, CH-4106 Therwil, Phone +41 61 725 11 22, Fax +41 61 725 15 95
Officies:
Switzerland: Aquametro SA, Rue du Jura 10, CH-1800 Vevey, Phone +41 21 923 51 30, Fax +41 21 922 58 44
Belgium: Aquametro Belgium SPRL, Dallaan, 67, B-1933 Sterrebeek, Phone +32 2 241 62 01, Fax +32 2 216 22 63
Czech Republic: Aquametro s.r.o., Prosecká 811 / 76a, CZ-190 00 Praha 9, Phone +42 02 86 88 77 78, Fax +420 02 86 88 95 59
Germany: Aquametro Messtechnik GmbH, Zum Panrepel 24, D-28307 Bremen, Phone +49 421 / 871 64-0, Fax +49 421 / 871 64-19
Marketing-Officies:
Japan: Aquametro Representative Office, Yasuhiko Takahashi, 1-18-4, Nakane, Meguro-ku, Tokyo 152-0031, Phone +81 3 3723 8611, Fax +81 3 5729 4607
Korea (south): Aquametro Representative Office, Dennis Kwak, The # Centum Park 102-2704, Haeundae gu Jaesong 1-dong 1200, Busan Korea, Phone +82 5 1314 3017, Fax +82 5 1988 3017
Singapore: Aquametro Representative Office, Deniel Wong, 273 Thomson Road, #03-03 Novena Gardens, Singapore 307644, Phone +65 6 256 8152, Fax +65 6 256 9917
www.aquametro.com

Motor control valve in two way form 421 ... E
PN 16 / 25, GGG-40. Page 1 of 2
Body: GGG-40.3, two way form,

for water and steam,
Pressure range: PN 16, PN 25
Flanges acc. to DIN,
Spindle sealing: spring loaded PTFE-V-ring unit,
for media temperatures up to 250°C
alternatively: graphite-packing
Internal parts: stainless steel
Flow characteristic: equal percentage
Leakage: acc. to VDI/VDE 2174
Actuator: with integrated manual emergency

and load dependent limit switches
Thrust: 2000 N
Power input: 10 VA
alternatively: 4000 N / 20 VA (appendix ..c)
5500 N / 20 VA (appendix ..d)
Power supply: 230V /50...60Hz
other voltages on request
Protection class: IP65
Accessories, special types:

Add. signal switches (see page 49e, 49w)
Feedback potentiometer (see page 49f)
Integrated positioner (see page 49sr)
Other voltages (on request)
Other positioning speed (on request)
Reduced kvs-values (on request)
Order text:
Motor control valve PN . ., DN . .
in two way form with PTFE-V-ring unit,
Power supply . . ., List-No. 421 . . .
Max. operating pressure:

by: 120 200 250 °C
PN 16 16 13 13 bar
PN 25 25 20 18 bar
DN List-No. Kvs Stroke Pos. speed Closing pressure (bar)

PN 16 PN 25 m³/h mm sec 2000N 4000N 5500N
15 421 400 421 500 4,0 20 66 25,0
20 421 401 421 501 6,3 20 66 25,0
25 421 402 421 502 10 20 66 25,0
32 421 403 421 503 16 20 66 17,3 25,0
40 421 404 421 504 25 20 66 10,8 25,0
50 421 405 421 505 40 20 66 6,6 16,0 23,0
65 421 406 421 506 63 30 100 3,4 9,1 13,3
80 421 408 421 508 100 30 100 2,0 5,8 8,6
100 421 410 421 510 160 30 100 1,1 3,5 5,4
data subject to alteration 421-1-E.DOC / 0411517

Motor control valve in two way form 421 ... E
PN 16 / 25, GGG-40. Page 2 of 2
153
Space required
Actuator type: 145 to remove
2kN: 4e1230 (for 4-6kN-actuator: 190) the bonnet
4(6)kN: 4e14(6)30
Bonnet
Motor
Limit switch
Gear
Spring plate-unit H*
Spindle (actuator)
Hand wheel
Mounting rod
PTFE-V-ring-unit
Spindle
Plug
Valve body type: vg21...

L
DN 15 20 25 32 40 50 65 80 100
Height H * 491 505 499 505 511 513 556 557 564
Immersion lenght L 130 150 160 180 200 230 290 310 350
Weight kg 13 14 15 17 18 20 33 37 47
* = add. 45mm for 4-6 kN-actuator
Electrical wiring: Accessories (optional):

Limit switch Potentiometer Signal switch
M load dependent travel dependent
for valve position
CLOSE OPEN
1 2 3 4 5 11 12 13 14 15 16 21 22 23 24 25 26 31 32 33 34 35 36
N L on 2 = Straightway closes
L on 3 = Straightway opens
data subject to alteration 421-2-E.DOC / 0411504

Installation and operating manual B4E
for motor control valves
Installation:
Attention!: - Installation, operation and maintenance should be done only by qualified personnel.
- Disconnect supply before working on the valve.
- It is not permitted to work on the valve body and to exchange the actuator as long as
the valves are subjected to pressure and temperature.
The mounting site should be easily accessible and have sufficient clearance for maintenance
and for removing the actuator. Ensure that the pipe line axes are flush and connection flanges
are parallel. Provide suitable measures to absorb possible tensile and pressure forces.
The valve must not serve as a fixed point. It must be carried by the piping.
Clean pipelines thoroughly prior to installing the control valves in order to avoid damage through
residual installation material, welding beads or forging scale. If possible, provide a dirt trap
in front of each control valve.
Installation position should be vertical to horizontal. Ensure that the installation direction is
correct (directional arrows of the flow on the valve housing). Observe a 10 x DN spacing
to flanges, elbows, etc., to avoid an impaired valve function.
Regard the permitted max. operating pressure and temperatur as described in the
corresponding valve specification sheet.
Observe the ambient temperature limits (-20...+60°C), if necessary, provide a drive heater
at lower temperatures, and for higher temperatures insulate the pipeline, provide conductive
plates or cooling possibilities.
Retighten the screws of all flange connections (also lid and connection piece flanges) prior
to commissioning/start-up and following initial heat-up.
Electrical connection:
Check supply voltage according to the rating plate, loosen screws on the motor hood
and remove hood
Route signal and control lines separately from high-voltage lines, if necessary, run in
screened cables. Insert cables (1.5 mm²) through a wringing nipple or cable screw
connection.
Perform electrical connection with the supply voltage switched off according to the
connection diagram (observe VDE and EVU regulations).
In the event of deviations, the connection diagram in the motor hood has precedence
Maintenance:
Following the initial temperature and pressure load, retighten the screws of all flange connections
(also lid and connection piece flanges), the valve cone should be located in the centre.
Attention! Never loosen the lid and flange screws as long as the fittings are subjected
to pressure and temperature.
Protect valve spindle against soiling, if necessary, clean and grease lightly in order to protect
stuffing boxes and deflector hoods against increased wear.
Retighten stuffing box seals slightly in the event of leaks.
No further maintenance work is required for fittings with deflector hoods or bellows.
Undertake maintenance on the drive in accordance with the corresponding information in the
separate operating instructions.
data subject to alteration 4BA-E.DOC / 0210525

n
c
e
s
g
E
w
A
iar:lc
ie
s
to
r
Electric actuator 4e1 4e1... E

Page 1 of 2
Electric actuator for valves

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

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

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

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

Bonnet remove the bonnet h
Motor
Gear
Limit switch for

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

wiring diagram
Limit switch for

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

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

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

N mm mm mm mm mm mm mm
4e1134 1500 195 40 81 146 145 M12 24
4e1230 2000 200 45 86 146 145 M16 32
4e1231 2000 218 63 104 146 145 M16 32
4e1232 2000 231 76 117 146 145 M16 32
4e1235 2000 250 95 136 146 145 M16 32
4e1430 4000 200 45 86 191 190 M16 32
4e1431 4000 218 63 104 191 190 M16 32
4e1432 4000 231 76 117 191 190 M16 32
4e1435 4000 250 95 136 191 190 M16 32
4e1630 5500 200 45 86 191 190 M16 32
4e1631 5500 218 63 104 191 190 M16 32
4e1632 5500 231 76 117 191 190 M16 32
4e1635 5500 250 95 136 191 190 M16 32
data subject to alteration 4e1-2-E.DOC / 0411504
Electric actuator 4e1 B 4e1... E
Operating instructions Page 1 of 2
Attention:
- Adjustment of and work on the actuator may only be done by skilled labour
- Disconnect power supply before removing the cover
- Observe local instructions and terminal diagram
Actuator disassembly: Actuator assembly:

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

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

Add. lower switch
Lower limit switch

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

Electric actuator 4e1 B 4e1... E
Operating instructions Page 2 of 2
01
02
03
04
05
06
07
08
09
10
11
12
13
detail X
14
15
16
17
19
20
X
18
Fig.2
No. Designation Part-No.

01 Bonnet: 2kN / 4kN e3h136 / e3h180
02 Motor 230V / 50/60Hz: 2kN / 4kN*** e2m220 / e2m220.4
02a Capacitor: 2kN / 4kN e2k033 / e2k068
03 Gear: pos. speed 3,3s/mm / pos. speed 2,2s/mm e2g1875 / e2g1250
04 Limit switch for spindle position "down" eheo
05 Mounting plate for motor e3zp
06 Terminal bar e6k12
07 Gear wheel e3zr75
08 Mounting plate with wiring diagram e3hb
09 Limit switch for spindle position "up" eheu
10 Base plate e3gp
11 Screw-type cable bushing PG11 e1kv11
12 Spring housing e3fg
13 Set of disc springs e5ft355+e5fs335
14 Spindle e3s
15 Mounting rods e3s... / e3s...n
16 Hand wheel with blocking lever ehhr
17 Stroke indicator e5ak
18 Hexagonal nut M16 e8mv16
19 Coupling nut e5vk
20 Screw collar ring e3sr...
*** = only for standard actuator: voltage 230V / 50/60Hz
data subject to alteration 4E1_2BE.DOC / 0310522

Parts list vg21-t E
Control valve in two way form, type 21, GGG-40.3, PN16/25 Page 1 of 2
01
02
03
04
05
06
07
08
09
10
11
No. Designation Part-No.

01 Screw joint with scaper 6a21dv..
02 Gasket 6a21sd..
03 V-rings 6a21dm
04 Mounting bonnet 6a21vd..
05 Guiding bush 6a21gb
06 Spring 6a21f
07 Studs with hexagon nuts 6a21ss..
08 Gasket 6a21dd..
09 Plug with spindle 6a21ks..
10 Seat ring 6a21s..
11 Valve body 6a21vg..
data subject to alteration Vg21-te.doc / 0104518

Replacing of the PTFE-V-ring unit B vg31-badm E
Control valve body in 3-way-form type 31
(((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((((
01
02 Screw joint complete
03
04
05
06
A AB
%+30)*/1- 2, 5.+ $&#"!’!4/1- 61/5

(8 :.95*,. <1. +.558? ;.*5 2< 2; 78< 7.,.;;*:@ <8 :.68>. <1. ,87<:85 >*5>. /:86 <1. 929.527.
)& ;CKMSC QFC ?AQR?QMO$ RLPAOCT QFC AMJJ?O OGLE DOMK QFC S?JSC PNGLBJC !()" ?LB OCKMSC
QFC AMRNJGLE LRQ ?LB QFC JMAIGLE LRQ GD LCACPP?OU
*& =LPAOCT QFC PAOCT HMGLQ !(*"
+& :RJJ MRQ QFC ERGBGLE @RPF !(." ?LB >%OGLE RLGQ !(-" DOMK QFC PAOCT HMGLQ !(*" MO DOMK KMRLQGLE
@MLLCQ !(," GD LCACPP?OU
487 < -*6*0. <1. 27;2-. ?*55 8/ <1. ;,:.? 3827<!
,& 3JC?L QFC spindle (01) if necessary
Dameged spindle must also be replaced a new V-ring unit will soon start leaking again with
a damaged spindle!
&% :RQ the V-ring unit (05) ?LB QFC ERGBGLE @RPF !(." GLQM QFC PAOCT HMGLQ !(*"
7*4. ;=:. <1*< <1. 9*:<; *:. 27;<*55.- 27 <1. ,8::.,< 8:-.: *7- 98;2<287 ";.. -:*?270 *+8>.#!
.& Replace the gasket (03)
/& :RQ PAOCT HMGLQ RLGQ !(*#(+#(-#(." GLQM QFC KMRLQGLE @MLLCQ$
’*4. ;=:. <1*< <1. )$:270; *:. 78< -*6.0*- <1:8=01 <1. ;927-5.$<1:.*-!
0& <AOCT ML QFC PAOCT HMGLQ !(*" ?LB QGEFQCL GQ !V).( 8K"
B?Q? PR@HCAQ QM ?JQCO?QGML >6+)%2147%5&493 ’ (-()-*-

For Sejin Industries,
Danfoss Pressure Switch Model ; KPS 35
Data sheet
Pressure switches and thermostats, type KPS
Description
KPS units are pressure-controlled switches. The KPS series covers most outdoor as well as indoor
The position of the contacts depends on the application requirements.
pressure in the inlet connection and the set KPS pressure switches are suitable for use in alarm
scale value. In this series, special attention has and regulation systems in factories, diesel plant,
been given to meeting important demands compressors, power stations and on board ship.
for:
• a high level of enclosure,
• robust and compact construction,
• resistance to shock and vibration.
Contents Page
KPS pressure switches, description .............................................................................................................................1
Approvals .................................................................................................................................................................................2
Ship approvals ........................................................................................................................................................................2
Survey ........................................................................................................................................................................................2
ISO 9001 quality approval ..................................................................................................................................................2
Technical data and ordering..............................................................................................................................................3
Terminology ........................................................................................................................................................................3-4
Installation ...............................................................................................................................................................................5
Function ....................................................................................................................................................................................6
Dimensions and weight ......................................................................................................................................................7
Accessories ..............................................................................................................................................................................8
KPS thermostats, description .........................................................................................................................................9

Approvals .................................................................................................................................................................................9
Ship approvals ........................................................................................................................................................................9
Technical data and ordering..............................................................................................................................................9
Function ................................................................................................................................................................................. 10
Installation ............................................................................................................................................................................ 11
Electrical connection......................................................................................................................................................... 12
Examples ............................................................................................................................................................................... 12
Dimensions and weight ................................................................................................................................................... 12
Accessories ........................................................................................................................................................................... 13
IC.PD.P10.C2.02 - 520B2981
Data sheet Pressure switches and thermostats, type KPS
Approvals EN 60 947-4-1 Underwriters Laboratories Inc., USA

EN 60 947-5-1 CCC, China Compulsory Certificate
Ship approvals American Bureau of Shipping Registro Italiano Navale, Italy

Germanischer Lloyd, Germany RMRS, Maritime Register of Shipping, Russia
Bureau Veritas, France Nippon Kaiji Kyokai, Japan
Includes thermostats with fixed sensor CCS, China Classification Society
and pressure controls with armoured
capillary tube.
Survey Type KPS pressure switches

1. Standard pressure switches
Range Type Further
Pe information
-1 0 10 20 30 40 50 60 bar bar page
0 - 2.5 KPS 31 3
0 - 3.5 KPS 33 3
0-8 KPS 35 3
6 - 18 KPS 37 3
10 - 35 KPS 39 3
2. Type KPS pressure switches for high pressure and strongly pulsating media
Range Type Further
Pe information
-1 0 10 20 30 40 50 60 bar bar page
1 - 10 KPS 43 3
4 - 40 KPS 45 3
6 - 60 KPS 47 3
Range Type Further

Pe information
-50 0 50 100 150 200 200 °C bar page
-10 - 30 KPS 76 9
20 - 60 KPS 77 9
50 - 100 KPS 79 9
70 - 120 KPS 80 9
60 - 150 KPS 81 9
100 - 200 KPS 83 9
ISO 9001 quality approval Danfoss A/S is certificated by BSI in accordance

with international standard ISO 9001. This means
that Danfoss fulfils the international standard in
respect of product development, design, produc-
tion and sale. BSI exercises continuous inspection
to ensure that Danfoss observes the requirements
of the standard and that Danfoss’ own quality
assurance system is maintained at the required
level.
2 IC.PD.P10.C2.02 - 520B2981
Technical data and ordering 1. Pressure switches

When ordering, please state Setting range Adjustable/ Permissible Max. test
type and code number Pe fixed operating pressure Pressure
Code no. Type
differetial pressure Pe connection
[bar] [bar] [bar] [bar]
0 - 2.5 0.1 6 6 G 1/4 060-311066 KPS 31
0 - 2.5 0.1 6 6 G 3/8 A 060-310966 KPS 31
0 - 3.5 0.2 10 10 G 1/4 060-310466 KPS 33
0 - 3.5 0.2 10 10 G 3/8 A 060-310366 KPS 33
0-8 0.4 - 1.5 12 12 G 1/4 060-310566 KPS 35
0-8 0.4 - 1.5 12 12 G 3/8 A 060-310066 KPS 35
0-8 0.4 12 12 G 1/4 060-310866 KPS 35
KPS 31, 33 6 - 18 0.85 - 2.5 22 27 G 1/4 060-310666 KPS 37
6 - 18 0.85 - 2.5 22 27 G 3/8 A 060-310166 KPS 37
10 - 35 2.0 -6 45 53 G 1/4 060-310766 KPS 39
10 - 35 2.0 - 6 45 53 G 3/8 A 060-310266 KPS 39
2. Pressure switches for high pressure and strongly pulsating media

Setting Adjustable Permissible Max. test Min. burst
range Pe diff. see also overpres- pressure pressure Pressure
Code no. Type
figs. 1, 2, sure connection
[bar] and 3 [bar] [bar] [bar]
1 - 10 0.7 - 2.8 120 180 240 G 1/4 060-312066 KPS 43
4 - 40 2.2 - 11 120 180 240 G 1/4 060-312166 KPS 45
6 - 60 3.5 - 17 120 180 240 G 1/4 060-312266 KPS 47
KPS 35, 37, 39
Terminology Max. test pressure
Range setting The highest pressure the unit may be subjected
The pressure range within which the unit will give to when, for example, testing the system for leak-
a signal (contact changeover). age.
Therefore, this pressure must not occur as a
Differential recurring system pressure.
The difference between make pressure and break
pressure (see also fig. 8, page 6). Min. bursting pressure
The pressure which the pressure-sensitive
Permissible overpressure element will withstand without leaking.
The highest permanent or recurring pressure the
KPS 43, 45, 47 unit can be loaded with.
A: Range setting
B: Differential scale
C: Obtained
differential
Fig. 1 Fig. 2 Fig. 3
IC.PD.P10.C2.02 - 520B2981 3
Switch Ambient temperature

Single pole changeover (SPDT) KPS 31 - 39: –40 to +70 °C
Contact material: Gold-plated silver contact KPS 43 - 47: –25 to +70 °C
Contact load Temperature of medium
(when Au surface is burnt away) KPS 31 - 39: –40 to +100 °C
1. Alternating current: KPS 43 - 47: –25 to +100 °C
Ohmic: 10 A, 440 V, AC-1 For water and seawater, max. 80°C.
Inductive: 6 A, 440 V, AC-3
4 A, 440 V, AC-15 Vibration resistance
Starting current max. 50 A (locked rotor) Vibration-stable in the range 2-30 Hz,
amplitude 1.1 mm og 30-300 Hz, 4 G.
2. Direct current: 12 W, 220 V, DC-13
See curve, fig. 4 Enclosure
IP 67 to IEC 529 and DIN 40050.
The pressure switch housing is enamelled
pressure die cast aluminium (GD-AlSi 12). The
cover is fastened by four screws which are
anchored to prevent loss.
The enclosure can be sealed with wire.
Cable entry
Pg 13.5 for cable diameters from 5 to 14 mm.
Identification
The type designation and code no. of the unit is
stamped in the side of the housing.
Scale accuracy
KPS 31: ±0.2 bar KPS 39: ±3.0 bar
KPS 33: ±0.3 bar KPS 43: ±1.0 bar
KPS 35: ±0.5 bar KPS 45: ±4.0 bar
KPS 37: ±1.0 bar KPS 47: ±6.0 bar
Mean value of snap point variation after
400 000 operations
KPS 31: ±0.1 bar KPS 39: ±0.7 bar
KPS 33: ±0.2 bar KPS 43: ±0.2 bar
KPS 35: ±0.3 bar KPS 45: ±1.0 bar
Fig. 4. d.c.-load KPS 37: ±0.4 bar KPS 47: ±1.5 bar
Curve A gives the maximum load.
Hatched area B: Acceptable load for the gold plating
of the contact.
Materials in contact with the medium
KPS 31, 33 Bellows capsule: Deep-drawn plate, material no. 1.0524 (DIN 1624)
Bellows: Stainless steel,material no. 1.4306 (DIN 17440)
Pressure connection: Steel C20, material no. 1.0420 (DIN 1652)
KPS 35, 37,39 Bellows: Stainless steel, material no. 1.4306 (DIN 17440)
Pressure connection: Brass,W.No. 2.0401 (DIN 17660)
KPS 43, 45, 47 Diaphragm capsule: Nickel-plated brass, DIN 50 968 Cu/Ni 5 (DIN 1756)
Diaphragm: Nitrile-Butadien rubber
4 IC.PD.P10.C2.02 - 520B2981
Installation Installation Setting

KPS pressure switches are fitted with a 3 mm steel When the pressure switch cover is removed, and
mounting plate. The units should not be allowed the locking screw (5) is loosened, the range can
to hang from the pressure connection. be set with the spindle (1) while at the same time
the scale (2) is being read. In units having an ad-
Pressure connection justable differential, the spindle (3) must be used
When fitting or removing pressure lines, the to make the adjustment. The differential obtained
spanner flats on the pressure connection should can be read direct on the scale (4) or, with types
be used to apply counter-torque. KPS 43, 45, 47, can be determined by reading the
scale value and using the nomograms in figs. 1, 2,
Steam plant 3 (page 3). The working line for determining the
To protect the pressure element from excessive differential must not intersect the shaded areas in
heat, the insertion of a water-filled loop is the nomograms.
recommended. The loop can, for example, be
made of 10 mm copper tube as shown in fig. 5.
1. Range spindle
2. Range scale
3. Differential spindle
4. Differential scale
Fig. 6 5. Locking screw
Selection of differential
To ensure that the plant functions properly, a
suitable differential pressure is necessary.
Fig. 5 Too small a differential will give rise to short
running periods with a risk of hunting. Too high
a differential will result in large pressure
Water systems oscillations.
Water in the pressure element is not harmful, but
if frost is likely to occur a water-filled pressure Electrical connection
element may burst. To prevent this happening, KPS pressure switches are fitted with a
the pressure control can be allowed to operate Pg 13.5 screwed cable entry that is suitable for
on an air cushion. cable diameters from 5 to 14 mm.
Contact function is shown in fig. 7.
Media-resistance
See table of materials in contact with the
medium, page 4. If seawater is involved, types
KPS 43, 45, 47 are recommended.
Pulsations
If the pressure medium is superimposed with
severe pulsations, which occur in automatic
sprinkler systems (fire protection), fuel systems
for diesel motors (priming lines), and hydraulic
systems (e.g. propeller systems), etc., types Fig. 7
KPS 43,45,47 are recommended. The maximum
permissible pulsation level for these types is
120 bar.
IC.PD.P10.C2.02 - 520B2981 5
Function 1. KPS 31 I. Alarm for falling pressure given at the set

Contacts 1-2 make and contacts 1-4 break when range value.
the pressure falls under the set range value. The II. Alarm for rising pressure given at the set
contacts changeover to their initial position when range value plus the differential.
the pressure again rises to the set range value
plus the differential (see fig. 8).
Scale setting
Mechanical
differential
Fig. 8
2. All other KPS pressure switches I. Alarm for rising pressure given at the set
Contacts 1-4 make and contacts 1-2 break when range value.
the pressure rises above the set range value. The II. Alarm for falling pressure given at the set
contacts changeover to their initial position when range value minus the differential.
the pressure again fails to the range value minus
the differential (see fig. 9).
Scale setting
Mechanical
differential
Fig. 9
Example 1 Choose a KPS 45 (range 4 to 40 bar).

An alarm must be given when the lubricating oil The range value must be set at 36 bar.
pressure in a motor fails below 0.8 bar. The alarm is The differential of 6 bar must be set in accordance with
in the form of a lamp. the nomogram, fig. 10, at approx. 2 on the differential
Choose a KPS 31 (range 0 to 2.5 bar). scale.
The minimum permissible lubricating oil pressure of The required start function is obtained by connection to
0.8 bar must be set on the range spindle. terminals 1 and 2 in the pressure control.
The differential is fixed at 0.1 bar, i.e. the alarm will
not cut out before the pressure rises to 0.9 bar. The
lamp must be connected to terminals 1 and 2 in the
pressure control.
Example 2
An alarm must be given by a bell when the pressure
in a boiler rises to 10 bar. The normal operating pres-
sure is 9 bar.
Choose a KPS 36 (range from 6 to 18 bar).
The range value of the pressure control must be set
at 10 bar, the differential at 1 bar.
The bell must be connected to terminals 1 and 4.
Example 3
The pressure in a start air reservoir must be
regulated with a compressor controlled by a KPS
pressure switch so that it lies between 30 and 36 bar.
6 IC.PD.P10.C2.02 - 520B2981
Dimensions and weight
Weight:
KPS 31 - 39 approx. 1.0 kg
KPS 43 - 47 approx. 1.3 kg
IC.PD.P10.C2.02 - 520B2981 7
Accessories Part Description Code no.

G 3/8 connector, nipple and washer
Connector with
(10 mm) o.d. x 6.5 mm i.d.), for braz- 017-436866
nipple
ing
Connector with G 3/8 connector, nipple and washer
017-422966
nipple (10 mm o.d. x 6.5 mm i.d.) for welding
G 3/8 x 7/16 - 20 UNF (1/4 flare)

Reducer 017-420566
reduction with washer
Adapter G 3/8 x 1/8 - 27 NPT with washer 060-333466
Nipple G 3/8 o.d x 7/16 - 20 UNF (1/4 flare) 060-324066
Nipple G 3/8 A - 1/4 NPT with washer 060-333566
Adapter G 3/8 x 1/4 - 18 NPT with washer 060-333666
G 1/4 A x G 3/8 A 060-333266

Nipple
G 1/4 A x o.d. M10 x 1 with washer 060-333866
Damping coil with 1/4 flare
connectors and 1 m copper capillary
tube. Damping coils used for applica-
060-007166
Damping coil tions with 3/8 RG
connector requires the use of reducer.
For informations about capillary tube
lengths, please contact Danfoss
Damping coil with G 3/8 connectors 060-104766

Damping coil
and 1.5 m copper capillary tube
Damping coil with G 3/8 connectors

Armoured and 1 m armoured copper capillary
060-333366
damping coil tube.
Standard washers included.
8 IC.PD.P10.C2.02 - 520B2981
Thermostats KPS thermostats are temperature-controlled The KPS series covers most outdoor as well as
switches. The position of the contacts depends indoor application requirements.
Description on the temperature of the sensor and the set
scale value. In this series, special attention has KPS thermostats are suitable for use in monitoring,
been given to meeting demands for : alarm and regulation systems in factories, diesel
• a high level of enclosure, plant, compressors, power stations and on board
• robust and compact construction, ship.
• resistance to shock and vibration.
Approvals EN 60 947-4-1 CCC, China Compulsory Certificate

EN 60 947-5-1 Underwriters Laboratories Inc., USA
Ship approvals Det norske Veritas, Norway Registro Italiano Navale, Italy
American Bureau of Shipping RMRS, Maritime Register of Shipping, Russia
Lloyds Register of Shipping, UK Nippon Kaiji Kyokai, Japan
Germanischer Lloyd, Germany CCS, China Classification Society
Bureau Veritas, France
Includes thermostats with fixed sensor and
pressure controls with armoured capillary tube.
Technical data and ordering When ordering, please state type and code number
Setting Mech. Max. Suitable sensor length Cap. Code no.
range diff. sensor see also “Accessories” tube
adjust- temp. length
able/
fixed
Type
°C °C °C mm m
-10 - 30 3 - 10 80 65 75 110 160 2 060L311266 060L311366 KPS 76
20 - 60 3 - 14 130 - 75 - - - 060L311866 KPS 77
20 - 60 3 - 14 130 - - 110 - - 060L310066 KPS 77
20 - 60 3 - 14 130 - - - 160 - 060L313666 KPS 77
20 - 60 3 - 14 130 65 75 110 160 2 060L310166 060L310266 KPS 77
20 - 60 3 - 14 130 - - 110 160 5 060L311966 060L312066 KPS 77
KPS with rigid sensor 50 - 100 4 - 16 200 - 75 - - - 060L312166 KPS 79
50 - 100 4 - 16 200 - - 110 - - 060L310366 KPS 79
50 - 100 4 - 16 200 - - - 160 - 060L313766 KPS 79
50 - 100 4 - 16 200 65 75 110 160 2 060L310466 060L310566 KPS 79
50 - 100 4 - 16 200 - - 110 160 5 060L312266 060L312366 KPS 79
50 - 100 4 - 16 200 - - 110 160 8 060L312466 060L312566 KPS 79
50 - 100 4 - 16 200 65 75 110 160 3 060L314366 KPS 79
50 - 100 9 200 - 75 - - - 060L3141661) KPS 79
70 - 120 4.5 - 18 220 - 75 - - - 060L312666 KPS 80
70 - 120 4.5 - 18 220 - - 110 - - 060L312766 KPS 80
70 - 120 4.5 - 18 220 - - - 160 - 060L313866 KPS 80
70 - 120 4.5 - 18 220 - - - 200 - 060L315766 KPS 80
70 - 120 4.5 - 18 220 65 75 110 160 2 060L312866 060L312966 KPS 80
KPS with remote sensor 70 - 120 4.5 - 18 220 65 75 110 160 3 060L315666 KPS 80
70 - 120 4.5 - 18 220 - - 110 160 5 060L313066 060L313166 KPS 80
70 - 120 4.5 - 18 220 - - 110 160 8 060L313266 060L313366 KPS 80
60 - 150 5 - 25 250 65 75 110 160 2 060L310666 060L310766 KPS 81
60 - 150 5 - 25 250 - - 110 160 5 060L313466 060L313566 KPS 81
60 - 150 5 - 25 250 - - 110 160 8 060L311166 KPS 81
60 - 150 5 - 25 250 - - 200 - - 060L311066 KPS 81
100 - 200 6.5 - 30 300 65 75 110 160 2 060L310866 060L310966 KPS 83
100 - 200 18 300 65 75 110 160 2 060L3139661) KPS 83
1)
Thermostat with max. reset
KPS with remote sensor and

armoured capillary tube
IC.PD.P10.C2.02 - 520B2981 9
Contact load (Alternating current):

(when Au surface is burned away)
Ohmic: 10 A, 440 V, AC-1
Inductive: 6 A, 440 V, AC-3
4 A, 440 V, AC-15
Starting current max. 50 A (locked rotor)
Ambient temperature –40 to +70 °C
Vibration resistance
Vibration-stable in the range 2-30 Hz, amplitude
1.1 mm og 30-300 Hz, 4 G.
Enclosure
IP 67 to IEC 529 and DIN 40050.
The thermostat housing is enamelled pressure
die cast aluminium (GID-AlSI 12). The cover is
fastened by four screws which are anchored to
prevent loss.
The enclosure can be sealed with fuse wire.
Cable entry
Pg 13.5 for cable diameters from 5 to 14 mm.
Identification
The type designation and code no. of the unit is
stamped in the side of the housing.
Fig. 1
Curve A gives the maximum load.
Hatched area B: Acceptable load for the gold Scale accuracy
plating of the contact.
KPS 76: ±3 °C KPS 80: ±3 °C
KPS 77: ±3 °C KPS 81: ±6 °C
Switch KPS 79: ±3 °C KPS 83: ±6 °C
Single-pole changeover switch (SPDT).
Contact material: Gold-plated silver contact. Snap point variation after 400 000 operations.
Direct current: 12 W, 220 V, DC-13 – See fig. 1 KPS 76-83: max. drift 2 °C.
Function Selection of differential The thermal differential is always greater than

To ensure that the plant functions properly, a the mechanical differential and depends on three
suitable differential is necessary. Too small a dif- factors:
ferential will give rise to short running periods 1) the flow velocity of the medium,
with a risk of hunting. Too high a differential will 2) the temperature change rate of the medium,
result in large temperature variations and
3) the heat transmission to the sensor
Differentials
The mechanical differential is the differential that Thermostat function
is set by the differential spindle in the thermostat. Contacts 1-4 make while contacts 1-2 break when
The thermal differential (operating differential) is the temperature rises above the scale setting. The
the differential the system operates on. contacts changeover to their initial position when
the temperature falls to the scale setting minus
the differential. See fig. 6.
I. Alarm for rising temperature

given at range setting value.
II. Alarm for falling temperature
given at range setting value
minus the differential.
Scale setting
Mechanical
differerential
Fig. 6
10 IC.PD.P10.C2.02 - 520B2981
Installation Installation Flow velocity of the medium is also of signifi-

Location of unit: KPS thermostats are designed to cance. (The optimum flow velocity for liquids is
withstand the shocks that occur, e.g. in ships, on about 0.3 m/s).
compressors and in large machine installations. For permissible media pressure see fig. 2.
KPS thermostats with remote sensor are fitted
Brass Stainless steel
with a base of 3 mm steel plate for fixing to
bulkheads, etc. KPS thermostats with bulb sensor
are self-supporting from the sensor pocket.
Resistance to media
Material specifications for sensor pockets:
Sensor pocket, brass

The tube is made of Ms 72 to DIN 17660, the
threaded portion of So Ms 58Pb to DIN 17661.
Fig. 2. Permissible media pressure on the
sensor pocket as a function of temperature
Sensor pocket, stainless steel 18/8
Material designation 1.4305 to DIN 17440. Setting
When the thermostat cover is removed, and the
Sensor position locking screw (5, fig. 3) is loosened, the range can
As far as possible the sensor should be positioned be set with the spindle (1) while at the same time
so that its longitudinal axis is at right angles to the scale (2) is being read.
the direction of flow. The active part of the sensor In units having an adjustable differential, the
is Ø13 mm x 50 mm long on thermostats with spindle (3) can be used while the scale (4) is
rigid sensors and 2 m capillary tube. The active being read.
length on the other thermostats is 70 mm (5 m
and 8 m capillary tubes). 1. Range
spindle
The medium 2. Range
The fastest reaction is obtained from a medium scale
having high specific heat and high thermal 3. Differential
spindle
conductivity. It is therefore advantageous to use
4. Differential
a medium that fulfills these conditions (provided scale
there is a choice). 5. Locking
screw
Fig. 3
Scale correction
The sensor on KPS thermostats contains an Scale deviation factor
adsorption charge. Therefore function is not affected
whether the sensor is placed warmer or colder than
the remaining part of the thermostatic element
(bellows and capillary tube). However, such a charge
is to some extent sensitive to changes in the
temperature and bellows and capillary tube.
Under normal conditions this is of no importance, Relative
but if the thermostat is to be used in extreme scale
setting
ambient temperatures there will be a scale
in %
deviation. The deviation can be compensated for as
follows:
Scale correction = Z x a
Z can be found from fig. 4, while a is the correction
factor from the table below.
Regulation Correction factor a

range for thermostats
Type with rigid with 2 and with 8 m
sensor 5 m cap. cap. tube Fig. 4
°C tube
KPS 76 -10 - +30 1.1
KPS 77 20 - 60 1.0 1.4
KPS 79 50 - 100 1.5 2.2 2.9
KPS 80 70 - 120 1.7 2.4 3.1
KPS 81 60 - 150 3.7
KPS 83 100 - 200 6.2
IC.PD.P10.C2.02 - 520B2981 11
Electrical connection KPS thermostats are fitted with a Pg 13.5 screwed

cable entry suitable for cables from 5 to 14 mm.
Contact function is shown in Fig. 5
Fig. 5
Examples Example 1 Example 2

A diesel engine with cooling water temperature Find the necessary scale correction for a KPS 80
of 85 °C (normal). An alarm must be triggered if set at 95 °C in 50 °C ambient temperature.
the cooling water temperature exceeds 95 °C.
Choose a KPS 80 thermostat (range 70 to 120 °C). The relative scale setting Z can be calculated
Main spindle setting: 95 °C. from the following formula:
Differential spindle setting: 5 °C.
The required alarm function is obtained by Setting value – min. scale value x 100 = %
connecting to thermostat terminals 1-4. After max. scale value – min. scale value
the system has been in operation, assess the
operating differential and make a correction if Relative scale setting: 95 – 70 x100 = 50%
necessary. 120 – 70
Factor for scale deviation Z (fig. 4 page 11),

Z ≅ 0.7
Correction factor a (table under fig. 4
page 11) = 2.4
Scale correction = Z × a = 0.7 × 2.4 = 1.7 °C

The KPS must be set at 95 + 1.7 = 96.7 °C
Dimensions and weight
Sensor pocket Sensor

length “A” length ” L”
75 105
110 138
160 190
200 230
KPS with remote sensor KPS with remote sensor and armoured KPS with rigid sensor
Weight: ca 1.2 kg capillary tube Weight: ca 1.0 kg
(incl. 2 m capillary tube) Weight : ca 1.4 kg (incl. 2 m capillary tube)
12 IC.PD.P10.C2.02 - 520B2981
Accessories: Sensor pockets Sensor A Thread Code no. Sensor A Thread Code no.
for KPS thermostats pocket mm B pocket m B
Brass 65 1/2 NPT 060L326566
Brass 75 1/2 NPT 060L326466 Steel 18/8 75 G 1/2A 060L326766
75 G 1/2 A 060L326266
75 G 3/8 A 060L326666
75 G 1/2 A (ISO 228/1) 060L328166
Brass 110 1/2 NPT 060L328066 Steel 18/8 110 G 1/2 A 060L326866
110 G 1/2 A 060L327166 110 1/2 NPT 060L327066
110 G 1/2 A (ISO 228/1) 060L340666
110 G 3/4 A (ISO 228/1) 060L340366
Brass 160 G 1/2 A 060L326366 Steel 18/8 160 G 1/2 A 060L326966
160 G 3/4 A (ISO 228/1) 060L340566
Brass 200 G 1/2 A 060L320666 Steel 18(8 200 G 1/2 A 060L323766
200 G 1/2 A (ISO 228/1) 060L340866 200 G 3/4 A 060L323866
200 G 3/4 A (ISO 228/1) 060L340266
Brass 250 G 1/2 A 060L325466
Supplied without gland nut, Brass 330 G 1/2 A 060L325566
gaskets and washer
Brass 400 G 1/2 A 060L325666
Part Description Code no.
For KPS thermostats with remote

Clamping band 017-420466
sensor (L = 392 mm)
For KPS thermostats with sensor fitted in a sensor pocket. Compound for
Heat-conductive
filling sensor pocket to improve heat transfer between pocket and sensor.
compound 041E0114
Application range for compound:between pocket and sensor.
(4.5 cm2 tube)
Application range for compound: –20 to +150 °C, momentarily up to 220°C.
Gasket set For KPS thermostats without armoured capillary tubes 060L327366
Gasket set For KPS thermostats with armoured capillary tubes 060L036666
® Danfoss A/S 05-07/ AC-DSL/mr
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products
already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed.
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
IC.PD.P10.C2.02 - 520B2981 13

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Screw pumps

A Member of the Low pressure pumps

Installation and Start-up Instruction

This instruction is valid for all standard low pressure pumps:

LPD 015 N 1 I V B P Pumpunit

ACD 025 L 6 I V B P Pumpunit

ACG/UCG 045 K 6 I V B E A101 O = max 6 bar

ACF/UCF 080 K 4 I R B E A020 O = max 10 bar

ABQ 160 B 5 I R Y O A328 O = max 5 bar

(1) See Product description or Service instruction for specified Option

2 IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 LP 1205GB

Failure to comply with these instructions

Transport and storage

All work carried out on the pump has to be

Fig. 2 Lifting of pump

Lifting a complete pump unit, using slings

See table below D4 ø max 0.3 mm An angular

Alignment and shaft couplings

provided the radial forces are kept within the

Fig. 3 Alignment of the IMO AB standard coupling

4 IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 LP 1205GB

Shaft seal drain

Fig. 11 Liquid trap

6 IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 LP 1205GB

Pressure relief valve

Pressure testing and flushing

Oil leakage may make the floor slippery and

LP 1205GB IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 7

The arrow is placed on different spots depending on

8 IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 LP 1205GB

Adjusting the tuning

LP 1205GB IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 9

Connecting and discon-

The pump cannot be primed - Wrong direction of rotation. See above.

10 IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 LP 1205GB

- Counter pressure in the dis- Check the discharge line.

- Motor is undersized for the Check the motor.

- Electrical power supply faulty. Check the motor and motor

- Incorrect setting of Y/D starter. Readjust the setting of the start-

- Bad alignment Check alignment, see page 4.

- Free air in the liquid or gas For pumps with Tuning:

- Faulty electrical supply. Check all three phases of the

LP 1205GB IMO AB, Telephone: + 46 8 50 622 800, Telefax: + 46 8 645 15 09 11

Components included in spare parts sets:

451 463 463A 401

Connecting and disconnecting of electric

Service intervals Inspection of shaft seal

125 (xTxx, xQxx)

Allen key Fine Oil can

Shaft seal - assembly drawing

Stationary member Rotating member

S5 S8 Version code xTxx

• Turn the electricity OFF.

• Close the valves.

• Remove the shaft • Remove the key 113.

• Remove the • Remove the front cover 501 and power

• Separate the front

• Place the front cover 501 on a pair of

K. xTxx and xQxx L. 202

• Insert two suitable

E. F. xTxx and xQxx

506 • Fit the screws

• Install the pump