2-1920-2002 EX ERMA BWTS Vol. lII

Equipment Operations & Technical
Manual
ERMA FIRST BWTS FIT 1x2000 EX for HN 2140
Vol. III – Suppliers’ manuals

Generic OMSM rev.05 Dated 11/09/2018
© ERMA FIRST ESK ENGINEERING SOLUTIONS

Schisto Industrial Park ( VIPAS ), Block 13, Keratsiniou–Skaramagas Ave,
188 63, Perama, Greece
Tel: (+30) 2104093000 / Fax: (+30) 2104617423
E-mail: info@ermafirst.com
2-1920-2002 EX Equipment Operation & Technical manual –Vol III Rev. -
22/7/2019 Chapter: Overall information and specifications HN 2140
The current Operation Safety and Maintenance Manual (OMSM) is in line with the Generic Operation
Safety and Maintenance Manual (OMSM) revision 5, dated 11 September 2018, as this has been
approved by the USCG TAC 162/060/6/2.
The Rev. number of this document stated on the headers of each page indicate the ship specific
OMSM revision as per vessel's class and flag requirements, but at no case diverts from the operation
principles described on the Generic OMSM Rev.05.
© ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 1
Copyright ERMA FIRST ESK ENGINEERING SOLUTIONS SA
All rights reserved.
The data contained in this document is proprietary to ERMA FIRST ESK ENGINEERING SOLUTIONS SA
You are respectfully reminded that none of the following may be directly or indirectly released,
reproduced, modified or used in anyway without the explicit permission of ERMA FIRST S.A., neither
can it be used for the reproduction of the BWT System or any of its components.
All specifications included in this manual are subject to change without notice
ERMA FIRST ESK Engineering Solutions S.A. shall not be responsible or liable for damages resulting from
misapplication or misuse of its products.
Contact Details:
ERMA FIRST ESK Engineering Solutions S.A.
Schisto Industrial Park ( VIPAS ), Block 13,

Keratsiniou–Skaramagas Ave,
188 63, Perama, Greece
Tel: (+30) 2104093000 / Fax: (+30) 2104617423
E-mail: technical@ermafirst.com
info@ermafirst.com
WEB: http://www.ermafirst.com/
Overall information and specifications

Hull Number: 2140
Vessel Name: CELSIUS ROSKILDE
BWTS model: ERMA FIRST BWTS FIT 1x2000 EX
BWTS Serial No: 10-2000RF-2-1003
Document No: 2-1920-2002 EX
Project No: 002-001687
Document Revision -
Date 22/7/2019
BWTS capacity: 2100 m³/h
Max. power consumption: 252.23 kW
Cooling Water flow: 3 m³/h
Ballast water temperature range: -2° – 40° C
Minimum intake water salinity: 1.07 PSU at -2° C/ 0.9 PSU at 3° C
Average operation pressure: 0.5 - 5 bar
Approved for use in explosive

Yes
atmospheres:
Max. allowable dosage concentration of

10 mg/L
TRO (Cl2):
Holding time in tank prior to neutralization: > 1h
Max. allowable discharge concentration of

< 0.1 mg/L
TRO (Cl2)after neutralizing:
Max. Hydrogen gas generation: ≤ 1.6% vol. (40% LEL)
Max. differential pressure across filter, prior

0.3 bar
to flushing:
22/7/2019 Chapter: Revision details HN 2140
Revision details
Rev. Date Description Created Checked

Nr.
00 22/7/2019 Original Volume lll of Operation Manuals I. LEONTI A. ADAMI
22/7/2019 Chapter: INDEX HN 2140
INDEX
OVERALL INFORMATION AND SPECIFICATIONS
INDEX
CONTROL PANEL
Power source replacement
FILTER(S)
ELECTROLYTIC CELL(S)
TRANSFORMER/ RECTIFIER(S)
FLOW METER
TRO MONITORS
DOSING PUMP(S)
FLOW SWITCH(ES)
TEMPERATURE SENSOR(S)
PRESSURE TRANSMITTERS
SHUTTER VALVES
SALINITY MEASURING DEVICE
SUCTION PUMP
HYDROGEN SENSOR
DIAPHRAGM AIR PUMP
BUTTERFLY VALVES
PRESSURE & TEMPERATURE SWITCH
LEVEL SENSORS
CONTROL PANEL
Power source replacement

Power source (battery) lifetime: 3-4 years (depending on the use).
Steps for safe replacement
Disconnect the cables in

front and near the power
source
Figure 1: Disconnect the cables
Open the cover and

remove the power source
Check the
polarity of the power
source (battery) before
removing it.
Figure 2: Remove power source
Replace the power source

(replacement time should
not exceed 5 minutes).
Power source tech.

specifications:
- Lithium battery
- 3.6 volt
- Indicative type
(from Schneider)
TSXPLP01
Figure 3: Power source
Replacement time MUST NOT EXCEED 5 minutes
Replace the power source
Be careful of the polarity.
Figure 4: Replace the power source
Close the cover and re-

connect the cables.
Figure 5: Replace cables
2-1920-2002 EX Equipment Operation & Technical manual –Vol llI Rev. -
FILTER(S)
FILTREX ACB® FILTREX ACB®
AUTOMATIC SELF-CLEANING FILTREX

BACKWASHING FILTER FILTER DATA SHEET
ITEM DESCRIPTION
1 1 ea. Filter
Maker: FILTREX S.r.l.
Type: Filter
®
ACB
Filter element type: Woven Mesh single basket
Backflush liquid: Own medium
Parameters
Medium: Ballast water
Pre-separation Filtration: 15mm
Application: Ballast water treatment
Density: 1 000 kg/m³
Operating temperature: -2°C to 55°C
Flow (size dependent): Model-Size Flow Range with single filter (*)
ACB-902-50 6 - 25 m³/h
ACB-903-65 8 - 35 m³/h
ACB-904-80 10 - 55 m³/h
ACB-906-100 15 - 87 m³/h
ACB-910-150 25 - 135 m³/h
ACB-915-150 35 - 190 m³/h
ACB-935-200 35 - 255 m³/h
ACB-945-200 45 - 340 m³/h
ACB-955-250 50 - 515 m³/h
ACB-985-300 65 - 770 m³/h
ACB-999-350 95 - 1040 m³/h
ACB-9100-400 126 - 1.500 m³/h
ACB-9120-500 126 - 2.100 m³/h
ACB-9200-600 126 - 3.000 m³/h
Combination of smaller filters can be used in place of one larger filter due to constraints or
to manage flowrates over 1040m³/h. Parallel installations not affect filters performance.
Operating pressure: 1.5 bar

Design pressure: 10 barg
Filtration level: 40µ- 20µ ‐ Woven Mesh
Pressure drop over clean filter DPo: ≤0.10 bar at 0°C
Back flushing time: 20s
Back flushing flow rate: ≥ 5% of the filter capacity (l/sec)
OPERATING AND MAINTENANCE MANUAL Please refer to technical data of each
filter size.
Flushing initiated on pressure drop: 0.3 bar
Alarm on pressure drop: 0.5 bar
12 UPDATE NA MM FS 09/02/2018
11 UPDATE NA MM FS 08/06/2017 (*) the filter performance is not affected by variations of the flow not exceeding ± 5%.
10 UPDATE NA MM FS 26/05/2017
Rev. Description Compiled Checked Approved Date
ACB® Automatic Self-cleaning Backwashing Filter OMM.73 ® OMM.73

rev.12 © ERMA FIRST ESK ENGINEERINGACB AutomaticSA
SOLUTIONS Self-cleaning Backwashing
All rights reserved Filter
| Confidential | Pages 11
rev.12
(Feb 2018) (Feb 2018)
Page 0 of 66 Page 1 of 66
FILTREX FILTREX
FILTER DATA SHEET FILTER DATA SHEET
ITEM DESCRIPTION
ITEM DESCRIPTION
Notes:
Connections 1. The filter can be supplied with the inlet/outlet nozzles in the same or opposite side
Inlet: Depending on flow‐rate [mm] direction relatively to each other. ( To be done before purchasing/production of filter)
Outlet: Depending on flow‐rate [mm]
Backflush: Depending on filter size [mm] 2.The backflush nozzle can be oriented in 90° steps. (To be done before
purchasing/production of filter ).
Materials of construction
3. Working outside the filters' technical data, shall cause warranty void
Housing & cover: Ni-Al-Bz (Bronze-Aluminum Alloy)
Flanges : P265GH (carbon steel ) Ni-Al-Bz (Bronze-Aluminum Alloy) 4. During back flushing the flush‐water passes through the filter screen from the
Filter element: Ni-Al-Bz (Bronze-Aluminum Alloy) & AISI 316L outer chamber to the inner chamber, thus cleaning the accumulated residues on
Gaskets: Perbunan the inside of the screen. The back‐flushing does not influence the operation of the
Internal parts Ni-Al-Bz (Bronze-Aluminum Alloy) & AISI 316L filter, only taking out a minor part of the flow.
Bushings: Bronze (GZ‐CUSN7ZNPB)
Mud drain valve: Pneum. actuated ball valve 5. The filtering element is AISI 316L woven mesh wire and can have an aperture of 100, 40,
30, 20, 10 and 6µm
Electric components/ equipment
Gear motor: 0,12 to 0,55 kW 6. The filter is controlled by the Control System.
Please refer to technical data of each filter
size. 7. The filter requires a backpressure downstream the filter to operate properly. The
Power supply: 380 to 480 VAC, 3ph low‐Pressure control Valve (FPV) could be installed to maintain this pressure.
The required back pressure is 1,5 barg, and the FPV will maintain such pressure during
Control voltage: 2 24 Vac, 1ph + 24Vdc operation.
Mud drain valve actuator: Pneumatic In case of lower pressure available (>0.7 bar), the filter may require a backflushing pump.
Differential pressure gauge switch: Filtrex Type S17 and Filtrex Type S98 Suitable pump can be delivered by the BWTS provider as an option or be supplied by the
customer.
Conservation
8. The filter requires a limited service area above to dismantle the interiors of the
Internal surface: Ni-Al-Bz (Bronze-Aluminum Alloy)
unit. This will vary with the size filter chosen. For actual area needed – refer to
External surface: Ni-Al-Bz (Bronze-Aluminum Alloy)
detailed drawing.
Optional equipment 9. In case the filter is inoperative for more than 48 hrs and filled with sea water, it is strongly
‐ Back flushing pump: recommended to drain it and CLEAN/REFILL it with fresh water to prevent growth inside and
‐ Sacrificial anode: Zinc to preserve it properly.
‐ Filter mesh: Superduplex 1.4410 10. In case of fluid with presence of iron Filtrex recommends to clean the filter and the
‐ Differential Pressure Transmitter: 4 to 20 mA filtering element every 3-6 months with a descaling product suitable for stainless steel and
‐ Pressure transmitters: 4 to 20 mA Bronze-Aluminum alloy for its preservation
‐ Backwash valve
11. As described in the start-up phase ( QSG pag. 3 par.1.3), the filter must be slowly filled
‐ Filtration degree Down to 6 µm with water at every time to avoid water hammer that can damage the filter.
‐ ATEX/IECEx Ex II 2G IIC T4
‐ Adapter plates
2 1 ea. Back flushing Pump
Depending on the required treated flow
Please refer to technical data of each filter size.

rev.12
(Feb 2018) (Feb 2018)
OPERATING PRINCIPLE
TABLE OF CONTENTS
1. SCOPE ............................................................................................................................. 7
2. WARRANTY AND LIABILITY .............................................................................................. 7
3. COPYRIGHT ..................................................................................................................... 8
Type: ACB® FILTREX Filter
4. CAUTIONS AND WARNINGS FOR HS&E HAZARDS ............................................................ 8
4.1. EQUIPMENT USE ................................................................................................................ 8
4.2. CONVENTIONAL SIGNS USED IN THIS MANUAL ................................................................. 9
4.3. BASIC CAUTIONS & WARNINGS .......................................................................................... 9
4.4. BINDING OF THE USER / OPERATOR ................................................................................. 10
Filter element : Single basket, mesh 40 micron (**) 4.5. ADDITIONAL MEASURES .................................................................................................. 10
5. INTRODUCTION ............................................................................................................. 11
5.1. FILTRATION IN BALLAST WATER TREATMENT .................................................................. 11
5.2. ACB FILTER FEATURES ...................................................................................................... 12
6. TECHNICAL DATA .......................................................................................................... 14
6.1. MAIN ELEMENTS .............................................................................................................. 14
6.2. NAMEPLATE ..................................................................................................................... 15
7. FILTER SECTIONAL DRAWING ........................................................................................ 16
7.1. PARTS LIST ........................................................................................................................ 16
8. INSTALLATION ............................................................................................................... 17
8.1. BASIC INSTRUCTIONS ....................................................................................................... 17
8.2. INSTALLATION OF THE FILTERING SET .............................................................................. 18
8.2.1. FILTER FLOOR FIXING .................................................................................................... 18
8.2.2. FLOW DIRECTION .......................................................................................................... 18
8.2.3. FILTER-PIPING CONNECTIONS ...................................................................................... 19
8.2.4. FILTER COVER VENT ...................................................................................................... 19
8.2.5. ELECTRICAL CONNECTIONS........................................................................................... 20
9. OPERATION ................................................................................................................... 21
9.1. FILTER FUNCTIONAL DESCRIPTION ................................................................................... 21
9.1.1. STANDARD CONFIGURATION ....................................................................................... 21
9.1.2. HIGH BACKWASH COUNTERPRESSURE CONFIGURATION ............................................ 23
9.2. ELECTRIC GEARMOTOR FUNCTIONAL DESCRIPTION ....................................................... 25
9.3. LOCAL CONTROL PANEL FUNCTIONAL DESCRIPTION ....................................................... 26
9.3.1. RECOMMENDED LOGIC FOR OPERATION ..................................................................... 26
(**) Other mesh size are available down to 6 µm
9.5. FILTERING ELEMENT FUNCTIONAL DESCRIPTION ............................................................ 29
9.6. START-UP & COMMISSIONING ......................................................................................... 30
9.7. REMOVAL FROM SERVICE AND DISPOSAL ........................................................................ 31

rev.12
(Feb 2018) (Feb 2018)
10. MAINTENANCE AND SERVICING .................................................................................... 32 1. SCOPE

10.1. BASIC SAFETY INSTRUCTIONS ....................................................................................... 32
10.2. MAINTENANCE INTERVALS ........................................................................................... 33 Scope of this manual is to give information on the preservation, erection, operation, and
10.3. TOOLS AND EQUIPMENT .............................................................................................. 34 maintenance of the Filter based on the specifications of the unit delivered from our factory for the
10.3.1. EQUIPMENT ................................................................................................................ 34 proper intended uses.
10.4. INSPECTION AND CLEANING PRELIMINARY OPERATIONS ............................................ 35
In case post-delivery alterations have been made to the unit, we recommend to contact Filtrex S.r.l.
10.5. DISASSEMBLING PROCEDURE ....................................................................................... 36
10.5.1 ALTERNATIVE DISASSEMBLING PROCEDURE FOR ACB-9100-400, ACB-9120-500 or our local branch for an updated manual.
AND ACB-9200-600 ...................................................................................................................... 42 This manual makes reference to other pieces of literature, such as schematics and drawings that
10.6. FILTERING ELEMENT CLEANING PROCEDURE ............................................................... 45 are added to the manual as needed depending on the filter parameters and configuration.
10.7. ASSEMBLING PROCEDURE ............................................................................................ 46 The Filter type ACB construction and operation are identical for all series nominal sizes.
11. TROUBLESHOOTING ...................................................................................................... 47 In order to prevent hazards and have the maximum benefit from your Filter, as repair costs,
12. SPARE PARTS ................................................................................................................ 49 reduction of down times and increase of reliability, adhere and read carefully this manual’s sections
concerning preservation, installation, start-up, operation and maintenance prior the product
13. APPENDIX ..................................................................................................................... 50
installation, and operation.
13.1. FILTER............................................................................................................................ 50
Additional instructions required by existing national and international regulations for the prevention
13.2. FILTER ELECTRICAL GEARMOTOR ................................................................................. 64
13.3. FILTER DIFFERENTIAL PRESSURE SWITCH ..................................................................... 65 of accidents and environmental protection are mandatory.
13.4. FILTER DIMENSIONAL DRAWINGS ................................................................................ 66 Operating instructions shall be made available at site for qualified personnel task, work, and
performance relevant the transportation, installation, operation and maintenance of the filter.
Do not hesitate to contact Filtrex S.r.l. or our local branch for any further technical information you
may require.
2. WARRANTY AND LIABILITY
Filtrex assumes no liability for any mistakes by improper use of the product.
We reserve the right to change this description without prior notice. The general terms and conditions of Filtrex S.r.l. apply.
When ordering spare parts or requesting technical assistance, always state the serial number of
the Filter and data reported on unit name plate.
All illustrations are for reference only.
Unless special permission has been granted by Filtrex S.r.l. do not attempt to repair or dismantle
Filtrex S.r.l. reserves the right to change them without prior notice.
the Filter or any of its components within the warranty period of the unit (with exception of any
dismantling necessary for the replacement of filter element).
Failure to seek the said permission will cause the guarantee on the said parts to be void!
Filtrex S.r.l. product warranty and liability does not cover technical modifications to the filter unit
unless Filtrex S.r.l. in writing has accepted such extension of warranty / liability.
Filtrex assumes no claims for personal and material damages, warranty and liability for any
mistakes by improper use of the product or damages by incorrect operation or maintenance against
the given instructions.
Filtrex S.r.l. reserves the right to change this description without prior notice.

rev.12
(Feb 2018) (Feb 2018)
3. COPYRIGHT 4.2. CONVENTIONAL SIGNS USED IN THIS MANUAL

The following conventional signs are used in this manual to highlight particularly important
This document is property of : information to be fulfilled avoiding impacts on HSE and filter damages:
DANGER
FILTREX S.r.l. A danger indicates a potential high risk hazard with serious personal injury
and damage to the equipment if the problem is not avoided.
Via Rubattino, 94/B
20134 Milan, ITALY
Tel +39-02-75.33.841 WARNING
A warning indicates a potential medium risk hazard with possible personal
Fax +39-02-75.31.383 injury and malfunction of the equipment if the problem is not avoided.
E-mail : info@filtrex.it
marine_diesel@filtrex.it
STOP
A stop indicates a potential low risk hazard and malfunction of the
and is released to the final User of the filter with the sole scope of assure performance operation equipment if the problem is not avoided. The filter shall be put out of
STOP
and maintenance of the equipment. service.
All information included in this document cannot be reproduced, distributed or otherwise made
available to others, either in full or in part, without the express permission of FILTREX s.r.l. which NOTE
will reserve its rights according to law. Highlight important information to avoid further problems or damages.
4. CAUTIONS AND WARNINGS FOR HS&E HAZARDS

4.1. EQUIPMENT USE NOTE
Highlight important information to avoid environmental impacts.
Construction of the filter is in accordance with recognized safety rules and latest status of art
technology. However improper use of the filter may result in risk hazard to the life of user involved
people and / or damage to the filter various equipment. 4.3. BASIC CAUTIONS & WARNINGS
Filter need to be used properly, and only if it is in perfect condition in compliance with operating The following basic caution and warnings shall be considered before any subsequent activities
instructions and the required inspection and maintenance conditions. related to this operation and maintenance manual.
Special precautions shall be taken to assure safety and avoid hazards in accordance with the The Filter does not require to be inspected daily.
operating instructions and relevant filter performance limits.
WARNING
A prompt remedial to any faults shall be performed to avoid subsequent impacts which may Check to be sure the available electrical power matches the voltage, phase
and cycle requirements of the electric motor and automatic control panel.
compromise safety.
Damage may occur if improperly connected.
Design of the filter is intended for filtering liquid media only and installation in pipes, in accordance
with the Pressure Equipment Directive 97/23/EC. WARNING
The type of fluid and adherence to process conditions limit values for operating pressure and Do not expose the equipment to working pressure & temperature over the
Design Pressure & Temperature. Monitoring of the working pressure &
temperature as stated in the order and in the technical data sheet are mandatory. temperature shall be considered by the user.
Failure to comply with all the above use conditions is regarded as improper use, and therefore the
manufacturer / supplier is not liable for any damage caused as a result of improper use. The user WARNING
solely bears the risk. In order to avoid opening the cover when the filter is pressurized, the user
shall install on the inlet pipeline to the Filter, downstream of any isolation
valve, a pressure indicator.

rev.12
(Feb 2018) (Feb 2018)
4.4. BINDING OF THE USER / OPERATOR

5. INTRODUCTION
Filter operating instructions shall be made available to involved people at the place of use, 5.1. FILTRATION IN BALLAST WATER TREATMENT
integrated by the user with supplementary instructions derived from the local regulations for the
The problem of invasive species is considered as one of the 4 major threats of the world’s oceans,
prevention of accidents and environmental protection which need to be respected.
next to land-based marine pollution, overexploitation of living marine resources, and physical
Rules obligation for the environmental protection and the prevention of accidents, such as handling
alteration/destruction of habitats.
hazardous accidents and/or providing/wearing personal safety clothing and equipment, are
The ballast water is loaded with particulate sediment and an enormous variety of (living)
mandatory.
organisms, which ranges from juvenile stages larvae and eggs of fish and larger zooplankton to
Operating instructions shall be integrated by user site own instructions, including supervision and
macro algae, phytoplankton, bacteria and viruses.
reporting obligations for specific operational matters, e.g. with regard to organisation of work,
In general, the organisms loaded as stowaways during the ballasting operation belong to the
working sequences and the appointed staff.
natural ecosystem in and around the port of origin, but they may not be occurring naturally in the
All filter related activities shall be performed by appointed, trained and properly instructed staff.
coastal waters and port of destination at the end of a ships voyage.
Responsibility of staff for installation, operation, maintenance and servicing must be clearly
In hundreds of cases around the world, the non-native organisms transported through the ships’
appointed before performance of any activity.
ballast water developed into a plague, and this has resulted in severe damage to the receiving
Keep in good conditions all existing safety instructions and danger signs, and observe all safety
ecosystem and to human health. This often has a high impact on the marine environment and can
instructions and hazard warnings of the filter.
cause economical damage, as it results in a decrease of stocks of commercially valuable fish and
Do not make modifications of any kind to the filter which may compromise safety, without the
shellfish species and, occasionally, outbreaks of diseases such as cholera.
permission of the manufacturer.
Ships transport 5-10 billion tons of ballast water annually all over the globe. If action is not
Use only original spare parts which comply with the technical requirements set out by the
taken, the problem of invasive species will increase in an exponential manner for several reasons.
manufacturer to assure equipment guarantee.
Ships are getting larger, faster and the amount of traffic across the oceans is expected to increase
The user is responsible for the selection of materials, the chemical resistance of the installed
rapidly during the coming decades and therefore also the chance of non-indigenous organisms to
components, internal linings and coatings and the technical details when ordering the filter.
have large enough numbers for settling and expanding.
Adhere to the maintenance procedures, tasks and intervals stated in this manual.
Treatment of ballast water is considered the best solution of reducing the risk of invasive
species. To minimize the future risks related to the current use of ballast water, the International
4.5. ADDITIONAL MEASURES
Maritime Organization (IMO) of the United Nations has adopted the Ballast Water Convention in
Follow the respective valid national and international regulations for the prevention of accidents 2004. The Convention stated that finally all ships should install proper ballast water management
and environmental protection. equipment onboard between 2009 and 2016. During recent years, numerous solutions for
Adhere to the maintenance tasks and intervals set out in the operating instructions, including treatment of ballast water have been mentioned and tested with the ultimate goal to reduce the
instructions on the replacement of parts / equipment. amount of organisms in ballast water. Most of them foresee the use of an automatic self-cleaning
Only use original spare parts. backwashing filter, together with a disinfection unit.
If the installed type of 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.
Follow the respective safety regulations when handling fluid to be filtered and/or fluid used for
cleaning.

rev.12
(Feb 2018) (Feb 2018)
5.2. ACB FILTER FEATURES - Very small backwash flowrate

Great cost savings. The ACB filter uses a very small amount of backwash fluid, thus
Next to being compliant with the Ballast Water Systems performance standard requirements (IMO
requiring a very low power consumption for pump and motor.
BWM Convention, 2004, par. D-2), the system should be :
Minimal counter-pressure required at filter outlet side.
§ Handy
Minimal or no flowrate reductions during backwash.
§ Environmentally acceptable
§ Cost effective
- Enhancement of personnel’s life by reducing maintenance activity
Starting from this concept, Filtrex has developed its ACB filter, a tailored solution that will fulfill the
Reduced maintenance activity required. It virtually eliminates the requirements for a
current and future BWMS requirements.
routinely planned maintenance on the BWMS.
This is possible thanks to our considerable commitment to research, design and resource
Improvement of BWMS reliability and performance characteristics. Human factor, and
optimization.
thus error, are completely eliminated since the filter does not need intervention a huge
amount of operation hours.
The ACB filter entails many advantages:
- Smaller than any other filter of its category
- Minimizes the impact on the environment
Lower weight. The specific design for ballast water application and Filtrex attention to the
There is no need of disposing the used filtering element.
choice of materials make the ACB filter one of the smallest and lightest products in the
market.
Smaller footprint. Thanks to its small dimensions, it is extremely easy to install, even in
retrofit cases.
- Made of few pieces

Easy maintenance. Maintenance of the ACB filter is minimal. The access to the internal
parts is very simple and easy. The filter consists of few modular parts (filtering element,
backwashing shaft and motor) that can be inspected or serviced in a few minutes without
any special tool or equipment.
Less spares. When a replacement is needed for periodic maintenance, the small number of
elements results in great cost savings.
No need for special tools.
Simple construction.
- Body made of Bronze-Aluminum alloy

High durability, less maintenance, lower TCO. Filtrex takes into great consideration the
choice of noble materials for its products. The ACB body is made of a Bz-Al alloy ASTM
B148 C95800, which results in a higher durability of the product. As a result, Filtrex can
guarantee the lowest Total Cost of Ownership (TCO) over the entire service life of every
ACB filter.
No need for internal coating. Thanks to the chosen alloy, the ACB filter does not need any
coating material (resin or rubber).

rev.12
(Feb 2018) (Feb 2018)
6. TECHNICAL DATA 6.2. NAMEPLATE

The Filter is equipped with a stainless steel engraved nameplate fixed on the front side of the filter
6.1. MAIN ELEMENTS housing, with all information relevant to fluid maximum pressure & temperature operating conditions
The special shape of FILTREX ACB filters allows to get a light and efficient continuous working and as well as the identification data that can be referred to for any spare parts or clarification
ensures a safe and easy replacement of the clogged filtering element. requirements.
The ACB filter mainly consists of:

· A housing provided with :
a) two main flanged connections, one for the inlet and the other one for the outlet. The
direction of the fluid is marked on the above mentioned flanges.
b) a backwash shaft (and nozzle).
c) other connections as requested by the process conditions.
d) a cover fixed to the housing by means of bolting.
· A filtering element, placed into the housing with the appropriate filtration degree, according to
the customer’s request; its size has been calculated according to the design flow rate and
normal pressure drop.
· Pre-filter, placed in the dirty side under the main filtering element, acts to the collection of the
biggest impurities.
· An electric motor with gear reducer for the rotation of the backwashing arm during the on-
condition cleaning of the filtering element.
· A differential pressure gauge with switch.
· A pneumatic actuated valve installed on the backwash line for the automatic discharge of the NOTE
impurities during the backwashing phase, complete with solenoid valve (***) For any enquiries or spare parts orders, please provide always the
information reported on the filter nameplate.
· Vent and drain plugs and/or valves.
· A set of gaskets for startup and commissioning.
· An engraved stainless steel nameplate, for the product identification through the model and
serial number.
Refer to attached 13. APPENDIX for the actual limit of supply.

Other optional accessories are available on request.
(***) The backwash valve can be supplied by Filtrex or by Ballast Water Treatment System
providers

rev.12
(Feb 2018) (Feb 2018)
7. FILTER SECTIONAL DRAWING 8. INSTALLATION

7.1. PARTS LIST LEGEND
P Feed Pump
POS. DESCRIPTION
1 Gear reducer S Grid Strainer
2 Gear shaft O
3 Electric motor B By-Pass Valve 6
4 Thrust bearing flange fixing bolt O Outlet Valve
5 Gear reducer flange/cover fixing bolt
6 Thrust bearing I Inlet Valve
7 Backwash nozzle gasket
7a Backwash shaft bushing gasket 2 Electric Motor & Gear
8 Self-cleaning filter vent plug B
4 Differential Gauge Switch
9 Self-cleaning filter cover
10 Self-cleaning filter cover bolt 6 Backwash Valve
11 Backwash shaft bushing
12 Filtering element fixing bolt
Backwash Pump I
7 S
13 Self-cleaning filter cover gasket (layout with pump)
14 Self-cleaning filter body
15 Self-cleaning filtering element
16 Backwash nozzle P
17 Self-cleaning filtering element gasket
18 Backwash shaft bushing 7
19 Self-cleaning filter drain plug
6
20 Backwash line gasket
21 Differential pressure instrument
22 Instrument root valve
26 Differential pressure gauge pipe fittings
29 Differential pressure gauge fittings
30 Backwash nozzle support
31 Backwash nozzle fixing bolt
32 Backwash nozzle support gasket
33 Base frame 8.1. BASIC INSTRUCTIONS
34 Base frame fixing bolt
35 Instrument root valve fitting Make sure that the foundation has sufficient load-bearing strength for installation of the filter.
36 Greaser
40 Ring spear The filter must be installed by qualified specialist staff or persons who have received the relevant
41 Thrust bearing upper flange
42 Thrust bearing lower flange instruction.
43 Seeger Observe the minimum and maximum permitted operating temperatures and pressure values for the
44 Cover lifting lug
45 Rotation indicator filter and assure that design conditions are not exceeded by suitable overpressure relief device and
77 Backwash shaft bottom bushing
80 Pre-filter over temperature limiting device.
150 Backwash valve flange gasket
151 Pneumatic actuator
152 Backwash valve body
153 Solenoid valve DANGER
155 Backwash valve fixing bolt To avoid risk of accident and material damage by incorrect installation, use
suitable lifting gear.
170 Backwash pump flange gasket Assure appropriate personnel safety equipments and clothing.
171 Electric motor pump
172 Backwash pump
Assure a potential equalisation of filter by installation of a suitable ground
2
173 Backwash pump fixing bolt cable section (at least 10 mm ).
NOTE
For any special question or data regarding installation activities please
contact the manufacturer at the address that can be found at the end of
operating instructions.

rev.12
(Feb 2018) (Feb 2018)
8.2. INSTALLATION OF THE FILTERING SET 8.2.3. FILTER-PIPING CONNECTIONS

6. Connect the filtering unit to the inlet/outlet piping, making sure that all closing means (nuts, bolts,
To install the filtering set follow these usual operations. For further information refer to ”ACB® FILTER
valves, etc.) are fast tightened.
QUICK START-UP GUIDE, QSG.73".
7. Inlet and Outlet piping should be self supported and carefully aligned to avoid stressing the filter
connections during installation.
8.2.1. FILTER FLOOR FIXING
8. Installation of shut-off valves on either side of the vessel is recommended so that it can be
1. Before installation of the filter, be sure that there is sufficient room all around for maintenance
independently drained for filtering element change or inspection.
and servicing work and replacing filter element.
9. Connect all the remaining nozzles provided on the vessel.
2. Align the filter and screw the filter housing to the fastening points on the floor.
3. Filter basement fastening shall be such that the filter housing is not twisted.
WARNING
To avoid any risk of damage to the filter assure that no external forces or
WARNING moments are acting on the filter housing and connection flanges.
Be sure that sufficient headroom is provided for easy removal of the
internal parts. This requires a clear height above the top (refer to 13.
APPENDIX). Clearance for rigging equipment must also be considered.
8.2.2. FLOW DIRECTION WARNING

4. Identify the vessel inlet and outlet. Position the vessel in the line so that the fluid enters the inlet A vigorous backwash flow is necessary for proper operation of the filter. It is
therefore important to prevent back-pressure by having a short, vented, free-
connection in order to perform properly and to avoid damage to the system. flowing backwash line with a minimum of bends, elbows or vertical risers.
5. Before final interface piping connection, check correctness of filter fluid flow directions which are
cast marked on the filter connection flanges as “INLET” and “OUTLET” .
8.2.4. FILTER COVER VENT

10. The filter cover vent screw has the task to depressurise the filter chamber before cover opening
for maintenance.
11. When opening the vent screw, proceed with extreme caution preventing pressurised medium
from being expelled uncontrollably in case of incorrect operation.
NOTE
Adhere to the regulations for environmental protection.
Make sure that leaks and any expelled medium are caught and disposed
properly and in an environmentally friendly manner.

rev.12
(Feb 2018) (Feb 2018)
8.2.5. ELECTRICAL CONNECTIONS 9. OPERATION

12. Before electrical connection, assure cut-off of electric power to the wiring circuits. 9.1. FILTER FUNCTIONAL DESCRIPTION
13. Connect the earthing lug (when provided) to the general earthing system with a ground cable
2 9.1.1. STANDARD CONFIGURATION
with a cross section of at least 10 mm to assure potential equalization and avoid any risk of
personnel injury.
PHASE 1 : FILTRATION PHASE
14. For detailed information on connection and wiring of the differential pressure indicator, refer to
The filter works with on-condition back-washing using its own filtered fluid. The water enters from
13. APPENDIX.
the inlet flange (A) and flows through all the sectors (1) (inside-outside filtration). The filtered water
15. Connect power source to the electric motor and all other electrical components included in the
is collected in the chamber (D) and exits from the outlet flange (B). During this phase, the filter
scope of supply (e.g. local panel, solenoid valve, instrumentation, etc.). It is advisable to use
operates as a static filter, and no cleaning processes of the filtering element are taking place; the
flexible power cable with extra length to allow for filter cover removal without having to disconnect
motor (2) is not operating, the nozzle (3) is not rotating, and the backwash valve (6) is closed.
the motor.
As more and more impurities build up on the cartridge surface, the differential pressure Δp shown
on the differential gauge (4) gradually increases with time until it reaches the set-point value. This
DANGER starts the filtration and cleaning phase (Phase 2).
To avoid any risk of accidents from electric shock during electrical connection
of the filter, make sure that electric power is cut-off.
Electrical connection of the filter shall be performed only by a qualified
LEGEND
electrician and according to the rules.
A Inlet Flange
B Outlet Flange
WARNING
D Filter Chamber
Check to be sure the available electrical power matches the voltage, phase
and cycle requirements of the electric motor, the electro-pneumatic valves, 1 Filter Basket Element Sectors
the backwash pump and the automatic control panel. Damage may occur if
improperly connected. 2 Electric Motor & Gear
3 Nozzle
4 Differential Gauge with Switch
6 Backwash Valve

rev.12
(Feb 2018) (Feb 2018)
PHASE 2 : FILTRATION AND CLEANING PHASE

9.1.2. HIGH BACKWASH COUNTERPRESSURE CONFIGURATION
When the differential pressure shown on the indicator (4) reaches the set-point value, the
backwashing phase starts. The motor (2) starts and drives the nozzle (3), while the backwash valve
(6) opens.
The filter works with on-condition back-washing using its own filtered fluid. The water enters from
While all the filtering sectors of the filtering element (1) assure the filtration of the fluid, the sector in
the inlet flange (A) and flows through all the sectors (1) (inside-outside filtration). The filtered water
front of the nozzle (3) is cleaned by a high-efficacy backwash flow. This flow is spilled from the
is collected in the chamber (D) and exits from the outlet flange (B). During this phase, the filter
filtered fluid present in the chamber (D), (outside-inside backwash), and exits from the nozzle (J)
operates as a static filter, and no cleaning processes of the filtering element are taking place; the
through the backwash valve (6). As a result, the impurities on the filtering element surface are
motor (2) and the backwash pump (7) are not operating, the nozzle (3) is not rotating, and the
removed by the same backwash fluid (filtered water) into the duct (5), and evacuated from the
backwash valve (6) is closed.
nozzle (J).
As more and more impurities build up on the cartridge surface, the differential pressure Δp shown
At the end of the backwash set-time, the motor (2) stops, and the backwash valve (6) closes, thus
on the differential gauge (4) gradually increases with time until it reaches the set-point value. This
returning to the filtration phase (Phase 1).
starts the filtration and cleaning phase (Phase 2).
LEGEND
LEGEND
A Inlet Flange
A Inlet Flange
B Outlet Flange
B Outlet Flange
D Filter Chamber
D Filter Chamber
J Backwash Outlet Nozzle
1 Filter Basket Element Sectors
1 Filter Basket Element Sectors
2 Electric Motor & Gear
2 Electric Motor & Gear
3 Nozzle
3 Nozzle
6 Backwash Valve
5 Outlet Backwash Duct
7 Backwash Pump
6 Backwash Valve


rev.12
(Feb 2018) (Feb 2018)

NOTE
The pressure gradient produced between the outlet side and the backwash
When the differential pressure shown on the indicator (4) reaches the set-point value, the
side, together with the use of the backwash pump when required by the
backwashing phase starts. The motor (2) starts and drive the nozzle the nozzle (3), the backwash backwash back-pressure, results in an extremely efficient cleaning action.
pump (7) starts, and the backwash valve (6) opens.
While all the filtering sectors of the filtering element (1) a the filtration of the fluid, the sector in front
of the nozzle (3) is cleaned by a high-efficacy backwash flow. This flow is spilled from the filtered
fluid present in the chamber (D), (outside-inside backwash), and exits from the nozzle (J) through WARNING
the backwash valve (6). As a result, the impurities on the filtering element surface are removed by For the correct automatic operation of the filter, it is mandatory that the
pressure at the outlet is compliant with Filtrex operation requirements (refer to
the same backwash fluid (filtered water), through the chamber (C) into the duct (5), and evacuated FILTREX FILTER DATASHEET).
from the nozzle (J) by means of the suction of the pump (7).
At the end of the backwash set-time, the motor (2) and the pump (7) stop, and the backwash valve
(6) closes, thus returning to the filtration phase (Phase 1).
LEGEND 9.2. ELECTRIC GEARMOTOR FUNCTIONAL DESCRIPTION

A Inlet Flange
B Outlet Flange LEGEND 45 3
C Backwash Chamber 1 Gear reducer 1

D Filter Chamber 3 Electric motor 5
1 Filter Basket Element Sectors 5 Gear reducer flange/cover fixing bolts
10
2 Electric Motor & Gear 10 Self-cleaning filter cover bolts
3 Nozzle 45 Rotation indicator
5 Outlet Backwash Duct
6 Backwash Valve The electric motor, mounted on top of the filter cover provide the rotation of the cleaning arm
7 Backwash Pump through the coupled shaft gear reducer (1) designed and lubricated for life.
Power to electric motor is assured by the electric control panel which is connected through a power
cable and relevant cable gland to the motor wiring junction box.
Correct operation of the electric motor can be monitored by the visual rotation of the indicator (45)
coupled directly on the filter shaft rotating arm.

rev.12
(Feb 2018) (Feb 2018)
9.3. LOCAL CONTROL PANEL FUNCTIONAL DESCRIPTION 9.4. DPI FUNCTIONAL DESCRIPTION S17
The local control panel (which can be supplied with the filtering set as optional), monitors and The differential pressure indicator is the filter's pressure drop by contamination indicator.
operates the backwashing cleaning system. The differential pressure indicator with relevant inside electric switches is connected through a
The controls and signals of the filtering set are located on the front door of the local panel and control cable and relevant cable gland to the electric control panel.
mainly consist in: When the differential pressure between the filter inlet and filter outlet reaches the set point value
- Incoming circuit breaker Q the relevant inner switches start through the electric control panel the activation of the filter cleaning
- Push button PB to start manual backwash cycle by starting the filter rotating arm and the electric motor, and opening the backwashing valve.
- White lamp L1 for circuit ON If the differential pressure between the filter inlet and filter outlet is constantly within the yellow area,
- Green light L2 for backwash cycle ON the filter enters into a continuous backflushing condition. If this condition persists, this can indicate
- Red lamp L3 for cumulative alarm that the filtering element needs to be checked.
If the local control panel is provided as optional, its Wiring Diagram is supplied for the following Monitor and limit the differential pressure all times in order not to reach the alarm value indicated by
information: pointer red range to avoid filter element cleaning regeneration failure and consequent replacement.
- Details of control panel front layout and internal layout with parts list. NOTE
- Identification of cable size for wiring the electrical components on the filter to the control For further information of the function of the differential pressure indicator,
refer to 13. APPENDIX.
panel.
WARNING
For the correct operation of the filter, it is mandatory that the differential
WARNING pressure never reach the red range of instrument indicator pointer.
Before opening the control panel, cut-off incoming power supply.
WARNING
In order to ensure correct filter operation, it is absolutely essential that
warning alarms be connected and acted upon at the installation premises. If
the alarms are ignored, the back-flushing and filtration function will be
disrupted.
9.3.1. RECOMMENDED LOGIC FOR OPERATION
- During ballasting phase, filter in operation, if the differential pressure set-point is not
reached within 1 hour, Filtrex recommends to perform at least 1 cleaning cycle.
- Before stopping the filtering operations, Filtrex recommends to perform at least 2-3
cleaning cycles.
S98 differential pressure gauge

rev.12
(Feb 2018) (Feb 2018)
9.4.1 DPI START-UP & CHECKS S17 9.5. FILTERING ELEMENT FUNCTIONAL DESCRIPTION
15
17
1. Energize the electric motor and/or controls

2. Slowly introduce fluid in the filter to ensure the complete filling of the filter housing
3. Slightly unscrew the DPI vent plug ( 3) up to fluid come out from this port
4. When happened, tighten firmly the vent plug (3) and dry the instrument 15- Self-cleaning filtering element
5. Close the root valve in DPI outlet: the black pointer (6) must rotate clockwise up to reach the set
point. Open again the DPI outlet root valve before 1 bar is reached. 17- Self-cleaning filtering element gasket
6. Check the proper alarm is arrived at local control panel during the above procedure.
The basket element filters the flow from the inside to the outside.
Particles of dirt in the flow are filtered off by the filter basket through the cleaned medium which
exits from the filter basket to the filter outlet nozzle, which is partially delivered back towards the
filtering element inner side.
The basket element comprises an inner punched hole metallic protection plate, an outer punched
hole metallic protection plate and the intermediate pleated wire mesh filtering element (15).
The inner and outer protection plates protect the mesh of the filter baskets from damage when
being removed and installed.
The filtering element is connected to filter housing through hexagonal socket head fixing bolts
provided on top plate which assure the segregation between inner and outer filter basket.
Moreover, its base is press inserted into the filter body bottom assuring sealing to outer clean side
from the inner dirty side by the O-Ring seal gasket (17).

rev.12
(Feb 2018) (Feb 2018)
9.6. START-UP & COMMISSIONING

NOTE
To start the filtering set, follow these usual operations: Adhere to the regulations for environmental protection.
1. Check that all the valves installed on the vessel nozzles are in the relevant service position.
2. Energize the electric motor and/or controls.
3. Open the vent connection on the filter cover.
4. Slowly introduce fluid to be filtered, to ensure the complete filling of the housing and the
9.7. REMOVAL FROM SERVICE AND DISPOSAL
complete utilization of the whole filtering surface. When de-installing the filter and removing it from service for long periods, the following points are
necessary:
5. Close the vent connection when air is expelled and fluid begins to flow.
1. Disconnect the electrical connections.
2. The filter must be completely emptied.
WARNING
Before filling up the filter, make sure that all the valves connected on vessel 3. The filter must be thoroughly cleaned and protected.
nozzles are in the relevant service position. The filter must be sealed by applying appropriate plastic (or similar) dummy plugs to the connection
flange openings.
NOTE
When the filter or its individual components are finally disposed make sure
WARNING that them all are disposed of in an environmentally friendly manner.
Improper filling of the filter may damage the basket element.
It is not allowed to fill the filter against the indicated direction of the flow.
6. Insert the vessel into the operating process condition.
STOP
It is very important to consider that, during this start up phase or after
important works (long time not running period), the filter is submitted to
particularly heavy conditions, as it must provide the elimination of impurities
such as organisms, solid particulate and/or other contaminants that are by
chance introduced in the system. It is therefore important to keep carefully
STOP under control the Δp of the filter, to prevent the Δp increase reaching the
alarm value. If the alarm value is reached, the filter must be taken out of
service. Dismantle the filtering element and clean it (refer to 10.
MAINTENANCE AND SERVICING).

rev.12
(Feb 2018) (Feb 2018)
10. MAINTENANCE AND SERVICING 6. It is recommended to monitor the backflushing interval in order to evaluate the filtering
10.1. BASIC SAFETY INSTRUCTIONS element efficiency. Backflushing intervals (time between two consecutive backflushing
cycles) depend on the quantity of suspended solids in the medium that can result in heavy
Even with automatic filters, inspection and maintenance must be performed at regular intervals to
operating conditions up to a continuous cleaning. If after a cleaning cycle the differential
avoid accidents and material damage.
pressure will not be restored below the start cleaning cycle set point this can be an indication
Maintenance and servicing work must only be carried out by qualified specialist staff or persons
that the filtering element performance is decreasing.
who have received appropriate instruction.
When performing any work on the filter, always use the appropriate safety equipment and clothing. NOTE
It is extremely important to remember that, in spite of on condition back-washing, the mesh may Longer use is also possible if the filtering element is checked carefully.
become clogged over the course of time, depending on the quality of the fluid..
In order to maintain trouble-free operation, the following aspects are to be observed during
maintenance:
7. Replace the gaskets.
1. The filter must be switched off for all maintenance work.
2. Always exercise extreme caution when performing maintenance and removing the filter
element. Ensure the highest possible levels of cleanliness when opening the filter to avoid NOTE
It is advisable to replace all the gaskets during any overhaul.
foreign matters remain in the filter.
3. Checks filter differential pressure indicator, seals and connections for leaks or damages, and
replace them if necessary.
4. Check for the correct rotation of the backwash shaft by means of the gear motor.
NOTE 10.2. MAINTENANCE INTERVALS

After every cleaning make sure that the backwash shaft rotates freely.
The filter must be maintained regularly and checked every 6 (six) months.
If checks, performed on a regular intervals basis, reveal seals leaks or damages, the filter will need
maintenance work to be performed.
5. Carry out a careful visual check of the filtering element status every 6 (six) months. If the pressure difference between the filter inlet and filter outlet reaches the preset maximum value
(yellow/red display on the differential pressure indicator), the filter will need cleaning/maintenance
work to be performed.
STOP
Should a high differential pressure occur beforehand, the filtering element
NOTE
must be checked and, if necessary, cleaned. At the end of each ballasting phase, it is recommended to perform a manual
STOP
backwash cycle (for the outlet pressure requirements related to this
operation, refer to FILTREX FILTER DATASHEET).
This will guarantee that no impurities are retained by the filtering element
mesh during the filter stand-by period.
STOP
In case of high differential pressure, the operations must be stopped.
Continue to work with differential pressure over the alarm, shall cause
STOP warranty void NOTE

rev.12
(Feb 2018) (Feb 2018)
10.3. TOOLS AND EQUIPMENT 10.4. INSPECTION AND CLEANING PRELIMINARY OPERATIONS
No special tools are required and therefore not provided by the manufacturer with delivery.
For the ACB filter sectional drawing and legend of all parts mentioned in the description, please
refer to 7. FILTER SECTIONAL DRAWING.
It is advisable to have the sectional drawing clearly visible during the whole disassembling and/or
assembling procedure.
The following recommended tightening torque for filter bolts applies, with thread oiled.
THREAD SIZE TORQUE

M4 3 Nm
M6 7 Nm
M8 12 Nm
M 10 18 Nm
M 12 25 Nm
M 14 35 Nm
M 16 45 Nm Refer to 7. FILTER SECTIONAL DRAWING.
M 20 75 Nm For the inspection and cleaning of the filtering element proceed as follows:
M 24 105 Nm
1. The filter must be switched off for all maintenance work.
2. Open the by-pass line (if existing).
WARNING
To avoid damage to filter housing/cover connection, do not exceed the above 3. Close the closing devices at the filter inlet and outlet (if existing).
torque data.
4. De-energize the electric motor and electric control panel.
5. To proceed with the inspection, refer to the hereafter descriptions.
10.3.1. EQUIPMENT
WARNING
Depending on the ACB filter size, the following equipment may be required: Before dismantling any filter parts and discharging the fluid, make sure that
the filter is not pressurized.
· Lifting device (in line with filter centerline) depending on filter size ( refer to table below)
· No. 2 Belts, No. 2 Chains with relevant hooks
Indicative
Electric Motor Filter Cover Filtering element WARNING
Filter Weight to
Open-end wrench Open-end wrench Allen key be lifted During the assembling/disassembling operations, make sure to have a
sufficient handling space to lay down the components during maintenance
Size Size Size n° Extensions
Model-Size-ND ( 30 cm each) Kg and to work in a safety, clean and efficient manner.
ACB-906-100 13 (M8) 18 (M12) 6 (M8) 1 25

ACB-910-150 13 (M8) 18 (M12) 8 (M10) 2 35
WARNING
ACB-915-150 13 (M8) 18 (M12) 8 (M10) 2 45
During the assembling/disassembling procedure, take care not to damage the
ACB-935-200 13 (M8) 24 (M16) 8 (M10) 2 80
filtering element (15), the backwash nozzle (16) and the gaskets (13) and (17).
ACB-945-200 13 (M8) 24 (M16) 8 (M10) 2 95
ACB-955-250 17 (M10) 24 (M16) 10 (M12) 2 160
ACB-985-300 17 (M10) 24 (M16) 10 (M12) 3 220
ACB-999-350 18 (M12) 24 (M16) 10 (M12) 3 285
ACB-9100-400 18 (M12) 24 (M16) 10 (M12) 4 350 / 770 WARNING
ACB-9120-500 18 (M12) 24 (M16) 30 (M20) 4 580 / 1110
If found damaged after the disassembling procedure, the filtering element
shall be replaced. Damaged filtering elements must not be used again.
ACB-9200-600 18 (M12) 24 (M16) 36 (M24) 4 940 / 1700
WARNING
When using lifting equipment, wear a safety helmet and avoid working under
it. Make sure the lifted parts are securely connected to it..

rev.12
(Feb 2018) (Feb 2018)
10.5. DISASSEMBLING PROCEDURE 4. Unscrew the filter cover bolts (10).
The disassembling procedure shall be carried out as follows:

1. Empty the filter removing the drain plug (19) positioned on the bottom of the vessel.
2. Remove the gear reducer flange/cover fixing bolts (4).
3. Remove the gear motor (2) from its seat by means of a suitable mechanical lifting device, fastening
it with a belt around its center of gravity. Make sure that the gear motor does not cause any stress
on its seat during extraction.
Alternatively, you can remove it manually if the filter size allows it.
5. Remove the lifting lugs and screw two filter cover bolts (10) in the lifting lugs threaded holes until
the end of the thread is reached, in order to slightly raise the filter cover (9). Then remove the two
In any case, hold the gear motor with hands to prevent sudden movements. The gearmotor shall
cover bolts (10) and position the two lifting lugs again.
be temporarily positioned in a proper place according to the length of the existing electric cabling.

rev.12
(Feb 2018) (Feb 2018)
6. Remove the cover, fastening the mechanical lifting device to the lifting lugs. Be careful as the cover 7. After the extraction, lay carefully the cover (9), filtering element (15) and backwash shaft (16)
is lifted together with the filtering element (15) and the backwash shaft (16). During the first lifting assembly on its side, on a horizontal surface.
phase, the cover might have a sort of sticking effect, therefore be careful not to cause any sudden
jerks during the procedure.
8. Remove the backwash shaft seeger ring from the backwash shaft (16).
9. Unscrew the bolts connecting the bottom backwash nozzle support (30) with the filtering element
(15) and remove it.
10. Remove the backwash shaft (16)
WARNING
The lifting device must be in line with the filter centreline otherwise
maintenance procedures cannot be performed properly and safely.

rev.12
(Feb 2018) (Feb 2018)
11. After the extraction of the backwash shaft, lay carefully the cover (9) and filtering element (15) 14. Check the pre-filter status and in case remove trapped sediments.
assembly upside-down on a horizontal surface.
12. Unscrew the filtering element fixing bolts (12) from the cover, using a Hexagonal T wrench or
otherwise an Allen wrench.
15. The filter is now completely disassembled
13. Remove the self-cleaning filtering element (15) from the cover. If damaged, it shall be replaced.
®
For further information refer to ”ACB FILTER
MAINTENANCE MANUAL, DISASSEMBLING
AND ASSEMBLING

rev.12
(Feb 2018) (Feb 2018)
10.5.1 ALTERNATIVE DISASSEMBLING PROCEDURE FOR ACB-9100-400,

ACB-9120-500 and ACB-9200-600
The disassembling procedure for the ACB-9100-400, ACB-9120-500 and ACB-9200-600 could be also
carried out as follows:
1. Empty the filter removing the drain plug (19) positioned on the bottom of the vessel.
2. Remove the gear reducer flange/cover fixing bolts (4).
3. Remove the gear motor (2) from its seat by means of a suitable mechanical lifting device, fastening it
with a belt around its center of gravity. Make sure that the gear motor does not cause any stress on
its seat during extraction.
In any case, hold the gear motor with hands to prevent sudden movements. The gearmotor shall be
temporarily positioned in a proper place according to the length of the existing electric cabling.
4. Remove the outlet flange fixing bolts
5. Remove the connecting bolts between filter upper and bottom part.
6. Remove the filter's upper part, fastening the mechanical lifting device to the lifting lugs. Be careful as
the filter's upper part is lifted together with the filtering element (15) and the backwash shaft (16).
During the first lifting phase, the filter's upper part might have a sort of sticking effect, therefore be
careful not to cause any sudden jerks during the procedure. Use suitable devices for lifting and
handling.
Prepare a wooden pallet and some wooden beams to support the filter body; the filtering element is
longer than the filter body and it must not touch the floor.
WARNING
The vertical lifting device must be in line with the filter centreline otherwise
maintenance procedures cannot be performed properly and safely.
The lifting device must be able to move also horizontally to place the lifted
equipment in a suitable location. The installation of a rail for the lifting device
is recommended for properly and safely maintenance procedures.
8. Unscrew the filter cover bolts (10) ( as point 4 at chapter 10.5)
7. After the extraction, lay carefully the filter's upper part assembly on its side, on a horizontal surface.
9. Remove the lifting lugs and screw four filter cover bolts (10) in the lifting lugs threaded holes until the
end of the thread is reached, in order to slightly raise the filter cover (9). Then remove the two cover
WARNING
Locate the assembly on a wooden pallet and use some bolts (10) and position the four lifting lugs again ( as point 5 at chapter 10.5).
wooden beams to support the filter body and not the inner
filtering element.
10. Remove the cover, fastening the mechanical lifting device to the lifting lugs. Be careful as the cover is
lifted together with the filtering element (15) and the backwash shaft (16). During the first lifting phase,
the cover might have a sort of sticking effect, therefore be careful not to cause any sudden jerks
during the procedure.

rev.12
(Feb 2018) (Feb 2018)
10.6. FILTERING ELEMENT CLEANING PROCEDURE

In case the filter baskets are heavily contaminated (incrustations, residues, fibres, organisms), it
will have to be removed and cleaned.
The following steps need to be performed to complete the cleaning procedure:
1. Place the filter element in a container with the proper cleaning fluid, with the filter basket
openings facing upwards. For proper cleaning fluids contact Filtrex.
2. Remove loose particles, which float on the top of the cleaning fluid, during the soaking time
which will last from 1 to 4 hours depending on the level of contamination checking the
progress of cleaning whilst the filter element is soaking.
3. Remove the filter element from the cleaning fluid and allow the filter element to drip dry.
4. Remove the filter basket seal and assure that no dirt enter the outer side of the filter element.
5. Push the filter basket, with the opening pointing downwards, over a suitably dimensioned,
stable mandrel, and make sure to secure the filter element to prevent it from toppling
6. Spray thoroughly filtered water at 70÷80°C to the filter basket from the outside, with a high-
pressure cleaner with flat nozzle using. Possible alternatives are also brushing or water
rinsing.
When cleaning using a high-pressure cleaner and flat nozzle, the pressure must not exceed a
maximum of 15 barg.
If a higher-pressure cleaner is used, keep a sufficient distance from the mesh of the filter
element (minimum 30 cm) to avoid damages.
7. Blow the filter basket with compressed air (with 10 micron filter or finer) , from the outside to
the inside, along the entire length.
8. The large part of the contamination will be thus rinsed off.
Particles which are equal to the size of the mesh openings and thus remain stuck in the
mesh, are pushed and flushed out.
9. Place the filter basket in fresh proper cleaning fluid.
10. If the contamination on the filter element is easily removed, you can also rinse the filter
element by just lightly turning and moving it up and down in the cleaning bath.
11. Remove the filter element from the fresh cleaning fluid bath and allow the filter element to drip
dry.
12. Place the filter element on its head, so that the cleaning fluid can run off.
11. Proceed following the instruction from Point 7 chapter 10.5. 13. Blow out the filter basket with compressed air (with 10 micron filter or finer) cleaning gun from
the outside to the inside, along the entire length and allow the filter basket to dry with the
opening pointing downwards
14. You can improve the cleaning effects by rinsing with hot or cold water before blowing for a
second time.
15. Then check all filter basket for damage and replace damaged components (if any) as
necessary.

rev.12
(Feb 2018) (Feb 2018)
16. Check the results of cleaning by visual inspection of the outside surface through a 100x 11. TROUBLESHOOTING
magnification lens, and assure that a sample of filter elements is contaminants free. If the
FAULTS POSSIBLE CAUSE INTERVENTION/REMEDIES
filter element are not cleaned, repeat the cleaning process as necessary. If the filtering element is
still not clean, consult Filtrex S.r.l.
High solids loading in the process fluid Perform back wash cycle manually
17. Restore the filter basket seal and assure that no dirt enter the outer side of the filter element.
18. The cleaned filter element can be re-assembled by performing the steps for disassembly in
reverse order. Reduce the back-pressure at the back wash side ( shorten
the bacwash line, eliminate elbows, upwards pipe runs,
restriction due to valves, etc)
10.7. ASSEMBLING PROCEDURE High differential High back-pressure at the back wash
pressure piping
1. Re-assemble the filter in the reverse sequence to that described under points above and insert the Check whether the back wash operates during the back
wash phase
cover/filtering element/backwashing arm assembly inside the filter body without forcing.
Clogged filtering element Clean the filtering element manually or change it
Pre-filter clogged Clean manually the pre-filter or make a filter drain

WARNING
Prior to be installed, the filtering element shall undergo a visual examination Backwash fluid amount too low
Check if the back wash nozze or back wash piping are
and, if damaged, shall be replaced. clogged
Bolts not tightened Check bolts tighteness
Fluid leakages
Damaged gaskets Replace damaged gaskets
Obstruction between
filtering element and Remove obstruction
NOTE back wash shaft
®
For further information refer to ”ACB FILTER MAINTENANCE MANUAL,
DISASSEMBLING AND ASSEMBLING".
Misalignment of the
backwash arm Check back wash arm alignment
Motor overload
tripped
Backwash arm not Misalignment between
rotating filter connections
(INLET, OUTLET, Lose the bolts and try again to rotate the back wash shaft
BACKWASH) and
pipings.
Pressure difference
between filter OUTLET Contact Filtrex with the operating pressures ( OUTLET
and BACKWASH outlet and BACKWASH)
over 3 bar
Motor/reducer Incorrect power applied

Check power supply
failure to the electric motor
Incorrect power applied to control panel

and/or electric motor, valves, switches, Check power supply
etc
Incorrect wiring applied to control panel
and/or electric motor, valves, switches, Check electrical continuity
Control problems etc
Differential pressure switch improperly
Check functionality and calibration of the instrument
adjusted
Insufficient air pressure applied to the
Increase control ( instrument) air pressure
electropneumatic back wash valve

rev.12
(Feb 2018) (Feb 2018)
12. SPARE PARTS

FAULTS POSSIBLE CAUSE INTERVENTIONS/REMEDIES
FILTREX filters are so easy to operate and so accurately manufactured that there is no need of
Loss of incoming electric special spare parts for the ordinary maintenance.
a) System Light “L1” OFF Check electrical continuity
power supply
It is advisable to use only Filtrex Genuine spare parts. Only in this way the customer is sure of the
exact interchangeability of spare parts, and is possibly enabled to claim under the manufacturing
Blow-out of fuse F1 or F2
warranty stipulated by the purchase order.
b) Alarm Light “L3” OFF on auxiliary transformer Replace fuse
TR power supply To order the required spare parts, please refer to their Filtrex identification Code shown in 13.
APPENDIX.
c) Incoming circuit breaker “Q”
Auxiliary transformer TR For 1 year ordinary maintenance, it is advisable to keep in store 2 sets of the spare parts listed
ON Replace transformer
failure
hereafter.
a) System Light “L1” OFF

POS. DESCRIPTION
Filter motor electrical
Refer to “Backwash arm not rotating”
overload 7 Backwash nozzle gasket
b) Alarm Light “L3” OFF
7a Backwash shaft bushing gasket
Control Panel c) Incoming circuit breaker “Q”
cumulative alarm OFF Electrical short circuit Check electrical circuit integrity 13 Self-cleaning filter cover gasket
“ON”
17 Self-cleaning filtering element gasket
COMPLETE SET OF GASKETS
Differential pressure Check functionality and calibration of 20 Backwash line gasket
switch failure the instrument
32 (*) Backwash nozzle support gasket
Timer KT1 failure Replace timer
a) System Light “L1” ON 77 Backwash nozzle gasket
94 (*) Intermediate body flange gasket
(*) Present or not based on filter size.
For any further information or request of intervention of Filtrex highly skilled personnel, please
Motor contactor KC failure Replace contactor apply to the manufacturing firm at the following address:
b) Alarm Light “L3” ON
Backwash valve SOV
Check valve functionality
failure FILTREX S.r.l.
Filter clogged Clean the filtering element
Via Rubattino, 94/B
20134 Milan, ITALY
Tel +39-02-75.33.841
Fax +39-02-75.31.383
E-mail : info@filtrex.it
marine_diesel@filtrex.it

rev.12
(Feb 2018) (Feb 2018)
13. APPENDIX Technical data

13.1. FILTER
Filter
Technical data
Filter type ACB
Nominal connection diameter DN 65
Filter Housing size 903
Filter type ACB Flow rate 8 to 35 m³/h
Nominal connection diameter DN 50 Degree of filtration 40-20 μm
Housing size 902 Permitted operating pressure 10.0 barg
Flow rate 6 to 25 m³/h Permitted max. operating temperature 55 °C
Degree of filtration 40-20 μm Operating voltage 3 ph 380 to 480 Volt
Permitted operating pressure 10.0 barg Frequency 50 or 60 Hz
Permitted max. operating temperature 55 °C Control voltage 24 Vac + 24 Vdc
Operating voltage 3 ph 380 to 480 Volt Motor power 0.12 kW @ 400 V
Frequency 50 or 60 Hz Backflushing medium Internal medium
Control voltage 24 Vac + 24 Vdc Min. operating pressure downstream from filter 0.5 barg during filtration
Motor power 0.12 Kw @ 400 V 1.5 barg during cleaning
Backflushing medium Internal medium Control medium clean/dry air 4-6 bar
Min. operating pressure downstream from filter 0.5 barg during filtration Flushing time 20 s
1.5 barg during cleaning Min Backwash flowrate required 2.15 l/sec
Control medium clean/dry air 4-6 bar Max Backwash flowrate allowed 3,00 l/sec
Flushing time 20 s
Min Backwash flowrate required 1.70 l/sec Filter element
Max Backwash flowrate allowed 2,50 l/sec
Element type of filter Woven mesh single basket
Number of filter elements 1
Filter element
Element type of filter Woven mesh single basket
Number of filter elements 1

rev.12
(Feb 2018) (Feb 2018)
Technical data Technical data
Filter Filter
Filter type ACB Filter type ACB
Nominal connection diameter DN 80 Nominal connection diameter DN 100
Housing size 904 Housing size 906
Flow rate 10 to 55 m³/h Flow rate 15 to 87 m³/h
Degree of filtration 40-20 μm Degree of filtration 40-20 μm
Permitted operating pressure 10.0 barg Permitted operating pressure 10.0 barg
Permitted max. operating temperature 55 °C Permitted max. operating temperature 55 °C
Operating voltage 3 ph 380 to 480 Volt Operating voltage 3 ph 380 to 480 Volt
Frequency 50 or 60 Hz Frequency 50 or 60 Hz
Control voltage 24 Vac + 24 Vdc Control voltage 24 Vac + 24 Vdc
Motor power 0.12 kW @ 400 V Motor power 0.12 kW @ 400 V
Backflushing medium Internal medium Backflushing medium Internal medium
Min. operating pressure downstream from filter 0.5 barg during filtration Min. operating pressure downstream from filter 0.5 barg during filtration
1.5 barg during cleaning 1.5 barg during cleaning
Control medium clean/dry air 4-6 bar Control medium clean/dry air 4-6 bar
Flushing time 20 s Flushing time 20 s
Min Backwash flowrate required 2,66 l/sec Min Backwash flowrate required 4,09 l/sec
Max Backwash flowrate allowed 4,00 l/sec Max Backwash flowrate allowed 5,00 l/sec
Filter element Filter element

Element type of filter Woven mesh single basket Element type of filter Woven mesh single basket
Number of filter elements 1 Number of filter elements 1

rev.12
(Feb 2018) (Feb 2018)
Filter Filter


rev.12
(Feb 2018) (Feb 2018)
Filter Filter


rev.12
(Feb 2018) (Feb 2018)
Filter Filter


rev.12
(Feb 2018) (Feb 2018)
Filter Filter


rev.12
(Feb 2018) (Feb 2018)
Filter Filter


rev.12
(Feb 2018) (Feb 2018)
13.2. FILTER ELECTRICAL GEARMOTOR 13.3. FILTER DIFFERENTIAL PRESSURE SWITCH

DIFFERENTIAL PRESSURE SWITCH S17
ELECTRIC GEARMOTOR
Technical data sheet
GENERAL
Technical data sheet
Tag Number PDS
Service Filter Inlet / Outlet
GENERAL
Fluid Seawater
Tag Number GRM-01
Operating Temperature -2°C to 60°C
Service ACB Filter Cleaning Arm Rotation
Operating Presssure 0.5 bar to 6 bar
Fluid Seawater
Function Switch
Phase Liquid
Enclosure Protection IP-65
Max Temperature 55°C
Enclosure Material Stainless Steel
Inlet Power 0,12 to 0,75 kW
Body Material AISI316
Inlet Speed 1370 / 1760 rpm
Element Material AISI316
Gear Reducer Ratio 1 / 60 - 100
Mounting Bracket Wall Type
Connection Type 3/8"-F
CONSTRUCTION
Output Signal SPDT - 3A-24Vdc
Construction type Worm & Gear
Action Direct
Coupling to Motor Direct Fixed Flanged
Set Point Adj. Screw
Inlet Motor Flange PAM IEC 71 Frame
Cell Range 0 - 1,6
Inlet Shape B5 - IEC
Calibration 0 - 1,6
Coupling to Filter Flanged
Scale Linear
Outlet Flange Diam. (mm) 140 to 200 mm
Indicator Integral
Coupling Type Direct fixed joint integral with motor Accuracy +/-5 % F.S.
Materials DIFFERENTIAL PRESSURE SWITCH S98

Body Material Aluminium Alloy
Worm material Carbon Steel Alloy Technical data sheet
Gear Material Bronze GENERAL
Lubrication Sinthetic Oil for Life Tag Number PDS
Service Filter Inlet / Outlet
Electric Motor Fluid Seawater
Type Asinchr. Totally Enclosed Fan Cooled Operating Temperature -2°C to 60°C
Motor frame Aluminium Alloy Operating Pressure 0.5 bar to 7 bar
N° Poles 4 Poles Function Switch
Power 0.12 to 0,75 kW Enclosure Protection IP-65
220V to 480V ±10%, 50/60Hz depending on Enclosure Material Stainless Steel
Power Supply
voltage - 3Ph. Body Material AISI316
Protection degree IP-55 (IEC.60529) Inner Material AISI316 & Magnetic Ceramic
Insulation Class H (with rise to class B) Mounting Bracket Wall Type
Connection Type 1/8"- Gas F bottom entry
For further information contact Filtrex
Action Direct
Set Point fixed ( 1st switch contact) 0.3 SPDT
Alarm fixed ( 2nd switch contact) 0.5 SPST - N.C.
Scale Linear
Indicator Integral
Accuracy +/-5 % F.S.
For further information contact Filtrex

rev.12
(Feb 2018) (Feb 2018)
FILTREX ACB®
13.4. FILTER DIMENSIONAL DRAWINGS
For filters dimensions refer to the last revision of the Dimensional Table TD.73
ACB® Automatic Self-cleaning Backwashing Filter OMM.73

rev.12 © ERMA FIRST ESK ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 44
(Feb 2018)
Page 66 of 66
FILTREX ACB® INSTALLATION & COMMISSIONING FILTREX ACB® TROUBLESHOOTING
1 MECHANICAL CONNECTIONS FAULTS POSSIBLE CAUSE INTERVENTION/REMEDIES
High solids loading in the process fluid Perform back wash cycle manually
Consider the “service area” during
1,1 installation to allow proper
maintenance Reduce the back-pressure at the back wash side ( shorten
the bacwash line, eliminate elbows, upwards pipe runs,
restriction due to valves, etc)
High differential High back-pressure in the back wash
pressure piping
Check whether the back wash operates during the back
wash phase
Clogged filtering element Clean the filtering element manually or change it

Check lifting weights and install proper
1,2 lifting eye in line with the filter
Pre-filter clogged Clean manually the pre-filter or make a filter drain
centerline.
Check if the back wash nozzle or back wash pipe are
Backwash fluid amount too low
clogged
Bolts not tightened Check bolts tightness
Fluid leakages
Damaged gaskets Replace damaged gaskets
Obstruction between
Pipe connections to the filter filtering element and Remove obstruction
1,3 in accordance with flows back wash shaft
( INLET, OUTLET and BACKWASH)
Misalignment of the
backwash arm Check back wash arm alignment
1,4 Flush inlet and outlet pipes before connect the filter to remove impurities before connecting the filter.
Motor overload
tripped
Avoid external forces, moments and Backwash arm not Misalignment between
pipes misalignments on the filter rotating filter connections
Loosen the bolts and try again to rotate the back wash
(INLET, OUTLET,
1,5 connections and baseplate. shaft
BACKWASH) and
Proper filter functioning is otherwise
pipings.
jeopardized.
Pressure difference
between filter OUTLET Contact Filtrex with the recorded operating pressures
and BACKWASH outlet ( OUTLET and BACKWASH)
over 3 bar
Install the filter on a leveled floor. Motor/reducer Incorrect power applied

Check power supply
Avoid stress on the filter baseplate due failure to the electric motor
1,6 to fixing it to an inclined plane. Proper
filter functioning is otherwise Incorrect power applied to control panel
jeopardized. and/or electric motor, valves, switches, Check power supply
etc
Incorrect wiring applied to control panel
and/or electric motor, valves, switches, Check electrical continuity
Control problems etc
WHEN NO BACKWASH PUMP IS
Differential pressure switch improperly
INSTALLED: Check functionality and calibration of the instrument
adjusted
Minimize backpressure in the back Insufficient air pressure applied to the
Increase control ( instrument) air pressure
wash line. electropneumatic back wash valve
1,7
In case additional valves ( not supplied Growth Prevention When the filter is inoperative for more than 48 hrs and filled with sea water, it is strongly
by Filtrex) are installed in recommended to drain it and REFILL it with fresh water to prevent growth inside
the backwash line, make sure these are
left open.
QSG.73 rev.4 QSG.73 rev.4
READ BEFORE INSTALLING and COMMISSIONING (Feb 2018) READ DURING OPERATIONS (Feb 2018)
FILTREX ACB® START-UP FILTREX ACB® INSTALLATION & COMMISSIONING
1 PRELIMINARY FUNCTIONAL CHECKS ( Filter not in pressure)
2 ELECTRICAL and PNEUMATIC CONNECTIONS
Check that all valves are in correct
service position:
-Instrument (DPS) root valves
(manual) are OPEN
1,1 - Vent valve (manual) is
CLOSED 2,1 Connect the earth cable
- Drain valve (manual) is
CLOSED
- Backwash valve ( automatic) is
normally closed (automatic)
1,2 Energize the electric motor
Connect the differential pressure

switch (DPS) and/or the pressure
2,2
transmitters to the stand alone
Open the vent valve and SLOWLY fill Control panel or Remote Control
1,3
the filter with sea water System.
Check power supply voltage to the

2,3 electric motor (see electric motor data
plate)
When the filter is full, close the vent

1,4
valve and stop the water inlet
Check backwash valve, including:

- Correct Voltage of the Solenoid
1,5 Vent the differential pressure instrument as per the O&M Manual Valve driving the actuator of the
CHECKS: 2,4
backwashing valve
Manually start the filter clearing phase - Rotation of electric motor (rotation time as per filter datasheet) - Dry compressed air to the actuator of
1,6
( minimum 3 times) - Pressure during cleaning at INLET, OUTLET and BACKWASH the backwash valve
- Backwash valve proper open-close operations
2 FUNCTIONAL CHECKS ( Filter in pressure) – SEA WATER PUMP ON
2,1 Start the sea water pump 3 AUTOMATION
Standard automation control:
Check the pressures during normal a) Backwashing cycle is initiated by differential pressure ( 0,3 bar) or timer whichever come first.
3,1
filtration phase and during back wash b) Backwashing cycle duration 20 sec
phase. c) Electric motor starts rotating before backwash valve opens. Electric motor stops rotating after the backwash valve closes
2,2 During the backwashing cycle check
that the differential pressure between
OUTLET and BACKWASH is >1,5 bar
4 RECOMMENDATIONS
When the filter is inoperative for more than 48 hrs and filled with sea water, it is strongly recommended to drain it and REFILL it with
4,1
CHECKS: fresh water to prevent growth inside
Manually start the filter clearing phase - Rotation of electric motor (rotation time as per filter datasheet) In case of fluid with presence of iron Filtrex recommends to clean the filter and the filtering element every 3-6 months with a descaling
2,3 4,2
( minimum 3 times) - Pressure during cleaning at INLET, OUTLET and BACKWASH product suitable for stainless steel and Bronze-Aluminum alloy for its preservation.
- Backwash valve proper open-close operations
4.3 As described in the start-up phase, pag. 3 par.1.3, the filter must be slowly filled with water at every time to avoid water hammer that can
Check correct backwash starts at the
2,4 The backwash must start automatically when the set value is reached. damage the filter.
delta pressure and timer set values
3 AUTOMATION
Standard automation control:
a) Backwashing cycle initiated by differential pressure ( 0,3 bar) or timer first to cut in.
3,1
b) Backwashing cycle duration 20 sec
c) Electric motor starts rotating before backwash valve opens. Electric motor stops rotating after the backwash valve closes
4 RECOMMENDATIONS
When the filter is inoperative for more than 48 hrs and filled with sea water, it is strongly recommended to drain it and REFILL it with
4,1
fresh water to prevent growth inside
QSG.73 rev.4 QSG.73 rev.4
READ DURING START-UP (Feb 2018) READ BEFORE INSTALLING and COMMISSIONING (Feb 2018)
22/7/2019 HN 2140
ELECTROLYTIC CELL(S)
BWT EX Operations and Maintenance Manual BWT EX Operations and Maintenance Manual
Contents
User Operations and Maintenance Manual
1. Identification ........................................................................................................................................................................................... 3
1.1 Marking plate ................................................................................................................................................................................. 3
1.2 Type Identification ......................................................................................................................................................................... 3
ErmaFirst PermaChlor™ BWT EX 1.3

1.4
Description of the Ex code ............................................................................................................................................................. 4
EPL/Equipment Category ............................................................................................................................................................... 4
Ballast Water Treatment Cell: 6ppm, 3psu 1.5 Protection ...................................................................................................................................................................................... 4
BWT EX 500, BWT EX 750, BWT EX 1000 2. Product Certification ............................................................................................................................................................................... 5
2.1 List of applicable standards ........................................................................................................................................................... 5
3. Product Description ................................................................................................................................................................................. 6
II 2G Ex d e IIC T4 Gb 3.1 General .......................................................................................................................................................................................... 6

3.2 Design ............................................................................................................................................................................................ 6
3.3 Technical data ................................................................................................................................................................................ 7
4. Installation ............................................................................................................................................................................................... 8
4.1 Installation of cell........................................................................................................................................................................... 8
4.2 Installation of sensors .................................................................................................................................................................... 9
4.3 Cable field connection ................................................................................................................................................................... 9
4.3 Earth connection and equipotential bonding .............................................................................................................................. 13
5. Safety ..................................................................................................................................................................................................... 15
5.1 System safety ............................................................................................................................................................................... 15
5.2 Process safety .............................................................................................................................................................................. 15
5.3 Monitoring ................................................................................................................................................................................... 16
5.5 Training of service personnel ....................................................................................................................................................... 16
5.6 Functional tests............................................................................................................................................................................ 17
5.7 Special conditions of use ............................................................................................................................................................. 19
6. Operation .............................................................................................................................................................................................. 20
6.1 Start up ........................................................................................................................................................................................ 20
6.2 Shut down .................................................................................................................................................................................... 20
7. Maintenance ......................................................................................................................................................................................... 21
7.1 Daily – Self-monitoring ................................................................................................................................................................ 21
X-markings (Specific conditions of use): N/A
7.2 Monthly - Self-monitoring ........................................................................................................................................................... 21
7.3 Yearly ........................................................................................................................................................................................... 21
7.4 Every five year.............................................................................................................................................................................. 21
· Do not open, disconnect or dismantle this equipment! 8. Troubleshooting .................................................................................................................................................................................... 22
· Operation by authorized personnel only
9. Declaration of Conformity ..................................................................................................................................................................... 23
· Read this manual carefully before use
Permascand AB ǀ Folkets Husvägen 50 ǀ SE-840 10 Ljungaverk ǀ www.permascand.com Permascand AB ǀ Folkets Husvägen 50 ǀ SE-840 10 Ljungaverk ǀ www.permascand.com
1.3 Description of the Ex code

1. Identification
EU marking
1.1 Marking plate CE Conformity Marking: CE (2460)
Identification Number of Notified Body
2460
involved in production control stage:
Explosion Protection marking:
Equipment Group II
Equipment Category 2G
IEC marking
Explosion protection marking: Ex
Type of protection d, e
Equipment Group II C
T-class T4
Equipment protection level (EPL) Gb
1.4 EPL/Equipment Category
IEC EU Typical Zone

Definition of
EPL Group Category Group application
Gas atmospheres "high level of
Gb 2G 1
protection"
1.2 Type Identification II II
Gas atmospheres "enhanced level of
Gc 3G 2
protection"
Product name: ErmaFirst PermaChlor™ BWT EX
Type Designation: BWT PermaChlor B*X
*X = Model range: X = 500 (for water flow 600 m3/h) 1.5 Protection
All ErmaFirst PermaChlor™ BWT EX equipment comply with protection class IP66 according to EN 60529.
X = 750 (for water flow 800 m3/h)
However, in particularly exposed applications, protection in the form of shielding is recommended.
X = 1000 (for water flow 1200 m3/h)
3. Product Description
2. Product Certification
3.1 General
2.1 List of applicable standards An electrochemical cell like the ErmaFirst PermaChlor™ BWT EX produces sodium hypochlorite from
seawater and DC current; the capacity is maximum 6 ppm for the specific flow (m3/h) rating of the system.
Electrolysis is the most energy, cost and environment effective way to produce sodium hypochlorite. When
The ErmaFirst PermaChlor™ BWT EX cells are developed according to and in compliance with:
producing sodium hypochlorite on-site with available recourses like water, DC current and an
electrochemical cell, there is no need for transportation, handling or storing of sodium hypochlorite. The
· IEC 60079-0:2011, EN 60079-0:2012, Electrical apparatus for explosive gas atmospheres – part 0: ErmaFirst PermaChlor™ BWT EX is intended as disinfection unit incorporated in a complete Ballast Water
General requirements Treatment System (BWTS) and thus for use after proper mechanical pre-treatment (e.g. filtration,
· IEC 60079-1:2006, EN 60079-1:2007, Electrical apparatus for explosive gas atmospheres – part 1: hydrocyclone) and under the control of the overall BWTS.
Flameproof enclosures "d”
· IEC/EN 60079-7: 2007, Electrical apparatus for explosive gas atmospheres – part 7 : Increased
safety enclosures "e”
3.2 Design
· IEC 50186 The ErmaFirst PermaChlor™ BWT EX cell is a bipolar electrochemical cell which consists of an electrode
assembly package mounted in a cell house. To reduce weight and optimize strength the cell house is made
· EN 13121-1 ,2, 3:2008
of Glassfiber Reinforced Plastic (GRP). Both cathodes and anodes are made of titanium plates and the
Installation and Maintenance standards: specific anode areas with a specially developed coating are capable to produce sodium hypochlorite to a
· EN 60079-14, Electrical apparatus for explosive gas atmospheres – part 14: Electrical installation, concentration of up to 6ppm directly into the water. The ErmaFirst PermaChlor™ BWT EX electrochemical
design, selection and erection cell is designed for most energy and cost efficient production of sodium hypochlorite.
· EN 60079-17, Electrical apparatus for explosive gas atmospheres – part 17: Explosive atmospheres. Installation of the electrochemical cells into the piping is done by to the flange connections. The two
Electrical installations inspection and maintenance. ATEX/IECEx certified flow sensors and temperature sensor on inlet section are mounted from factory, as
well as the Ex (e) certified cabling boxes for contacting anode- and cathode side.
Furthermore, the ErmaFirst PermaChlor™ BWT EX cells are in conformity with listed EU Directive(s): Fig. 1: Design of ErmaFirst PermaChlor™ BWT EX electrochemical cell
· EMC Directive 2004/108/EC

· EN 61000-6-4:2007, Electromagnetic compatibility – Emission standard for industrial
environments
· EN 61000-6-2:2005, Electromagnetic compatibility – Immunity for industrial environments
1. Cell inlet flange connection

2. ATEX/IECEx Flow- and temperature sensors
3. Ex (e) connection boxes w. terminal connection plints
4. Cell outlet flange connection
4. Installation
3.3 Technical data
The ErmaFirst PermaChlor™ BWT EX cells are delivered pre-assembled incl. flow switches and temperature
ErmaFirst PermaChlor™ BWT EX cells are designed with the following parameters: sensor, and ready for installment in the ballast water piping and electrical connection of the sensors and
main power in the connection boxes.
ErmaFirst PermaChlor BWT EX 6ppm/3PSU
Model 500 750 1000
The installation must be performed as intended in order to have a safe system. In case of
Flow rate range (Min-Max) 300-600 500-800 800-1200 m3/h
doubt or uncertainties, contact Permascand AB!
Chlorine concentration
≤6 ≤6 ≤6 ppm
(TRO)
Salinity >3 >3 >3 psu
All national safety regulations must be fulfilled in connection with installation, start-up
Operating temperature
(Min-Max)
5 - 35 5 - 35 5 - 35 ˚C and operation of the ErmaFirst PermaChlor™ BWT EX. Furthermore, the requirements of
the Declaration of Conformity and national regulations for installations in explosion areas
Ambient temperature (Min-
-5 - 60 -5 - 60 -5 - 60 ˚C applies as well. Work in connection with the electrical actuations of this manual must be
Max)
Storage temperature (Min- performed only by professionals and qualified persons.
-30 - 60 -30 - 60 -30 - 60 ˚C
Max)
Voltage (nom. op. interval) 15 - 30 15 - 30 15 - 30 V
Amperage (max) 1000 1250 2000 A

4.1 Installation of cell
Power supply max. (V*A) 30 37.5 60 kW The ErmaFirst PermaChlor™ BWT EX is connected in-line the ballast water piping with the flange type of
Lifetime > 5000 > 5000 > 5000 h choice. Due to efficient evacuation of produced gases, cell outlet must always be located at higher vertical
position than inlet! Table 2 shows applicable torque values for installment of the cell into piping via inlet-
Design operating pressure 0-6 0-6 0-6 Bar(g) and outlet flanges:
Operating pressure 1-2 1-2 1-2 Bar(g)
Pressure tested 9 9 9 Bar(g) Model DIN PN10 JIS 10K JIS 5K

Nominal working pressure BWT 500 EX 75 85 75
0.6 0.6 0.6 Bar(g)
(DP) BWT 750 EX 75 85 75
BWT 1000 EX 125 125 115
Table 1. Technical data
Table 2. Tightening torque of connection flanges (Nm*)
* Manufacturer's rating of torque specifications are maximum safe limits
In relation to installment of cell into ballast water piping, check torque on main assembly bolts between
the two cellhouse halves – re-apply 330Nm at each bolt if required due to loosening after manufacturing.
Cell outlet must always be located at a vertically higher position than inlet. Either whole cell
installed in vertical position with inlet from below, or horizontally with the inlet water going into
the lower cell connection.
4.2 Installation of sensors Model One-core cable Three-core cable

Sensors (2xFlow switches + temperature sensor) are delivered mounted on the cell and shall not be BWT 500 EX 95mm2 (6x) 95mm2 (3x)
removed or disassembled in any way. The sensors shall be connected in accordance with respective BWT 750 EX 120mm2 (6x) 95mm2 (3x)
manufacturer’s instruction files/operational manuals (Appendix III and IV) technical specifications and
BWT 1000 EX 185mm2 (6x) N/A
must be done with the recommended and approved cables (not part of delivery). Furthermore,
equipotential bonding of sensor housings must be done via the earth connections of respective unit.
Table 4. Cable cross section requirements for contacting ErmaFirst PermaChlor™ BWT EX cells
For installation in hazardous areas (Zones 1 or 2) the contacting shall follow the requirements of standards
Flow switches are part of protective Safety Device which has to comply with 1.4 and 1.5 of Council IEC 60079-1:2006/EN 60079-1:2007 concerning Flameproof enclosures “d” and IEC/EN 60079-7: 2007
Directive 94/9/EC. They are required to be installed, used and approved accordingly in complete
concerning Increased safety enclosures "e”. Contacting is done via cable lugs connected to the terminal
BWTS installation!
plints located in the Ex (e) connection boxes for anode and cathode side. Cables are secured via cable
glands in the wall of the respective connection box. The cable glands are not included in general scope of
supply and must be suitable and pre-certified for use with Increased Safety type e and Flameproof type d
4.3 Cable field connection enclosures that are equipped with a secondary Increased Safety type e terminal enclosure (i.e. Ex de). They
The ErmaFirst PermaChlor™ BWT EX cells has the widest possible flexibility in terms of cabling connection are required to be suitable for use with armoured cables that provides mechanical cable retention and
options. General cable dimensioning is based on international standard IEC 60092-352. Cables used should electrical continuity via armour wire termination. See further Appendix II for cable gland requirements.
be suitable for temperatures up to minimum 90°C. The cable type must follow requirements given by
standards according to Table 3: Fig. 2-3 shows the parts included in the delivery and used for mounting of cable to the terminal plints via
the Ex (e) certified connection boxes. Approved lugs are also provided together with required bimetal
(Cu/Al) contact spacers for proper connection of the Cu cable lug to the Al terminal plint. Fig. 4 shows an
Property Standard example of approved cable gland type, which can be supplied as optional. The prevailing code of practice
for selection and installation of cables and glands shall be observed, e.g. IEC 60079-14.
Current rating IEC 60092-352
Design guideline IEC 60092-353
Insulation IEC 60092-351
Sheath IEC 60092-359
Flame retardant IEC 60332-3-22, Cat. A
Fire resistant IEC 60331
Halogen free IEC 60754-1
Low smoke IEC 61034-2
Fig.2: Cable lug Fig.3. Bimetal spacer Fig.4: Cable gland

Table 3. Cable property requirements for contacting PermaChlor™ BWT EX cells
The ErmaFirst PermaChlor™ BWT EX is obliged to be installed with a cable specified to the surrounding For contacting, the cables are first installed into the gland(s) (see also 4.3 Earth connection and
conditions and to the given diameter of the cable gland, and the cable must be equipped with braid for equipotential bonding for correct use of braid) and the connected glands fastened into the holes in the Ex
earthing via the glands. The different capacities of models in the ErmaFirst PermaChlor™ BWT EX product (e) box. Thereafter, the very important attachment of the cable lugs can be done to the cable end. The
range requires different of DC current (A) and thus required cable size (mm2 per cable or cable core) are cable shall be connected to the lug using crimping, preferably hexagonal, with a minimum pressure of
given by Table 4 below. Customer can choose if one-core or three-core cable option will be used. For cable 13tons for 95/120mm 2 cables and 20tons for 185mm2 cable. The maximum dimensions of crimped lugs
diameter specification, please refer to relevant instruction from the supplier of pre-certified gland, which must be controlled to secure adequate contacting. The connection shall fulfill electrical properties as
together with guidance of selecting correct recommended cable diameter for each the ErmaFirst required by standard IEC/EN 62138-1. Figure 5 and Table 5 shows proper crimping geometry, together
PermaChlor™ BWT EX model can be found in Appendix I. with maximum dimensions of crimped lug for each size:
Cable lugs are thereafter connected to the terminal connection plints. All contact surfaces, including both
sides of the bimetal spacers, shall be applied with suitable contact paste, such as e.g. PENETROX TM oxide
inhibiting compound, for preventing of oxidation. The cable lugs are then contacted via the spacers onto
the plint using suitable bolts and washers. Table 6 shows correct bolt size and correct applied torque for
the connection, and Figure 6 shows the correct positioning of cables at the plint:
Cross section (mm 2) Bolt Torque (Nm)

95 M10 50
120 M12 90
185 M12 90
Fig.5: Geometry of crimped lug and measuring points for contacting control Table 6. Bolt size and correct torque for connecting the cable lugs to the terminal plint
Crimping of Cable Lug

Conductor size (mm 2) Max dimension N (mm)
95 16.0
120 17.9
150 20.3
185 21.9
Table 5. Maximum dimensions for crimped cable lug
The crimping shall be done by authorized staff and with recommended tools only!
Cables used should be suitable for temperatures up to minimum 90°C
Fig.6: Detail of terminal plint, with correctly connected cable lugs (cables not visible in figure)
Cables coming from connection boxes must be secured externally at a maximum

distance of 30cm from exit via the glands, in order to unload the cable weight from
the boxes and cell!
4.3 Earth connection and equipotential bonding

Equipotential bonding between separated insulated and conducting parts must be done to avoid static
Earthing of both anode/cathode side and the two Ex (e) boxes is done via the armour braid of the cable electricity build-up. In the case of ErmaFirst PermaChlor™ BWT EX cells this is solved by separate
and the cable glands and shall be conducted in accordance with Figure 7: grounding of cellhouse via the earthing point(s) at the cellhouse. Ex (e) boxes are automatically earthed
via the cable braid connected to the glands. Fig. 8 shows principle of grounding the cellhouse, together
with correct torque and connection of the cable:
Fig.8: Grounding principle and connection of cell house

Fig.7: Earth connection of anode- and cathode side via cable armour braid
Functional test of safety control function(s) must be performed before use (see 5.6)
Test of correct contacting of cables must be performed before use (see 5.6)
(LEL) of 4%. With the ErmaFirst PermaChlor™ BWT EX cell on-site generation the produced
hydrogen will follow the treated water from the cell and never pose any explosion hazard in the
5. Safety cell.
5.3 Monitoring
5.1 System safety
All operating parameters shall be recorded by the control/PLC unit of the BWTS. As a minimum,
For own safety and to allow a proper use of the electrochemical cell; it is important that you read through
parameters to be recorded are current (A), voltage (V), temperature log (°C) and total time in operation
this manual, including tips and warnings before start/using the ErmaFirst PermaChlor™ BWT EX for the
(h).
first time. In order to avoid unnecessary mistakes and accidents; it is important that anyone who manages
Chlorination kinetics effect the chlorine consumption at temperatures above 35°C. This can be compensated
the electrochemical cell have good knowledge of its area of use and its safety features. Save this manual
by increased current feed to the electrolytic cell. For electrolytic cell dry running/ water stagnation avoidance,
and ensure that it accompanies the electrochemical cell if it is moved so that all users have accurate safety
set power cut-off alarm at maximum temperature of 40°C.
information and information on how to manage it.
• It is dangerous to alter the specifications or attempt to modify this product in any way. Pay 5.5 Training of service personnel
attention to Special Conditions of use (5.7)
Personnel handling the electrochemical cell must have good knowledge of this product and its
• The voltage across the terminals of the cell is max 30 V (DC). In case of bad contact due to non- management. It is the product owner’s responsibility to make sure that the involved personnel has
compliant installment, the connection terminals might become very hot. External short-cuts are sufficient expertise and adequate training in accordance with requirements, especially installment of EX
. Er
avoided by the shielding from connection boxes, certified equipment into hazardous zones For increased general knowledge of maFirst PermaChlor™
BWT EX products, courses can be ordered from Permascand AB or product supplier, including any of
• The electrochemical cell is not intended for use by persons with reduced physical or sensory ability,
following areas:
lack of sensory ability, or lack of experience and knowledge if they are not instructed and
supervised by a person responsible for their safety.
a) Review of equipment
• The installation must be professionally done by suitably trained personnel. When disassembling b) Review of the manuals
the system for replacement, it must first be emptied of water. c) Operation and supervision
• Repairs carried out by inexperienced staff can result in injury or serious malfunctioning. Always d) Troubleshooting, including cleaning of electrodes
contact your dealer or Permascand AB service department. Always insist on genuine Permascand e) Personnel safety and machinery safety in the use of the electrochemical cell
spare parts. Pay attention to Special Conditions of use (5.7)
5.2 Process safety

Sodium hypochlorite produced by electrolysis is the most effective and safe from a working environment
perspective.
• Handling and transport of chlorine. The risks are avoided because the only thing handled and
transported is seawater.
• Storage of sodium hypochlorite. There is no storage of sodium hypochlorite since it is made
directly in the seawater flow, inside the electrolysis cell.
• Free chlorine gas. There is no free chlorine gas because the electrolysis process takes place directly
in the seawater flow where the chlorine gas immediately reacts with the water and becomes
dissolved sodium hypochlorite.
• Fire and explosion. A small amount of hydrogen is formed as by-product in the electrolysis of salt
and water, the same principle as when the batteries in an electric truck are being charged.
Hydrogen gas is fire and explosion hazardous at concentrations above the Lower Explosion Limit
5.6 Functional tests The above resistance control test must be repeated also between the reference point and respective cable
After contacting of cables to terminal plints, a test of proper connections shall be done before operation. ends, in order to include the important connection of cables into the cable lugs. The same criteria for
This test is carried out as a resistance test described in the scheme given in Figure 9. All connections, on acceptance applies: resistance between reference point and respective cable ends must not deviate more
terminal plints of both anode- and cathode side, must be checked against common reference points given than 5% (higher) from mean value of all measurements.
in the figure (“G3”). Criteria for adequate connection is, that resistance (µΩ) against reference point
must not exceed 5% deviation from mean value of all ohmic resistances after complete test schedule.
Table 7 shows a simple template which could be used for registry of measured values, for evaluation. Functional test of the approved Installation and function of Safety Device including the approved flow
switches must be checked before initial start of the complete BWTS which integrates the ErmaFirst
PermaChlor™ BWT EX. It is required that this installation is complying 1.4 and 1.5 of Council Directive
94/9/EC, which can be arranged in several ways. The test of proper function of Safety Device must thus
be evaluated and executed based on the arrangement of each specific case.
The flow switches are suited and approved for use in safety-instrumented loops according to IEC 61508,
and pre-calibrated according to minimum allowed flow velocity. Fig. 10 shows the principle diagram for
installation of the approved flow switches into the arrangement of Safety Device:
Fig.9: Control resistance test of cabling connections
Resistance control of connection after cable contacting
Ref. Point Resistance [µΩ] Deviation [%] OK/Not

G3 3.1
G3 3.2
G3 3.3
G3 3.4
G3 3.5
G3 3.6
G3 3.7
G3 3.8
G3 3.9
Mean: Fig.10: Power circuit and control circuit (=included in Safety Device arrangement) of ErmaFirst PermaChlor™ BWT EX cells
Table 7: Resistance control schedule for test and evaluation of cable contacting
6. Operation
5.7 Special conditions of use
· The ErmaFirst PermaChlor™ BWT EX cells are intended for use as disinfection component Correct start-up and shut down process are handled by main control system of the BWTS. Functional
in Ballast Water Treatment Systems (BWTS) by the manufacturer(s) of such equipment. It system and control are not part of delivery. Below indications are for reference only. The ErmaFirst
is the responsibility of the BWTS manufacturer to ensure and properly follow the PermaChlor™ BWT EX could be controlled by several of principles, e.g. via TRO concentration, flowrate
requirements as set by Permascand AB regarding the use in respect of correct installation etc.
parameters, control, operation and maintenance.
· The used DC power supply (the rectifier) must be limited to maximum output current (A)
in accordance with maximum design current for the specific capacity – see Table 1 6.1 Start up
Technical data. a) Ensure that there is a flow of water in the pipe system where the electrochemical cell is mounted.
· Installation in hazardous areas must only be done in compliance with the restrictions as (i.e. proper integration of control logic of BWTS towards operation of cell)
given by the specific ATEX/IECEx product code (see 1.3), as well as any other restrictions
b) Switch on main power at the power supply.
as set by Permascand AB.
c) Check that current and voltage have the correct values within limits as indicated in Table 1.
· Flow switches are part of protective Safety Device which has to comply with 1.4 and 1.5
Technical data.
of Council Directive 94/9/EC. They are required to be installed, used and approved
accordingly in complete BWTS installation! d) The electrochemical cell ErmaFirst PermaChlor™ BWT EX cell delivers requested
· When failure, damage or defect occurs, the ErmaFirst PermaChlor™ BWT EX cell must be amount/concentration of sodium hypochlorite to the water system and shall be controlled by the
replaced. A failing cell must under no circumstances be repaired. regulation system from the PLC unit of the BWTS system.
· No modifications which could damage the explosion-safety and protection are allowed on
any part or component of the ErmaFirst PermaChlor™ BWT EX, the cable glands or on the
6.2 Shut down
cables. a) Turn off the main power at the control cabinet.
· Demounting of a ErmaFirst PermaChlor™ BWT EX should be done in a non-explosive area b) If the pipe system where the electrochemical cell is mounted will be shut down; rinse the cell with
(safe area) water.
· Functional test of safety control function(s) must be performed before use (see 5.6)
7. Maintenance 8. Troubleshooting
The ErmaFirst PermaChlor™ BWT EX is primarily maintenance free, except for the flame paths that need
Problem Probable cause(s) Solution
to be inspected regularly according to the code of protection Ex “d”. The inspection intervals and
definitions are to be seen in standard IEC 60079-17 and the corresponding Inspection schedules-table.
For efficient hypochlorite production, make sure
Operators must under no circumstances try to repair or open the ErmaFirst PermaChlor™ BWT EX unit. A Too low salinity
salinity of treated water is >3PSU
failing or damaged unit is to be replaced and the failing product shipped to Permascand AB.
High/max
Sensors (flow switches and temperature sensor) are pre-calibrated at delivery.
voltage, low
current Clean electrodes with weak (5%) hydrochloric acid:
Cathodic scaling
fill cell and/or recirculate for 5-24h
7.1 Daily – Self-monitoring
a) All operating parameters shall be recorded on the PLC unit of the BWTS system.
Electrodes worn out Exchange the ErmaFirst PermaChlor BWT EX
b) Check leaks and if any fix them immediately.
c) Visual check for any physical damage. Low
d) Keep equipment clean externally. hypochlorite see previous see previous
production
7.2 Monthly - Self-monitoring
a) Check the bolts at the cable connection on the cell and in the control cabinet. Voltage over
accepted Connecting cables/cableshoes to the Unscrew cableshoes, clean contact surfaces from
7.3 Yearly value, cell and/or to the terminals at the oxides and re-apply antioxidant contact paste. Re-
a) Measure both the voltage the current during operation with volt- and ampere meter. Make sure heated control cabinet have loose, bad or connect cableshoes to terminal plints via bimetal
it is consistent with the values in the display of the power supply or PLC unit for the BWTS system. junction oxidized connections or damages. spacers. Check contacting similarly at rectifier.
b) Clean electrodes with weak (5%) hydrochloric acid: fill cell and/or recirculate for 5-24h boxes
c) Check torque on main assembly bolts of cellhouse two parts – re-apply 330Nm at each bolt if
required.
7.4 Every five year

a) Replace the electrochemical cell if necessary.
9. Declaration of Conformity
We, Permascand AB Folketshusvägen 50, 840 10 Ljungaverk
hereby declare that:

ErmaFirst PermaChlor™ BWT EX cells
with Type Designation: BWT PermaChlor B*X

*: X = 250 (for water flow up to 300m3/h)
X = 500 (for water flow up to 600 m3/h)
X = 750 (for water flow up to 800 m3/h)
X = 1000 (for water flow up to 1200m3/h)
is in conformity with the applicable requirements towards the Directive 94/9/EC (ATEX directive)
and the product certificate. The units are developed in accordance with and complies with all
applicable Essential Requirements of the following Directive(s):
IEC 60079-0:2011, EN 60079-0:2012, Electrical apparatus for explosive gas atmospheres – part 0: General requirements No. Rev. Date Sign. Comments
IEC 60079-1:2006, EN 60079-1:2007, Electrical apparatus for explosive gas atmospheres – part 1: Flameproof enclosures "d” 1 0 2015-07-26 JET NB reviewed & approved version
IEC/EN 60079-7: 2007, Electrical apparatus for explosive gas atmospheres – part 7 : Increased safety enclosures "e”
2 1 2016-02-09 JET Product name + max. flowrate update
IEC 50186
EN 13121-1 ,2, 3:2008
Name and ID of Notified Body: DNV PreSafe, 2460
EC-Type Examination Certificate No.: Presafe 15 ATEX 6521

QAN reference no.: Presafe 15 ATEX 6713Q
IECEX CoC No./date: IECEx PRE 15.0027
QAR refernce no.: NO/PRE/QAR15.0016/00
22/7/2019 HN 2140
TRANSFORMER/ RECTIFIER(S)
User Guide Page 1(28) 77-107.0296 GB
FlexKraft Marine 2018-01-02
Rev. B
USCG
1 Safety instructions
SAFETY INSTRUCTION
There are hazardous voltages inside this product. If

touched, they may cause electric shock, burns or death.
This product is only intended for use as a constant DC-power supply for industrial
processes, the product may only be used for other purposes after approval from
User Guide KraftPowercon. The product must not be used for charging batteries or welding.
Read the instruction manual before installing, using or working on the product.
FlexKraft Marine USCG
77-107.0296 GB Rev. B WARNING! Only authorised personnel may install this product. It
must be installed in accordance with the installation
instructions and local regulations.
WARNING! Only authorised personnel may carry out servicing or

maintenance.
WARNING! Always safely disconnect the electric power supply

before starting servicing or maintenance work. The
work must be done in accordance with the service
instructions in the Technical Description.
CAUTION! Water along with electricity needs special attention.

Pay attention to errors in the cooling system and check that
no water has leaked into the electronics.
The product is intended only for professional use. It must not be used in homes
and offices.
KraftPowercon Sweden AB. P.O.Box 2102. SE-445 02 SURTE. Sweden Tel: +46 31 97 97 00. www.kraftpowercon.com
User Guide Page 2(28) 77-107.0296 GB User Guide Page 3(28) 77-107.0296 GB
Rev. B
Rev. B
USCG USCG
Table of Contents
1.1 Description of safety symbols used on FlexKraft Marine:
1 SAFETY INSTRUCTIONS .................................................................................1 Warning, risk of electric shock!

1.1 Description of safety symbols used on FlexKraft Marine: .......................................3
1.2 Standards ......................................................................................................................4 Before operating the unit:
2 GENERAL..........................................................................................................5 - Carefully read the manual.
3 BASIC CONTROL..............................................................................................6
3.1 Normal operation ..........................................................................................................7
3.1.1 Keypad.............................................................................................................7
3.1.2 LED indication..................................................................................................8 Danger, risk of electric shock!
3.1.3 Audio signals ...................................................................................................8
3.1.4 LCD display .....................................................................................................8
3.1.5 Special functions .............................................................................................8 Before opening the unit:
3.1.6 Alarms / Warnings / Fault messages ..............................................................9 - Isolate from the electrical supply.
3.1.7 Operating modes ...........................................................................................12
3.1.8 Brief overview of functions.............................................................................15
3.1.9 Starting the rectifier .......................................................................................16
3.1.10 Stopping the rectifier......................................................................................17
3.1.11 Blocking the rectifier RUN/BLOCK ................................................................17
3.1.12 Blocking rectifier START/STOP ....................................................................18
3.1.13 Setting polarity (optional function) .................................................................18 Connection point for the protective earth.
3.1.14 Setting the time limit ......................................................................................19
3.1.15 Setting the Ah limit.........................................................................................20
3.1.16 Setting the start ramp ....................................................................................22
3.1.17 Setting the auto-dosing function (optional) ....................................................23 Warning, risk of electric shock!
3.1.18 Running program ...........................................................................................25
3.1.19 Setting the remote control .............................................................................26
3.1.20 Locking keypad to enter parameters in SLAVE mode...................................27
Before opening the unit:
3.1.21 Setting the under voltage / short circuit detection..........................................27 - Isolate from the electrical supply.
3.2 Calibration/Configuration...........................................................................................28 - WAIT UNTIL REMAINING VOLTAGE
3.3 Password .....................................................................................................................28 HAS
4 WARRANTY.....................................................................................................28 DISCHARGED
5 APPENDICES, SEE FOLLOWING PAGES.....................................................28
5.1 List of figures ..............................................................................................................28 DO NOT FREEZE!
5.2 List of tables ................................................................................................................28
THERE IS A MAJOR RISK OF
MALFUNCTION AND REPAIR NEED IF
5.3 Description of order-specific equipment, where applicable...................................28
THE RECTIFIER FREEZE WITH WATER
This description applies to software versions: INSIDE THE COOLING SYSTEM.
FLX-10 VER. 2.18 and later. In case of any freezing risk must unit be
PMC-01 VER. 1.09 and later. emptied of water, see Technical
Description 77-107.0295 section 8.3.1.
Slight differences can exist between the program versions.
Warning, risk of crushing hands or feet!
To upgrade the software from earlier versions, contact KraftPowercon service. During installation or under ship inclination:
Be aware of the risk of crushing under
The manufacturer reserves the right to change specifications. rectifier and in the wire isolators.
Internal CUST-3051
Rev. B
Rev. B
USCG USCG
1.2 Standards
The following European standards or technical specifications apply: 2 General
Document no. Edition Year Title FlexKraft Marine is a modular designed rectifier for use in industrial processes. The
rectifier consists of one control module and one to ten identical power modules. If more
2014/30/EU - 2014 Electromagnetic compatibility directive current or power is needed from an existing rectifier, power modules can be added, up
EN 61000-6-2 2.0 2005 EMC Immunity standard for industrial environments to a maximum of 50.
EN 61000-6-4 2.0 2007 EMC Emission standard for industrial environments FlexKraft Marine has built in EMC filter according to the EMC directive.
IEC 62477-1 1.0 2012 Safety requirements for power electronic converter systems
and equipment - Part 1: General
1 Top
IEC 60092-101 4.0 1994 Electrical installations in ships - Part 101: Definitions and 2 Control module
general requirements 3 Power module
4 Base
IEC 60092-304 3.0 1980 Electrical installations in ships - Part 304: Equipment - 5 Display with keys
Semiconductor convertors 6 Connection to mains supply
7 Connections for control
signals
Signs with connection
Society Document no. Year Title information.
8 Protective cover (metal) for
DNVGL DNVGL-CP-0338 2015 DNV GL type approval scheme DC busbars
DNVGL DNVGL-CG-0339 2015 Environmental test specification for electrical, 9 Water connections
electronic and programmable equipment and systems 10 Vibration dampers
DNVGL DNVGL-CP-0395 2015 Semiconductor converters Side A is on the left when

viewed from in front
DNVGL DNVGL-RU-SHIP- 2016 Part 4 Systems and components Chapter 8 Electrical
Pt4Ch8 installations
USCG 46 CFR 162.060-30 2015 Testing requirements for ballast water management
system (BWMS) components
IMO MEPC 174(58) 2008 Guidelines for approval of ballast water management
Figure 1. Overview of components.
systems (G8)
IACS E10 (Revision 6) 2014 Test Specification for Type Approval
Table 1. Standards
Rev. B
Rev. B
USCG USCG
3.1 Normal operation

The rectifier is operated using the display unit on the front of the control module.
Figure 4. FlexKraft Marine display unit

For more functions and detailed information see the Technical description 77-107.0295,
chapter Operating instructions
Figure 2. FlexKraft Marine with six power modules.
3.1.1 Keypad
The display unit membrane keypad has the following keys:
ON Starts the rectifier; (the contactor closes if fitted)

OFF Stops the rectifier; (the contactor opens if fitted)
Current έ Increase current
Current ί Decrease current
Voltage έ Increase voltage
Voltage ί Decrease voltage
Menu keys A – D Menu options
OK! Used to confirm a change (disabled in some submenus)
ESC Used to undo a change or back out of a menu
(disabled in some submenus)
The longer a key is held, the faster the set value changes. The value stops at
zero.
Figure 3. Five parallel rectifiers, Master rectifier to the left In REMOTE mode, some or all control functions cannot be operated from the display
Master rectifier must always be at one end. unit and are instead controlled by serial communication or by external analogue control
signals. If the rectifier is not in REMOTE mode it can only be operated from the display
unit.
3 Basic Control
This chapter deals with control from the local display. The rectifier will, in most cases, When SLAVE MODE is active, the keypad is disabled and no operating parameters can
probably be remotely controlled from an external control system. The local display unit be changed.
is useful for service and troubleshooting. The OFF key is also disabled, even if the rectifier is set in LOCAL mode.
The keypad is activated using a password-protected menu.
Pressing the OK key saves changes and pressing the ESC key discard changes!
Rev. B
Rev. B
USCG USCG
3.1.2 LED indication 3.1.6 Alarms / Warnings / Fault messages

The panel has LED indication for the following functions: An alarm signal from the rectifier is indicated by a red LED on the display unit. The
reason for the alarm is shown on the display.
ON Green LED Indicates rectifier on (contactor closed)
ALARM Red LED Indicates end of process or rectifier fault If the rectifier is fitted with the optional CONTACTOR, the contactor opens at the alarm.
The LED flashes to indicate a WARNING and glows steadily If the sound indication is set to “ON” in the CFG/USR menu, see the Technical
to indicate ALARM Description 77-107.0295, chapter Operating instructions, the buzzer goes on at the
REMOTE Yellow LED Indicates the rectifier is controlled by a remote control alarm. The buzzer is turned off by pressing any button.
To reset from fault mode: switch the rectifier off using the keypad or serial
3.1.3 Audio signals communication. Alternatively, send the ALARM RESET command using the DIG IN
The panel is equipped with a piezo buzzer that sounds to confirm keypad use, end of digital input.
process (EOP) and a rectifier fault. The buzzer sound indication can be turned off in the
CFG/USR menu. See in the Technical Description 77-107.0295, chapter Operating ALARM = The rectifier stops.
instructions WARNING = The rectifier continues to operate but possibly with reduced output.
The ALARM signal is activated in the event of either an ALARM or WARNING.

3.1.4 LCD display The POWER GOOD signal is deactivated when there is an ALARM or WARNING.
The LCD display is a high contrast graphic type with integrated background lighting.
The display contrast may need to be adjusted depending on the ambient temperature Message Explanation
and age. Adjustment is made from the configuration menu. “HIGH TEMP.” Excess temperature in a power module. Too high temperature
on the output causes over temperature in the power module.
Background lighting comes on when a key is pressed and remains on for 60 seconds (the output from the affected power module is stopped as long
after the last key is pressed. as the temperature remains too high. The ‘Power Good’ LED is
off on the power module that has sent the high temperature
signal). The rectifier remains running with the remaining power
3.1.5 Special functions modules, the output current is decreased accordingly.
The rectifier control system is configured on delivery, however, if for some reason you
wish to reset the settings to their default values this can be done by holding down the
ESC key for more than 8 seconds. CAUTION! The cooling water can be hot if the system has shut down
NOTE - The SET parameters, Ah counter and process timer are reset to zero. due to over temperature.
- The CFG settings are not changed (the buzzer is switched on if it has
been switched off)
-The loaded software is not changed.
The buzzer sounds when the system has been reset.
“HIGH TEMP C-M” Excess temperature in the control module. The rectifier runs.
The system is reset if the OFF key is held down for 5 seconds. The buzzer sounds The output current is unaffected.
to indicate that reset has occurred.
“RGL ERROR” Regulator control error in the rectifier. The rectifier runs, but the
output is not according to set values (in earlier system also
called ‘Phase missing’).
Rev. B
Rev. B
USCG USCG
Message Explanation Message Explanation

“WARNING!” One of the following warnings is active on at least one power “EXT ALARM 1” User configurable.
module:
· Regulation error EXT ALARM A/B Alarm from PRU (pole reverse unit) in case the unit is equipped
· RS485 communication lost with this optional function.
· Overcurrent Can also be used as be used as interlock from process.
· Overvoltage
Regulation error: In the case of an ALARM rectifier stops, See Technical Description 77-107.0295
One or both sides in one or more power modules are not able User menu.
to regulate properly. Check that mains supply is within range The reason for the ALARM should be determined. See Technical Description 77-
and has not lost a phase. 107.0295, chapter Service and Maintenance
RS485 communication lost:

One or more power modules lost RS485 communication. The display can also show four fault messages.
Overcurrent: Message Explanation

Overcurrent in one or both sides in one or more power “CHK USRCFG” Only applies with pole reversal option. Fault in
modules. Power cycle of the power module is needed to reset configuration of DIG IN or DIG OUT signals.
this warning.
Overvoltage: “MAX POWER!” The output of the rectifier does not correspond to the
High voltage on the busbar output in one or both sides in one or (ALARM LED flashes) set values of current and voltage due to power
more power modules. Power cycle of the power module is limitation. The set values for current and voltage are
needed to reset this warning. within the triangle 30-50V/125-100A@ mains 420-
480VAC. If the mains power is lower than needed to
Common for all warnings: give the set output, a Regulation error is generated
· The rectifier continues to run although the output instead of “MAX POWER”
current might decrease (due to that the affected power
module in the system is shut down). 1
Effektgräns
Power limit
· ‘Power Good’ LED is blinking when the warning is U
active
· When the warning has ceased to be active, ‘Power 50V
Good’ LED on affected power module is turned off to 30V 1 Power Limit
indicate that there has been a warning. 2 Voltage
3 Current
“MODULE FAILED!” Reverse current in a power module. (The rectifier stops. The
‘Power Good’ LED is off on the power module that has sent the
alarm signal).
I
100A 125A
“SHORT CKT!” The output voltage has been below the under voltage set value 3 Ström/Current
for a longer period of time than set time value.
“CAN FAIL” CAN communication lost (rectifier shuts down).

When an EOP for elapsed time limit or ampere hour limit is reached the “ALARM” LED
flashes, see 3.1.14 Setting the time limit and 3.1.15 Setting the Ah limit for information.
“CANWARNING” CAN communication is not working properly.
Rev. B
Rev. B
USCG USCG
3.1.7 Operating modes Example, mains voltage 420-480VAC (-0/+10%)

The rectifier has two operating modes (three with option pole reverse): SINGLE 2 submodules in
100V/100A series
Single Sub-modules can be connected in series for higher
voltage, and these sub-module groups can be connected
in parallel for higher current (ether side A to side B,
horizontal connections, or vertically adjacent sub-modules,
vertical connections). M=Master, S=Slave
Output voltage and current in this mode is 0- SINGLE 3 submodules in
30(50)V@125(100) A/module at 420-480V (-0/+10%) 150V/200A series
primary voltage.
See Technical manual 77-107.0295 for more information. 2 groups in
parallel over sides
Single See Technical manual 77-107.0297 for more information.
Pole reverse
(optional)
Dual Power module sub-modules are independent (side A and

B). Sub-modules can be connected in series for higher
voltage, and these sub-module groups can be connected in
parallel for higher current (within the side).
Sides A and B can be switched on and off independently
and behave like two rectifiers.
The set values for current and voltage can be different for DUAL 2x50V/200A 2 submodules in
each side. The time limits are the same for both sides. parallel
The Ah limit can be set independently for each side.
Rev. B
Rev. B
USCG USCG
DUAL 4 submodules in
2x200V/200A series. 3.1.8 Brief overview of functions
2 groups in Please note that some functions require that options are installed.
parallel on the
same side Heading Sub-function 1 Sub-function 2 Sub-function 3
Operating modes SINGLE (sides connected in series/parallel or both)

(SINGLE Pole Reverse , needs option pole reverse )
DUAL (groups connected in series in the group, in parallel, or both)
Remote control Serial communication RS485 PROFIBUS DP

MODBUS RTU
Analogue current 0-20mA

4-20mA
voltage 0-10VDC
0-6 VDC
0-5 VDC
6-0 VDC
10-0 VDC
contacts Increase/decrease current
Increase/decrease voltage
ON/OFF
START/STOP
RUN/BLOCK
Program No. 1-4 STEP

Several rectifiers can be connected in parallel to obtain higher output current, but U-RAMP
they must be equipped with the parallel configuration option. I-RAMP
PULSE
REPEAT
For examples with pole reverse, see Technical Description 77-107.0297.

Limits Ah limit Side A Stop rectifier
Side B Signal
HOLD function U/I
Time limit Side A+B Stop rectifier

Signal
HOLD function U/I
Under voltage Limits Side A Voltage

Limits Side B Time
Time limit Side A
Time limit Side B
Dosing function Side A Dosing pulse time

Side B
Total A+B
Monitoring Temperature
Regulation
Configuration
External emergency stop
See Technical Description 77-107.0295 for more information.

See Technical Description 77-107.0297 for option Pole Reverse.
Rev. B
Rev. B
USCG USCG
3.1.9 Starting the rectifier 3.1.10 Stopping the rectifier

When first switched on the display is dimmed and shows the following start displays. Switch the rectifier from “RUN” mode to “STANDBY” mode with the “OFF” key.
Side
A B Shut down the rectifier by pressing the “OFF” key again to switch from “STANDBY”
mode to “OFF” mode.
STATUS: - OFF - - OFF - - OFF -
Also see 3.1.19 Setting the remote control
PRESS ON TO START PRESS ON TO START

Flex Kraft The rectifier can also be stopped by set limits or alarms
SINGLE DUAL
www.kraftpowercon.com DUTY SET BLOCK CFG DUTY SET BLOCK CFG Rectifier stops after
set time. STATUS: TLIMIT! T-LIMIT! T-LIMIT!
Welcome screen Example of start screen
Displayed for some seconds The rectifier can be configured to go to OFF,
REMOTE, CONTINUE or RUN 00.00 V 000.0 A 00.00 V 00.00 V
when mains power is connected. 000000 Ah 00000 S 000.0 A 000.0 A
SINGLE DUAL DUTY SET BLOCK CFG DUTY SET BLOCK CFG
Switch on the rectifier DUTY SET
with the “ON” key. STATUS: STANDBY STANDBY STANDBY CFG
The backlight comes Rectifier stops after STATUS: AHLIMIT! AH-LIMIT! AH-LIMIT!
on and the display 00.00 V 000.0 A 00.00 V 00.00 V set number of Ah
changes. 000000 Ah 00000 S 000.0 A 000.0 A
00.00 V 000.0 A 00.00 V 00.00 V
DUTY SET BLOCK CFG DUTY SET BLOCK CFG 000000 Ah 00000 S 000.0 A 000.0 A
DUTY SET
CFG DUTY SET BLOCK CFG DUTY SET BLOCK CFG
DUTY SET
CFG
Start the rectifier by STATUS: RUN DC RUN DC RUN DC
pressing the ON key Rectifier stops due to STATUS: HIGH TEMP HIGH TEMP HIGH TEMP
once more - output excess temperature
current and voltage is 00.00 V 000.0 A 00.00 V 00.00 V
delivered. 000000 Ah 00000 S 000.0 A 000.0 A 00.00 V 000.0 A 00.00 V 00.00 V
000000 Ah 00000 S 000.0 A 000.0 A
DUTY SET BLOCK CFG DUTY SET BLOCK CFG
CFG DUTY SET DUTY SET BLOCK CFG DUTY SET BLOCK CFG
CFG DUTY SET
In order to control the rectifier locally, set the Remote control option to “NO” CFG
See Technical description 77-107.0295, chapter “Set menu” for further information.
3.1.11 Blocking the rectifier RUN/BLOCK
The rectifier can be blocked and stopped without entering “STANDBY”.
The blocking function turns the rectifier output off and it restarts with the set
values. In DUAL mode output A and B are blocked independently.
This can be done using the “BLOCK” key, from the SET menu, or by remote
control. In DUAL mode the rectifiers can only be operated independently from the
SET menu, or by remote control.
Rev. B
Rev. B
USCG USCG
3.1.14 Setting the time limit

3.1.12 Blocking rectifier START/STOP The rectifier can be set, once a specific time has elapsed, to:
The rectifier can be blocked and stopped without going to “OFF”. -Stop and give a signal
The ‘BLOCK’ function turns the rectifier output off immediately and then again the -Continue with operations and give a signal
‘RUN’ function restarts the rectifier with a start ramp to the set values. -Change the output data to a HOLD level and give a signal.
In DUAL mode outputs A and B can be operated independently. Set in CFG/USR menu using EOP MODE
SINGLE DUAL The time is set in the SET menu using TIMERLIMIT.
STATUS: STANDBY STANDBY STANDBY SINGLE DUAL

REMOTE CONTROL : NO REMOTE CONTROL : NO
00.00 V 000.0 A 00.00 V 00.00 V SETVOLTAGE : 00.00 V SETVOLTAGE A: 00.00 V
SETCURRENT : 000.0 A SETVOLTAGE B: 00.00 V
000000 Ah 00000 S 000.0 A 000.0 A RUN/BLOCK : RUN SETCURRENT A: 000.0 A
START/STOP : STOP SETCURRENT B: 000.0 A
DUTY SET BLOCK CFG DUTY SET BLOCK CFG TIMERLIMIT : -OFF- S RUN/BLOCK A : RUN
DUTY SET
CFG
← → ↓ ↑ ← → ↓ ↑
STATUS: STANDBY STANDBY STANDBY Press ↓ to get TIMERLIMIT
Setting whether the rectifier should stop, use HOLD level or only light the ALARM LED
00.00 V 000.0 A 00.00 V 00.00 V when the set limit has been reached (option: contact to remote system) is set using the
000000 Ah 00000 S 000.0 A 000.0 A CFG/USER menu with the EOP MODE parameter.
NOTE that the settings also apply for the Ah limit. The CFG menu is password
DUTY SET RUN CFG DUTY SET RUN CFG protected.
DUTY SET
CFG
The set menu The set menu SINGLE DUAL
REMOTE CONTROL : NO REMOTE CONTROL : NO STATUS: STANDBY STANDBY STANDBY

SETVOLTAGE : 00.00 V SETVOLTAGE A: 00.00 V
RUN/BLOCK : RUN SETCURRENT A: 000.0 A 00.00 V 000.0 A 00.00 V 00.00 V
START/STOP : STOP SETCURRENT B: 000.0 A
TIMERLIMIT : -OFF- S RUN/BLOCK A : RUN 000000 Ah 00000 S 000.0 A 000.0 A
← → ↓ ↑ ← → ↓ ↑ DUTY SET
CFG
SELECT SUB-MENU OR SELECT SUB-MENU OR
3.1.13 Setting polarity (optional function) PRESS ESC TO EXIT! PRESS ESC TO EXIT!
This function require that option Pole Reverse is fitted.
See Technical Description 77-107.0297
FIRMWARE FIRMWARE
FLX-01 VER xx.xx FLX-01 VER xx.xx
PROG USER CAL KRAFT PROG USER CAL KRAFT
Rev. B
Rev. B
USCG USCG
SINGLE DUAL
SINGLE DUAL
LCD-CONTRAST: 050.0 % LCD-CONTRAST: 050.0 %
PASSWORD :000001 PASSWORD :000001
PROTOCOL :PROFIBUS DP PROTOCOL :PROFIBUS DP STATUS: STANDBY STANDBY STANDBY
BYTESWAP : YES BYTESWAP : YES
ADDRESS : 00002 ADDRESS : 00002
BAUDRATE : AUTODETECT BAUDRATE : AUTODETECT 00.00 V 000.0 A 00.00 V 00.00 V
000000 Ah 00000 S 000.0 A 000.0 A
← → ↓ ↑ ← → ↓ ↑
Press ↓ to get to EOP MODE Press ↓ to get to EOP MODE DUTY SET
CFG
MBTIMEOUT: 000000MS MBTIMEOUT: 000000MS REMOTE CONTROL : NO REMOTE CONTROL : NO
SLAVEMODE: NO SLAVEMODE: NO SETVOLTAGE : 00.00 V SETVOLTAGE A: 00.00 V
POWERONMODE: OFF POWERONMODE: OFF SETCURRENT : 000.0 A SETVOLTAGE B: 00.00 V
OUTPUTMODE : SERIES OUTPUTMODE : SERIES RUN/BLOCK : RUN SETCURRENT A: 000.0 A
EOP MODE : STOP EOP MODE : STOP START/STOP : STOP SETCURRENT B: 000.0 A
HOLD LEVEL : 010.0% HOLD LEVEL : 010.0% TIMERLIMIT : -OFF- S RUN/BLOCK A : RUN
← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑
Press ↓ to get to AH-LIMIT Press ↓ to get to AH-LIMIT A / B

Press “OK” to activate change.
SETCURRENT : 000.0 A POLARITY A : FWD
RUN/BLOCK : RUN POLARITY B : FWD
When the set limit is reached, switch off the buzzer by pressing ESC. START/STOP : STOP TIMERLIMIT : -OFF- S
POLARITY : FWD AH-LIMIT A : -OFF-AH
Pausing the process: TIMERLIMIT : -OFF- S AH-LIMIT B : -OFF-AH
The process can be paused before the set limit is reached by pressing the “OFF” key AH-LIMIT : -OFF-AH START RAMP : 0000.5 S
and then restarted by pressing “ON” key. A restart is also made if the “OFF” key has
been pressed twice so that the rectifier is in “OFF” mode. ← → ↓ ↑ ← → ↓ ↑
Interrupting the process:

Setting whether the rectifier should stop, use HOLD level or only light the ALARM LED
Pause the process using the “OFF” key. Reset the counter in the DUTY menu with
when the set limit has been reached (option: contact to remote system) is set using the
CLEAR. Restart the process from zero with the “ON” key.
CFG/USER menu with the EOP MODE parameter.
Restart the process: NOTE that the settings also apply for the time limit. The CFG menu is password
When the process has completed and an EOP has been obtained, the rectifier is protected.
stopped/set in STANDBY mode using the “OFF” key. Restart the process from zero SINGLE DUAL
with the “ON” key.
See the Technical description for further setting options and programming functions. STANDBY STANDBY
STATUS: STANDBY
3.1.15 Setting the Ah limit 00.00 V 000.0 A 00.00 V 00.00 V

The rectifier can be set, once a specific number of ampere hours have elapsed, to: 000000 Ah 00000 S 000.0 A 000.0 A
-Stop and give a signal
-Continue with operations and give a signal DUTY SET BLOCK CFG DUTY SET BLOCK CFG
-Change the output data to a HOLD level and give a signal. DUTY SET
Set in CFG/USR menu using EOP MODE CFG
The number of ampere hours is set in the SET menu using AH-LIMIT A and AH-
LIMIT B.
Rev. B
Rev. B
USCG USCG
SINGLE DUAL SINGLE DUAL

SELECT SUB-MENU OR SELECT SUB-MENU OR
PRESS ESC TO EXIT! PRESS ESC TO EXIT! STATUS: STANDBY STANDBY STANDBY
FIRMWARE FIRMWARE 00.00 V 000.0 A 00.00 V 00.00 V

FLX-01 VER xx.xx FLX-01 VER xx.xx 000000 Ah 00000 S 000.0 A 000.0 A
PROG USER CAL KRAFT PROG USER CAL KRAFT DUTY SET BLOCK CFG DUTY SET BLOCK CFG
DUTY SET
CFG
LCD-CONTRAST: 050.0 % LCD-CONTRAST: 050.0 % REMOTE CONTROL : NO REMOTE CONTROL : NO
PASSWORD :000001 PASSWORD :000001 SETVOLTAGE : 00.00 V SETVOLTAGE A: 00.00 V
PROTOCOL :PROFIBUS DP PROTOCOL :PROFIBUS DP SETCURRENT : 000.0 A SETVOLTAGE B: 00.00 V
BYTESWAP : YES BYTESWAP : YES RUN/BLOCK : RUN SETCURRENT A: 000.0 A
ADDRESS : 00002 ADDRESS : 00002 START/STOP : STOP SETCURRENT B: 000.0 A
BAUDRATE : AUTODETECT BAUDRATE : AUTODETECT TIMERLIMIT : -OFF- S RUN/BLOCK A : RUN
← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑ ← → ↓ ↑
Press ↓ to get to EOP MODE Press ↓ to get to EOP MODE Press ↓ to get to START RAMP Press ↓ to get to START RAMP
RUN/BLOCK : RUN POLARITY A : FWD
MBTIMEOUT: 000000MS MBTIMEOUT: 000000MS START/STOP : STOP POLARITY B : FWD
SLAVEMODE: NO SLAVEMODE: NO POLARITY : FWD TIMERLIMIT : -OFF- S
POWERONMODE: OFF POWERONMODE: OFF TIMERLIMIT : -OFF- S AH-LIMIT A : -OFF-AH
OUTPUTMODE : SERIES OUTPUTMODE : DUAL AH-LIMIT : -OFF-AH AH-LIMIT B : -OFF-AH
EOP MODE : STOP EOP MODE : STOP START RAMP : 0000.5 S START RAMP : 0000.5 S
HOLD LEVEL : 010.0% HOLD LEVEL : 010.0%
← → ↓ ↑ ← → ↓ ↑
← → ↓ ↑ ← → ↓ ↑
When the set limit is reached, switch off the buzzer by pressing ESC. 3.1.17 Setting the auto-dosing function (optional)
The rectifier can be equipped with an auto-dosing function. This function requires that
See the Technical description 77-107.0295, chapter Operating Instructions for further the digital I/O or analogue I/O option is fitted to the rectifier.
setting options and programming functions.
The rectifier can be set to close a potential free contact when a preset number of Ah
3.1.16 Setting the start ramp hours have elapsed. The number of Ah hours between the start of each pulse is set
The rectifier can be set to ramp up voltage and current from zero to set value during a using parameter AUTODOS, and the closed time for the contacts is set by the
preset time. The time is set using the SET menu and the parameter START RAMP for parameter PULSLENG. in the CFG/USER menu. The menu is password protected.
both side A and side B.
Rev. B
Rev. B
USCG USCG
There are three adjustable Ah counters and three adjustable times. SINGLE DUAL
Side Parameter AH Parameter pulse time AUTODOS. : -OFF-AH AUTODOS. : -OFF-AH

PULSELENG. : 000.5 S PULSELENG. : 000.5 S
SINGLE AUTODOS. A : -OFF-AH AUTODOS. A : -OFF-AH
AUTODOS. PULSELENG. PULSELENG.A: 000.5 S PULSELENG.A: 000.5 S
AUTODOS. B : -OFF-AH AUTODOS. B : -OFF-AH
DUAL PULSELENG.B: 000.5 S PULSELENG.B: 000.5 S
A AUTODOS.A PULSELENG.A
B AUTODOS.B PULSELENG.B ← → ↓ ↑ ← → ↓ ↑

AUTODOS has a range of 0-30,000 Ah, and sets the number of ampere hours between
See the Technical description 77-107.0295, chapter Operating Instructions and Dosing
dosing.
function for further setting options and programming information.
PULSELENG has a range of 0-999.9 s, and sets the length of time that the contacts
remains closed. 3.1.18 Running program
The DIG OUT 1 to DIG OUT 4 parameter determines which contacts are used.
Parameters are set in the CFG/USER menu. The rectifier can be programmed with 4 different programs.
The program and operating mode are selected using the PROGRAMMODE and PROGRAM
SINGLE DUAL NO parameters in the SET menu.
SINGLE DUAL
STATUS: STANDBY STANDBY STANDBY
STATUS: STANDBY STANDBY STANDBY

00.00 V 000.0 A 00.00 V 00.00 V
000000 Ah 00000 S 000.0 A 000.0 A
00.00 V 000.0 A 00.00 V 00.00 V
DUTY SET BLOCK CFG DUTY SET BLOCK CFG 000000 Ah 00000 S 000.0 A 000.0 A
DUTY SET
CFG DUTY SET BLOCK CFG DUTY SET BLOCK CFG
SINGLE DUAL DUTY SET
CFG
SELECT SUB-MENU OR SELECT SUB-MENU OR REMOTE CONTROL : NO REMOTE CONTROL : NO
PRESS ESC TO EXIT! PRESS ESC TO EXIT! SETVOLTAGE : 00.00 V SETVOLTAGE A: 00.00 V
RUN/BLOCK : RUN SETCURRENT A: 000.0 A
FIRMWARE FIRMWARE START/STOP : STOP SETCURRENT B: 000.0 A
FLX-10 VER xx.xx FLX-10 VER xx.xx TIMERLIMIT : -OFF- S RUN/BLOCK A : RUN
PROG USER CAL KRAFT PROG USER CAL KRAFT ← → ↓ ↑ ← → ↓ ↑
Press ↓ to get to PROGRAMMODE Press ↓ to get to PROGRAMMODE

LCD-CONTRAST: 050.0 % LCD-CONTRAST: 050.0 %
PASSWORD :000001 PASSWORD :000001 POLARITY : FWD AH-LIMIT B : -OFF-AH
PROTOCOL :PROFIBUS DP PROTOCOL :PROFIBUS DP TIMERLIMIT : -OFF- START RAMP :0000.5 S
BYTESWAP : YES BYTESWAP : YES AH-LIMIT : -OFF-AH PROGRAMMODE A : NO
ADDRESS : 00002 ADDRESS : 00002 START RAMP :0000.5 S PROGRAMMODE B : NO
BAUDRATE : AUTODETECT BAUDRATE : AUTODETECT PROGRAMMODE : NO PROGRAM A NO : 01
PROGRAM NO : 01 PROGRAM B NO : 01
← → ↓ ↑ ← → ↓ ↑
← → ↓ ↑ ← → ↓ ↑
Press ↓ to get PULSELENG.A Press ↓ to get PULSELENG.A / B
(Note; when running SINGLE mode, PULSELENG.B is not used) Press “OK” to activate change.
Rev. B
Rev. B
USCG USCG
Programs are entered using the CFG/PROG menu. The menu is password protected.
REMOTE CONTROL : NO REMOTE CONTROL : NO
SETVOLTAGE : 00.00 V SETVOLTAGE A: 00.00 V
Basic functions: SETCURRENT : 000.0 A SETVOLTAGE B: 00.00 V
Number of programs: 4 RUN/BLOCK : RUN SETCURRENT A: 000.0 A
Program steps per program: 8 START/STOP : STOP SETCURRENT B: 000.0 A
Program repeat Yes, possible TIMERLIMIT : -OFF- S RUN/BLOCK A : RUN
← → ↓ ↑ ← → ↓ ↑
The parameters for remote control must to be set to give correct remote control
Basic functionality.
functions:
The protocol and parameters must be set for serial communication.
RAMP STEP PULSE For analogue remote control, the inputs must be activated and configured.
Individual adjustment of voltage and current for each program step. Use the CFG/USER menu (the menu is password protected).
3.1.19 Setting the remote control If the rectifier is delivered with remote digital or analogue control box, the parameters
The rectifier can be remotely controlled by serial communication or analogue signals. are factory set.
When the rectifier is remotely controlled, the local control is disabled. When controlled
remotely, parameters that are controlled by the analogue interface have precedence NOTE If the rectifier is set for analogue remote control of set values these values
over parameters sent by serial communication. take, in REMOTE mode, priority over set values via serial communication.
Special case: When using analogue remote control, some set values and functions can
be remotely controlled and others locally controlled from the keypad, REMOTE=ON See the Technical description 77-107.0295, chapter Programming for further
PROTOCOL=NONE. However, it is possible to read out actual values. The rectifier information.
cannot be switched OFF with the OFF key. LOCAL mode must first be selected in the
SET menu by setting REMOTE=NO.
If the rectifier loses contact with the master during PROFIBUS control, the keypad will 3.1.20 Locking keypad to enter parameters in SLAVE mode
be re-activated. When the rectifier is in SLAVEMODE the keys are disabled and no operating
parameters can be changed. The operating parameters can be displayed.
Remote control via serial communication is selected with the parameter REMOTE in The keypad is unlocked by deactivating SLAVEMODE using the password-
the SET menu. protected CFG/USER menu.
SINGLE DUAL
3.1.21 Setting the under voltage / short circuit detection
STATUS: STANDBY STANDBY STANDBY Due to voltage drop in DC-cabling a S.C: Level of 2-4V is appropriate.
A time delay of 30 -120 sec before shutdown effectively prohibits false alarms due to
normal variation of current.
00.00 V 000.0 A 00.00 V 00.00 V
000000 Ah 00000 S 000.0 A 000.0 A Default settings:
S.C. LEVEL 2,00V
DUTY SET BLOCK CFG DUTY SET BLOCK CFG S.C. DELAY 0sec = -OFF-
DUTY SET
CFG For SINGLE rectifiers the “A-side” parameters shall be used.
NB! The output voltage set value must be higher than the under voltage/short circuit
detection voltage. Otherwise the under voltage/short circuit detection is disabled.
User Guide Page 28(28) 77-107.0296 GB
Rev. B
USCG
3.2 Calibration/Configuration
The rectifier is calibrated and configured at the factory before delivery.
The rectifier can be calibrated from the CFG/CAL menu. The calibration menu is
password protected.
See Technical description 77-107.0295, chapter Operating Instructions for further

information
3.3 Password
Some menus and settings are password protected. KraftPowercon service can set a
new password should the old one be lost.
See the Technical description 77-107.0295, chapter Operating Instructions for further
information.
4 Warranty
KraftPowercon Sweden AB provides warranty terms according to the order
acknowledgement or contract. The warranty covers defects in design, materials and
manufacturing. Defects that can be shown to have arisen as a consequence of
incorrect use and/or maintenance are not covered. If a fault develops during the
warranty period, KraftPowercon Sweden AB or local representative must be contacted
before any work is undertaken on the rectifier.
KraftPowercon Sweden AB
P.O. Box 2102 Phone: +46 31 - 979700
SE-445 02 SURTE E-mail: service@kraftpowercon.com
Sweden Website: www.kraftpowercon.com
5 Appendices, see following pages

Description of order-specific equipment, where applicable
5.1 List of figures

Figure 1. Overview of components. 5
Figure 2. FlexKraft Marine with six power modules. 6
Figure 3. Five parallel rectifiers, Master rectifier to the left Master rectifier must always be at one end. 6
Figure 4. FlexKraft Marine display unit 7
5.2 List of tables

Table 1. Standards 4
5.3 Description of order-specific equipment, where applicable
22/7/2019 HN 2140
FLOW METER
SM/FEX300/FEX500/ATEX/IECEX-EN
ProcessMaster, HygienicMaster
FEX300, FEX500
ATEX / IECEx Zone 1, 2, 21, 22
Safety instructions for electrical

apparatus in potentially explosive areas,
in accordance with Directive 2014/34/EU
(ATEX) and IEC60079-0 (IECEx)
Electromagnetic Flowmeter
Ne u
Contents
IMPORTANT (NOTE)
Electromagnetic Flowmeter This document forms an integral part of the following manuals:
ProcessMaster, HygienicMaster • Operating Instruction OI/FEX300/FEX500
• Commissioning instruction CI/FEX300/FEX500
FEX300, FEX500
1 Safety ....................................................................................................................................................................4
1.1 Operator liability .............................................................................................................................................4
1.2 Technical limit values .....................................................................................................................................4
Safety instructions for electrical apparatus in potentially explosive areas, in accordance with 1.3 Safety information for electrical installation .................................................................................................... 4
Directive 2014/34/EU (ATEX) and IEC60079-0 (IECEx) - EN 1.4 Symbols and warnings ................................................................................................................................... 5
2 Device designs .................................................................................................................................................... 6
SM/FEX300/FEX500/ATEX/IECEX-EN
2.1 Model with compact design ............................................................................................................................ 6
2.1.1 ATEX/IEC Zone 1 .................................................................................................................................... 6
08.2017
2.1.2 ATEX/IEC Zone 2 .................................................................................................................................... 7
Rev. D
2.2 Model with remount mount design .................................................................................................................7
2.2.1 ATEX/IEC Zone 1 .................................................................................................................................... 8
Translation of the original instruction
2.2.2 ATEX/IEC Zone 2 .................................................................................................................................... 9
2.3 Overview: The fast track to the device data .................................................................................................10
2.4 Name plate ...................................................................................................................................................11
2.4.1 Name plate for model with integral mount design (dual-compartment housing) ..................................11
2.4.2 Name plate for model with integral mount design (single-compartment housing) ................................12
Manufacturer: 2.4.3 Name plate for model with remote mount design ................................................................................. 13
ABB Automation Products GmbH ABB Inc. ABB Engineering (Shanghai) Ltd. 2.4.4 Name plate for transmitter.....................................................................................................................14
Measurement & Analytics Measurement & Analytics Measurement & Analytics 3 Mounting ............................................................................................................................................................ 16
Dransfelder Straße 2 125 E. County Line Road No. 4528, Kangxin Highway, 3.1 Information about opening and closing the housing .................................................................................... 16
D-37079 Göttingen Warminster, PA 18974 Pudong New District, 3.2 Cable entries ................................................................................................................................................17
Germany USA Shanghai, 201319, P.R. China
3.3 High temperature version ............................................................................................................................. 18
Tel.: +49 551 905-0 Tel.: +1 215 674 6000 Tel.: +86(0) 21 6105 6666
Fax: +49 551 905-777 Fax: +1 215 674 7183 Fax: +86(0) 21 6105 6677 3.4 Protection class IP 68 ................................................................................................................................... 18
Mail: china.instrumentation@cn.abb.com 3.5 Rotating the transmitter housing .................................................................................................................. 19
Customer service center 3.6 Information about using the device in areas with combustible dust .............................................................20
Phone: +49 180 5 222 580 3.6.1 Maximum Allowable Surface Temperature ........................................................................................... 20
Fax: +49 621 381 931-29031 3.6.2 Minimum signal cable length .................................................................................................................20
automation.service@de.abb.com
4 Ex relevant specifications for operation in Zones 1, 21, and 22 .................................................................. 21
4.1 Electrical connection ....................................................................................................................................21
4.1.1 Flowmeter sensor and transmitter in zone 1 / Div. 1 ............................................................................21
4.1.2 Flowmeter sensor in zone 1 and transmitter in zone 2 or outside the hazardous area ........................ 22
4.2 Electrical data for operation in zones 1, 21, 22 / Div. 1 ................................................................................23
4.2.1 Devices with HART protocol .................................................................................................................23
4.2.2 Devices with PROFIBUS PA or FOUNDATION fieldbus ......................................................................24
4.3 Temperature data for operation in Zone 1 / Div. 1 ....................................................................................... 25
5 Ex relevant specifications for operation in zones 2, 21 and 22 .................................................................... 29
© Copyright 2017 by ABB Automation Products GmbH
5.1 Electrical connection ....................................................................................................................................29
Subject to changes without notice 5.1.1 Flowmeter sensor and transmitter in zone 2, or transmitter outside the hazardous area..................... 29
This document is protected by copyright. It assists the user in safe and efficient operation of the device. The contents of this 5.2 Electrical data for operation in zones 2, 21, 22 / Div. 2 ................................................................................30
document, whether whole or in part, may not be copied or reproduced without prior approval by the copyright holder.
Co nte nt s
5.2.1 Devices with HART protocol .................................................................................................................30
5.2.2 Devices with PROFIBUS PA or FOUNDATION fieldbus ......................................................................30
5.3 Temperature data for operation in Zone 2 / Div. 2 ....................................................................................... 30
SM/FEX300/FEX500/ATEX/IECEX-EN FEX300, FEX500 EN - 1 2 - EN FEX300, FEX500 SM/FEX300/FEX500/ATEX/IECEX-EN
Contents Safety
6 Commissioning ..................................................................................................................................................33 1 Safety
6.1 Preliminary checks prior to start-up .............................................................................................................. 33
6.2 Notes on combining the FEP325 flowmeter sensor with the FET325 transmitter or the FEP525 flowmeter 1.1 Operator liability
sensor with the FET525 transmitter .............................................................................................................33 The operator must strictly observe the applicable national regulations with regard to installation,
6.3 Special features of version designed for operation in Ex zone 1 / Div. 1 ..................................................... 34 function tests, repairs, and maintenance of electrical devices.
6.3.1 Configuring the current output ..............................................................................................................34 When operating the meter with combustible dusts, it is essential to comply with IEC 61241ff.
6.3.2 Configuration of the digital outputs .......................................................................................................34 The safety instructions for electrical apparatus in potentially explosive areas must be complied
6.4 Changing the type of protection ................................................................................................................... 36 with, in accordance with Directive 2014/34/EU (ATEX) and IEC60079-14 (Installation of
equipment in potentially explosive atmospheres).
7 Maintenance ....................................................................................................................................................... 37
To ensure safe operation, the requirements of EU Directive ATEX 118a (minimum requirements
7.1 General information ......................................................................................................................................37
concerning the protection of workers) must be met.
7.2 Replacing the transmitter or sensor .............................................................................................................38
7.2.1 Transmitter ............................................................................................................................................ 38
7.2.2 Flowmeter sensor .................................................................................................................................. 39 1.2 Technical limit values
8 Appendix ............................................................................................................................................................ 40 Particular attention must be paid to the limit values listed in the sections relating to "ex relevant
8.1 Approvals and certifications ......................................................................................................................... 40 specifications":
• The data for the signal inputs and outputs of the transmitter
• The permissible temperature data and limit values
1.3 Safety information for electrical installation

Never attempt electrical connection unless the power supply is switched off.
Ground the flowmeter sensor and transmitter housing. Make sure there is no risk of explosion.
Safety Device designs
1.4 Symbols and warnings 2 Device designs
DANGER – <Serious damage to health / risk to life> The devices are available in two series. ProcessMaster 300 / HygienicMaster 300 with basic
This symbol in conjunction with the signal word "Danger" indicates an imminent danger. functions and ProcessMaster 500 / HygienicMaster 500 with extended functions and options.
Failure to observe this safety information will result in death or severe injury. The series is identified by the fourth digit of the model number:
Model number / device series
DANGER – <Serious damage to health / risk to life>
This symbol in conjunction with the signal word "Danger" indicates an imminent electrical FEP3... ProcessMaster 300 FEP5... ProcessMaster 500
hazard. Failure to observe this safety information will result in death or severe injury. FEH3... HygienicMaster 300 FEH5... HygienicMaster 500
Devices suitable for use in potentially explosive atmospheres feature the corresponding Ex
WARNING – <Bodily injury> mark on their name plates.
This symbol in conjunction with the signal word “Warning“ indicates a possibly dangerous The design intended for use in Ex Zones 2, 21, and 22 is identified by the letter "M" in the
situation. Failure to observe this safety information may result in death or severe injury. model number, while the design intended for use in Zones 1 and 21 is identified by the letter
WARNING – <Bodily injury> "L".
This symbol in conjunction with the signal word "Warning" indicates a potential electrical Example:
hazard. Failure to observe this safety information may result in death or severe injury. FEP315-100A1S1D2B0A1A0M1A1C1, FEP325-100A1S1D2B0A1A1M1A0Y1,
FET325-1A0M1A1C1
CAUTION – <Minor injury>

2.1 Model with compact design
This symbol in conjunction with the signal word “Caution“ indicates a possibly dangerous
situation. Failure to observe this safety information may result in minor or moderate injury. The transmitter and the flowmeter sensor form a single mechanical entity.
This may also be used for property damage warnings.
IMPORTANT (NOTE)
NOTICE – <Property damage>!
For further information about the instruments' explosion protection approval please refer to the
The symbol indicates a potentially damaging situation.
Ex test certificates (available on the product CD or under www.abb.com/flow).
Failure to observe this safety information may result in damage to or destruction of the product
and/or other system components.
2.1.1 ATEX/IEC Zone 1
IMPORTANT (NOTE) ProcessMaster 300 / ProcessMaster 500 HygienicMaster 300 / HygienicMaster 500
This symbol indicates operator tips, particularly useful information, or important information FEP315.....L.... / FEP515.....L.... FEH315.....L.... / FEH515.....L....
about the product or its further uses. It does not indicate a dangerous or damaging situation. Zone 1, 21 Zone 1, 21
ATEX ATEX
Certificate: FM08ATEX0080 Certificate: FM08ATEX0080
DN3-300: II 2G Ex d e ia ma IIC T6 … T2 II 2G Ex d e ia ma IIC T6 … T2
>DN300 : II 2G Ex d e ia IIC T6 … T2
II 2 D Ex tD iaD A21 IP6X T70°C … Tmedium II 2 D Ex tD iaD A21 IP6X T70°C … Tmedium
IEC IEC
Certificate: FME08.0004 Certificate: FME08.0004
DN3-300: Ex d e ia ma IIC T6 … T2 Gb Ex d e ia ma IIC T6 … T2 Gb
>DN300 : Ex d e ia IIC T6 … T2 Gb
Ex tD iaD A21 IP6X T70°C … Tmedium Ex tD iaD A21 IP6X T70°C … Tmedium
Device designs Device designs
2.1.2 ATEX/IEC Zone 2 2.2.1 ATEX/IEC Zone 1
ProcessMaster 300 / ProcessMaster 500 HygienicMaster 300 / HygienicMaster 500 DANGER - Risk of explosion caused by incorrect transmitter installation
FEP315.....M.... / FEP515.....M.... FEH315.....M.... / FEH515.....M.... The FET321 / FET521 transmitter is not approved for hazardous areas.
Zones 2, 21, 22 Zones 2, 21, 22 The FET321 / FET521 transmitter must not be installed or operated in potentially explosive
atmospheres.
If the FEP325 flowmeter sensor is combined with the FET321 or FET325 transmitter (Zone 2),
the maximum permissible signal cable length is 50 m (164 ft) with a minimum conductivity of
5 µS/cm, without a pre-amplifier. The same is valid for the FEP525 flowmeter sensor with
FET521 or FET525 (Zone 2) transmitter.
ATEX ATEX If the FEP325 flowmeter sensor is combined with the FET325 transmitter (Zone 1), 10 m
Certificate: FM08ATEX0038, FM08ATEX0080 Certificate: FM08ATEX0038, FM08ATEX0080 (32.8 ft) signal cables are permanently connected to the transmitter. The same is valid for the
II 3 G Ex nA nC IIC T4 … T3 II 3 G Ex nA nC IIC T4 … T3 FEP525 flowmeter sensor with FET525 (Zone 1) transmitter.
II 2 D Ex tD A21 IP6X T70 °C … Tmedium II 2 D Ex tD A21 IP6X T70 °C … T medium
IEC IEC Flowmeter sensor
Certificate: FME08.0004 Certificate: FME08.0004 ProcessMaster 300 / ProcessMaster 500
Ex nA nC IIC T4 … T3 Ex nA nC IIC T4 … T3 FEP325.....L.... / FEP525.....L....
Ex tD A21 IP6X T70 °C … Tmedium Ex tD A21 IP6X T70 °C … Tmedium In Ex area, Zone 1, 21, 22
1) Single-compartment housing
2) Dual-compartment housing
2.2 Model with remount mount design

The transmitter is mounted in a separate location from the flowmeter sensor. The electrical
connection between the transmitter and flowmeter sensor may only be established using the ATEX
signal cable supplied. Certificate: FM08ATEX0080
DN3-300: II 2G Ex e ia ma IIC T6 … T2
>DN300: II 2G Ex e ia IIC T6 … T2
Signal cable II 2 D Ex tD iaD A21 IP6X T85 °C … Tmedium
Application D173D031U01 D173D027U01 IEC
Non-Ex. (< DN15) r a Certificate: FME08.0004
Non-Ex. (≥ DN15) a a DN3-300: Ex e ia ma IIC T6 … T2 Gb
>DN300 : Ex e ia IIC T6 … T2 Gb
Zone 2 / Div. 2 (< DN15) r a
Ex tD A21 IP6X T85 °C … T medium Gb
Zone 2 / Div. 2 (≥ DN15) a a
Transmitter
Zone 1 / Div. 1 In Ex area, Zone 1, 21, 22 In Ex area, Zone 2, 21, 22 Outside the Ex area
r a
(all nominal diameter) FET325.....L.... / FET525.....L.... FET325.....M.... / FET525.....M.... FET321 / FET521
r Application not permissible g Standard on delivery

a Application permissible
IMPORTANT (NOTE)
For further information about the instruments' explosion protection approval please refer to the
Ex test certificates (available on the product CD or under www.abb.com/flow). ATEX ATEX -
Certificate: FM08ATEX0080 Certificate: FM08ATEX0038, FM08ATEX0080 No Ex approval!
II 2 (2) G Ex d e [ia] IIC T6 II 3 G Ex nA nC T4
II 2 (2) D Ex tD [iaD] A21 IP6X T70°C II 2 D Ex tD A21 IP6X T70°C
IEC IEC
Certificate: FME08.0004 Certificate: FME08.0004
Ex d e [ia Gb] IIC T6 Gb Ex nA nC T4
Ex tD [iaD] A21 IP6X T70°C Ex tD A21 IP6X T70°C
2.2.2 ATEX/IEC Zone 2 2.3 Overview: The fast track to the device data
DANGER - Risk of explosion caused by incorrect transmitter installation These safety instructions related to explosion protection are valid in conjunction with the
The FET321 / FET521 transmitter is not approved for hazardous areas. following certificates:
The FET321 / FET521 transmitter must not be installed or operated in potentially explosive
atmospheres.
Validity area Certificates
Without a pre-amplifier, the maximum permissible signal cable length is 50 m (164 ft) with a ATEX FM08ATEX0038, FM08ATEX0080
minimum conductivity of 5 µS/cm. IEC FME08.0004
With a pre-amplifier, the maximum permissible signal cable length is 200 m (656 ft). NEPSI Cert No. GYJ091345
GOST
Flowmeter sensor Russia Ex certificate No. 8468478, GOST-R certificate No. 0634300
ProcessMaster 300 / ProcessMaster 500 HygienicMaster 300 / HygienicMaster 500 Kazakhstan Ex certificate No. 001032, GOST-K certificate No. 0025653
FEP325.....M.... / FEP525.....M.... FEH325.....M.... / FEH525.....M.... Ukraine Ex certificate No. 1093, DVSC certificate No. 1771
In Ex area, Zone 2, 21, 22 In Ex area, Zone 2, 21, 22 White Russia Ex certificate No. 05-687-2009, GGTN certificate No. 05-687-2009
Operation in Electrical connection Ex data

Model
zone Chapter
Zone1, 21 4.1.1 4.2 and 4.3

FEP315 or FEP515
ATEX ATEX Zones 2, 21, 22 5.1.1 5.2 and 5.3
Certificate: FM08ATEX0038, FM08ATEX0080 Certificate: FM08ATEX0038, FM08ATEX0080
II 3 G Ex nA IIC T6 … T3 II 3 G Ex nA IIC T6 … T3 FEP325 + FET325 Zone1, 21 4.1.1 4.2 and 4.3
II 2 D Ex tD A21 IP6X T85 °C … Tmedium II 2 D Ex tD A21 IP6X T85 °C … Tmedium or
FEP525 + FET525 Zones 2, 21, 22 5.1.1 5.2 and 5.3
IEC IEC
Certificate: FME08.0004 Certificate: FME08.0004 Zone1, 21 4.1.1 4.2 and 4.3
FEP325 + FET321
Ex nA IIC T6 … T3 Ex nA IIC T6 … T3
or
Ex tD A21 IP6X T85 °C … Tmedium Ex tD A21 IP6X T85 °C … Tmedium
FEP525 + FET521 Zones 2, 21, 22 5.1.1 5.2 and 5.3
Transmitter
(The flowmeter sensors illustrated above can be combined with the transmitters described Zone1, 21 4.1.1 4.2 and 4.3
below) FEH315 or FEH515
Zones 2, 21, 22 5.1.1 5.2 and 5.3
In Ex area, Zone 2, 21, 22 Outside the Ex area
FET325.....M.... / FET525.....M.... FET321 / FET521 FEH325 + FET325 Zone1, 21 4.1.1 4.2 and 4.3
or
FEH525 + FET525 Zones 2, 21, 22 5.1.1 5.2 and 5.3
FEH325 + FET321 Zone1, 21 4.1.1 4.2 and 4.3
or
FEH525 + FET521 Zones 2, 21, 22 5.1.1 5.2 and 5.3
ATEX - IMPORTANT (NOTE)

Certificate: FM08ATEX0038, FM08ATEX0080 No Ex approval! All documentation, declarations of conformity and certificates are available in ABB's download
II 3 G Ex nA nC T4 area.
II 2 D Ex tD A21 IP6X T70°C
www.abb.com/flow
IEC
Certificate: FME08.0004
Ex nA nC T4
Ex tD A21 IP6X T70°C
2.4 Name plate 2.4.2 Name plate for model with integral mount design (single-compartment housing)
2.4.1 Name plate for model with integral mount design (dual-compartment housing)
Fig. 1
1 Model number (for more detailed information about 17 Accuracy to which the unit was calibrated (e.g., 0.2% Fig. 2
the technical design, refer to the data sheet or the of rate) 15 Supply voltage
„A“ Name plate
order confirmation) 18 Version level (xx.xx.xx) 16 Year of manufacture
2 Order no. 19 Label indicating whether the unit is subject to the 1 Model number (for more detailed information about
17 Label indicating whether the unit is subject to the
3 Meter size and nominal pressure rating Pressure Equipment Directive (PED). the technical design, refer to the data sheet or the
Pressure Equipment Directive (PED).
4 Material: Flange/lining/electrode Information on the relevant fluid group. order confirmation)
Information on the relevant fluid group.
5 Tmed = maximum permissible fluid temperature Fluid group 1 = hazardous fluids, liquid, gaseous. 2 Order no.
Fluid group 1 = hazardous fluids, liquid, gaseous.
Tamb = maximum permissible ambient (Pressure Equipment Directive = PED). 3 Meter size and nominal pressure rating
(Pressure Equipment Directive = PED).
temperature If the pressure equipment is not subject to the 4 Tmed = maximum permissible fluid temperature
If the pressure equipment is not subject to the
6 Calibration value Qmax DN Pressure Equipment Directive 2014/68/EU, it is Tamb = maximum permissible ambient temperature Pressure Equipment Directive 2014/68/EU, it is
7 Calibration value Ss (span) classified in accordance with SEP (= sound 5 Protection type according to EN 60529 classified in accordance with SEP (= sound
Calibration value Sz (zero point) engineering practice) as per Art. 3 Para. 3 of the PED. 6 Calibration value Qmax DN engineering practice) as per Art. 3 Para. 3 of the
8 Communications protocol of transmitter If no such information is present, it means that the 7 Communications protocol of transmitter PED.
9 Excitation frequency of sensor coils device does not claim to comply with the requirements 8 Software version If no such information is present, it means that the
10 Software version of the Pressure Equipment Directive 2014/68/EU. 9 CE mark device does not claim to comply with the
11 Year of manufacture Water supplies and connected equipment accessories 10 Client-specific TAG number (if specified) requirements of the Pressure Equipment Directive
12 CE mark are classed as an exception in accordance with 11 Material: Flange/lining/electrode 2014/68/EU. Water supplies and connected
13 Serial number for identification by the manufacturer guideline 1/16 of Art. 1 Para. 3.2 of the Pressure 12 Excitation frequency of sensor coils equipment accessories are classed as an exception
14 Client-specific TAG number (if specified) Equipment Directive. 13 Supplementary information: EE = grounding in accordance with guideline 1/16 of Art. 1 Para. 3.2
15 Protection type according to EN 60529 20 Ex mark according to ATEX (example) electrodes, TFE = partial filling electrode of the Pressure Equipment Directive.
16 Supplementary information: EE = grounding 21 Ex mark according to IECEx (example) 14 Calibration value Ss (span)
electrodes, TFE = partial filling electrode Calibration value Sz (zero point)
Accuracy to which the unit was calibrated
IMPORTANT (NOTE) (e.g., 0.4% of rate)
Meters with 3A approval are labeled with an additional plate. „B“ Ex mark according to ATEX and IECEx „C“ Safety mark
(example)
IMPORTANT (NOTE)
Meters with 3A approval are labeled with an additional plate.
2.4.3 Name plate for model with remote mount design 2.4.4 Name plate for transmitter
Fig. 4: External transmitter, model: FET325 / FET525 for Zone 1 (dual-compartment housing)
1 Model number (for more detailed information about 5 Protection type according to EN 60529
Fig. 3: Remote mount design (external transmitter) the technical design, refer to the data sheet or the 6 Supply voltage
1 Model number (for more detailed information about 15 Excitation frequency of sensor coils order confirmation) 7 Communications protocol of transmitter
the technical design, refer to the data sheet or the 16 Label indicating whether the unit is subject to the 2 Order no. 8 Software version
order confirmation) Pressure Equipment Directive (PED). 3 Client-specific TAG number (if specified) 9 Version level (xx.xx.xx)
2 Order no. Information on the relevant fluid group. 4 Tamb = maximum permissible ambient temperature 10 Ex mark according to ATEX (example)
3 Meter size and nominal pressure rating Fluid group 1 = hazardous fluids, liquid, gaseous.
4 Material: Flange/lining/electrode (Pressure Equipment Directive = PED).
5 Client-specific TAG number (if specified) If the pressure equipment is not subject to the
6 Tmed = maximum permissible fluid temperature Pressure Equipment Directive 2014/68/EU, it is
Tamb = maximum permissible ambient temperature classified in accordance with SEP (= sound
engineering practice) as per Art. 3 Para. 3 of the PED.
7 Protection type according to EN 60529
If no such information is present, it means that the
8 Calibration value Qmax DN
device does not claim to comply with the requirements
9 Calibration value Ss (span)
of the Pressure Equipment Directive 2014/68/EU.
Calibration value Sz (zero point)
Water supplies and connected equipment accessories
10 Year of manufacture
are classed as an exception in accordance with
11 CE mark
guideline 1/16 of Art. 1 Para. 3.2 of the Pressure
12 Serial number for identification by the manufacturer
Equipment Directive.
13 Supplementary information: EE = grounding
17 Ex mark according to ATEX (example)
electrodes, TFE = partial filling electrode
18 Ex mark according to IECEx (example)
14 Accuracy to which the unit was calibrated
(e.g., 0.4% of rate)
IMPORTANT (NOTE)
Meters with 3A approval are labeled with an additional plate.
Fig. 5: External transmitter, model FET325 / FET525 for Zone 2 (dual-compartment housing)
1 Model number (for more detailed information about 5 Protection type according to EN 60529
the technical design, refer to the data sheet or the 6 Supply voltage
order confirmation) 7 Communications protocol of transmitter
2 Order no. 8 Software version
3 Client-specific TAG number (if specified) 9 Version level (xx.xx.xx)
4 Tamb = maximum permissible ambient temperature 10 Ex mark according to ATEX (example)
Device designs Mounting
3 Mounting
3.1 Information about opening and closing the housing
Fig. 7: Dual compartment housing - Cover safety device
Fig. 6: External transmitter, model FET325 / FET525 for Zone 2 (single-compartment housing)
„A“ Name plate 4 Tamb = maximum permissible ambient temperature
1 Model number (for more detailed information about 5 Communications protocol of transmitter
the technical design, refer to the data sheet or the 6 CE mark
order confirmation) 7 Client-specific TAG number (if specified)
2 Order no. 8 Protection type according to EN 60529
3 Supply voltage 9 Software version
„B“ Ex mark according to ATEX and IECEx „C“ Safety mark
(example)
Fig. 8: Single compartment housing
DANGER - Risk of explosion!

When the housing cover is open, the explosion protection is suspended.
Before opening the housing switch off the power to all connection lines and wait at least 20
minutes.
Dual compartment housing (Fig. 7)

Release the cover safety device by screwing in the Allen screw (1).
Before closing the housing make sure that the gasket (O-ring) for the housing cover is seated
correctly.
After closing the housing, lock the housing cover by unscrewing the Allen screw (1) to prevent
opening the cover accidentally.
Single compartment housing (Fig. 8)

Unscrew the Phillips-head screws (2) and remove the housing cover.
Mounting Mounting
3.2 Cable entries 3.3 High temperature version
The high temperature design allows for complete thermal insulation of the sensor, up to the
maximum illustrated device height.
The pipeline and sensor must be insulated after installing the unit according to the following
illustration.
The thermal resistance of the insulation must not exceed λ = 0.036 W/(mK); if it does, the
thickness of the insulation must be reduced accordingly.
Dual compartment housing Single compartment housing

Fig. 9
The cable glands (1) supplied are ATEX-/IECEx-certified.

Fig. 10
The black plugs (3) in the cable fittings are intended to provide protection during transport.
1 Insulation
Any unused cable entry points must be sealed prior to commissioning, using the seals (2)
supplied; these can be found in the terminal box. The surface temperature depends on the fluid temperature.
The use of standard cable fittings and seals is prohibited.
The outer diameter of the connecting cable must measure between 6 mm (0.24 in) and Model name Maximum surface temperature
12 mm (0.47 in) to ensure the necessary seal integrity.
FEP325 / FEH325
Make sure that the cable fittings and seals are correctly and tightly installed. T 85 °C (185 °F) ... Tmedium
FEP525 / FEH525
FEP315 / FEH315
Black cable fittings are installed by default when the device is supplied. If signal outputs are T 70 °C (158 °F) ... Tmedium
FEP515 / FEH515
connected to intrinsically safe circuits, we recommend that you replace the black caps on the
corresponding cable fittings with the blue ones supplied.
3.4 Protection class IP 68
IMPORTANT (NOTE) For installation, see the commissioning instruction.
In order to provide for the required temperature resistance, devices in low-temperature design
(optional, ambient temperature down to -40 °C (-40 °F) are delivered with a cable gland made
from metal.
When operating these devices on intrinsically safe current circuits, remove the metal cable
glands.
Mounting Mounting
3.5 Rotating the transmitter housing 3.6 Information about using the device in areas with combustible dust
The device with dual-compartment transmitter housing is approved for use in potentially
explosive areas (gas and dust).
The Ex certification is provided on the name plate.
DANGER - Risk of explosion!
The dust explosion protection is also provided by the housing.
Modifications to the housing are not allowed (e.g., removing or omitting parts).
3.6.1 Maximum Allowable Surface Temperature

Model name Maximum surface temperature
FEP325 / FEH325
T 85 °C (185 °F) ... Tmedium
FEP525 / FEH525
Dual compartment housing Single compartment housing FEP315 / FEH315
Fig. 11 T 70 °C (158 °F) ... Tmedium
FEP515 / FEH515
FET325 / FET525 T 70 °C (158 °F)
1. Loosen the Allen screws (3) on the front and back sides, but do not remove entirely.
2. Loosen screws (2) and rotate the transmitter housing (1) by 90° to the left or right.
The maximum surface temperature is applicable to dust layers of up to 5 mm (0.20 inch) in
3. Retighten screws (2) and Allen screws (3).
thickness. The minimum permissible ignition and smoldering temperatures of the dust
atmosphere should be calculated in accordance with IEC61241ff.
DANGER - Risk of explosion! With thicker dust layers, the maximum permissible surface temperature must be reduced. The
When the screws for the transmitter housing are loosened, the explosion protection is dust can be conductive or non-conductive. IEC61241ff must be observed.
suspended.
Tighten all screws (2, 3) for the transmitter housing prior to commissioning.
3.6.2 Minimum signal cable length
In explosion protection areas, the signal cable cannot be shorter than 5 m (16.4 ft).
Ex relevant specifications for operation in Zones 1, 21, and 22 Ex relevant specifications for operation in Zones 1, 21, and 22
4 Ex relevant specifications for operation in Zones 1, 21, and 22 4.1.2 Flowmeter sensor in zone 1 and transmitter in zone 2 or outside the hazardous area
4.1 Electrical connection FEP325 / FEP525 flowmeter sensor FET325 / FET525 transmitter FET321 / FET521 transmitter outside
(Zone 1) (Zone 2) the hazardous area
4.1.1 Flowmeter sensor and transmitter in zone 1 / Div. 1
A = Transmitter, B = Sensor
Fig. 12: HART, PROFIBUS PA and FOUNDATION fieldbus protocol
Ch ang e f ro m o ne to t wo co lum ns
Power supply connections Output connections

A = Transmitter, B = Sensor
AC power supply Terminal Function / Notes
Terminal Function / Notes 31 / 32 Current / HART output Fig. 13 HART, PROFIBUS PA and FOUNDATION fieldbus protocol
L Live / Phase The current output is available in "active" or "passive" Ch ang e f ro m o ne to t wo co lum ns
mode. The configuration must be specified ordering Power supply connections Output connections
N Neutral
PE / Protective earth (PE) the meter, because it is not possible to change the
configuration on site. AC power supply Terminal Function / Notes
97 / 98 Digital communication Terminal Function / Notes 31 / 32 Current / HART output
DC power supply The current output is available in "active" or "passive"
PROFIBUS PA (PA+ / PA-) or FOUNDATION L Live / Phase
Terminal Function / Notes mode.
fieldbus (FF+ / FF-) in acc. with IEC 61158-2. N Neutral
1+ + 97 / 98 Digital communication
51 / 52 Digital output DO1 passive PE / Protective earth (PE)
2- - Function can be configured locally as „Pulse Output" PROFIBUS PA (PA+ / PA-) or FOUNDATION
PE / Protective earth (PE) or „Digital Output". Factory setting is „Pulse Output". fieldbus (FF+ / FF-) in acc. with IEC 61158-2.
DC power supply
81 / 82 Digital input / contact input 51 / 52 Digital output DO1 active / passive
Terminal Function / Notes
Sensor cable terminal connections Function can be configured locally as „External Function can be configured locally as „Pulse Output"
1+ +
Only on remote mount design. output switch-off“, „external totalizer reset“, „external or „Digital Output". Factory setting is „Pulse Output".
2- -
totalizer stop“ or „other“. Only available in conjunction 81 / 82 Digital input / contact input
with current output „passive“. PE / Protective earth (PE)
Terminal Function / Notes Wire color Function can be configured locally as „External
M1 Magnet coil Brown 41 / 42 Digital output DO2 passive output switch-off“, „external totalizer reset“, „external
Function can be configured locally as „Pulse Output" Sensor cable terminal connections totalizer stop“ or „other“.
M2 Magnet coil Red
or „Digital Output". Factory setting is „Digital Output", Only on remote mount design. 41 / 42 Digital output DO2 passive
D1 Data line Orange
flow direction signaling. Function can be configured locally as „Pulse Output"
D2 Data line Yellow Terminal Function / Notes Wire color
PA Potential Equalization (PA) or „Digital Output". Factory setting is „Digital Output",
/ SE Shield - M1 Magnet coil Brown flow direction signaling.
E1 Signal line Violet M2 Magnet coil Red PA Potential Equalization (PA)
Note
1S Schield for E1 - The housing for the transmitter and flowmeter sensor must be D1 Data line Orange Functional ground
E2 Signal line Blue connected to the potential equalization PA. The operator must ensure D2 Data line Yellow (only with transmitter outside the hazardous area)
2S Schield for E2 - that when connecting the protective conductor (PE) no potential / SE Shield -
Measurement potential Green differences can occur between protective conductor and potential E1 Signal line Violet Note
3
equalization (PA). The housing for the transmitter and flowmeter sensor must be
1S Schield for E1 -
A temperature of 70 °C (158 °F) at the cable entry is assumed for the connected to the potential equalization PA. The operator must ensure
Ex calculations. Therefore, the cables used for the supply power and E2 Signal line Blue that when connecting the protective conductor (PE) no potential
the signal inputs and outputs must have a minimum specification of 2S Schield for E2 - differences can occur between protective conductor and potential
70 °C (158 °F). 3 Measurement potential Green equalization (PA).
A temperature of 70 °C (158 °F) at the cable entry is assumed for the
Ex calculations. Therefore, the cables used for the supply power and
the signal inputs and outputs must have a minimum specification of
70 °C (158 °F).
4.2 Electrical data for operation in zones 1, 21, 22 / Div. 1 4.2.2 Devices with PROFIBUS PA or FOUNDATION fieldbus
When operating in potentially explosive areas, observe the following electrical data for the signal inputs and outputs of the transmitter. For the
4.2.1 Devices with HART protocol correct design (PROFIBUS PA or FOUNDATION fieldbus), see the marking contained in the device's terminal box.
correct current output design (active/passive), see the marking contained in the device's terminal box. For devices in Zone 1 / Div. 1 the bus termination must conform to the FISCO model or the explosion protection regulations, respectively.
For devices in Zone 2 / Div. 2 the bus termination must conform to the FNICO model or the explosion protection regulations, respectively.
Dependent upon the device design, an "active" or a "passive" output will be available. For devices designed for use in Ex Zone 1, the current
output cannot be reconfigured locally. The configuration required for the current output (active/passive) must be specified when the order is
placed. Model: FEP315, FEH315 / FEP515, FEH515 or FET325 / FET525
Model: FEP315, FEH315 / FEP515, FEH515 or FET325 / FET525 The fieldbus and the digital output can be connected in zone 1 / Div. 1 in three different variants.
Operating values Type of protection Ex i, IS Variant 1: Intrinsically safe fieldbus connection in acc. with FISCO, intrinsically safe connection of the digital output
Inputs and outputs UN IN UO IO PO CO COPA LO
[V] [mA] [V] [mA] [mW] [nF] [nF] [mH] Operating values Type of protection Ex i, IS and FISCO
Active current / HART output (Terminals 31 / 32) 20 100 500 210 195 6 Inputs and outputs UN IN Ui Ii Pi Ci CiPA Li
Load: 250 Ω ≤ R ≤ 300 Ω [V] [mA] [V] [mA] [mW] [nF] [nF] [µH]
UI II PI CI CIPA LI
30 30 Passive digital output DO2 (terminals 41 / 42) 30 220 60 200 1) 5000 1) 3,6 3,6 0,17
[V] [mA] [mW] [nF] [nF] [mH]
60 425 4) 2000 4) 8,4 24 0,065 Fieldbus (terminals 97 / 98) 32 30 17 380 5320 1 1 5
Passive current / HART output (Terminals 31 / 32) UI II PI CI CIPA LI
Load: 250 Ω ≤ R ≤ 650 Ω 30 30 [V] [mA] [mW] [nF] [nF] [nH] 1) Intrinsically safe single-channel or multi-channel barriers (supply isolators) with resistance characteristic must be used.
60 500 4) 2000 4) 8,4 24 170
Passive digital output DO2 (Terminals 41 / 42) UI II PI CI CIPA LI Variant 2: Intrinsically safe fieldbus connection (not in acc. with FISCO!), intrinsically safe connection of the digital output
[V] [mA] [mW] [nF] [nF] [nH] Operating values Type of protection Ex i, IS
30 220
4251) 4) Inputs and outputs UN IN Ui Ii Pi Ci CiPA Li
60 2) 4)
2000 4) 3,6 3,6 170
500 [V] [mA] [V] [mA] [mW] [nF] [nF] [µH]
Passive digital output DO1 (Terminals 51 / 52) 4251) 4)
30 220 60 2000 4) 3,6 3,6 170 Passive digital output DO2 (terminals 41 / 42) 30 220 60 200 1) 5000 1) 3,6 3,6 0,17
5002) 4)
Passive digital input DI (Terminals 81/82)3) Fieldbus (terminals 97 / 98) 32 30 60 500 5000 1 1 5
30 10 60 500 4) 2000 4) 3,6 3,6 170
1) Intrinsically safe single-channel or multi-channel barriers (supply isolators) with resistance characteristic must be used.
1) For "active" current output
2) For "passive" current output Variant 3: Fieldbus connection in acc. with FNICO (Zone 2, Div. 2), connection of digital output (Zone 2, Div. 2)
3) Only available in conjunction with passive current output
4) Intrinsically safe single-channel or multi-channel barriers (supply isolators) with resistance characteristic must be used.
Operating values Type of protection Ex n, NI and FNICO
All inputs and outputs are electrically isolated from each other and from the power supply. Inputs and outputs UN IN Ui Ii Pi Ci CiPA Li
[V] [mA] [V] [mA] [mW] [nF] [nF] [µH]
Note Passive digital output DO2 (terminals 41 / 42) 30 220 - - - - - -
The output circuits are designed in such a way that they can be connected to both intrinsically-safe and non-intrinsically-safe circuits. It is not
permitted to combine intrinsically safe and non-intrinsically safe circuits. In the case of intrinsically safe circuits, potential equalization is Fieldbus (terminals 97 / 98) 32 30 60 500 1) 5000 1) 1 1 5
required.
The rated voltage of the non-intrinsically safe circuits is UM = 60 V. 1) Single-channel or multi-channel barriers (supply isolators) with resistance characteristic must be used.
Provided that rated voltage UM = 60 V is not exceeded if connections are established to non-intrinsically safe external circuits, intrinsic safety is
still guaranteed. All inputs and outputs are electrically isolated from each other and from the supply power.
If the installation is changed from type of protection "e" to "i" or vice versa, the device must be checked in accordance with the instructions Note
contained in section 6.4 "Changing the type of protection". The output circuits are designed in such a way that they can be connected to both intrinsically-safe and non-intrinsically-safe circuits. It is not
permitted to combine intrinsically safe and non-intrinsically safe circuits. In the case of intrinsically safe circuits, potential equalization is
required.
The rated voltage of the non-intrinsically safe circuits is UM = 60 V. Provided that rated voltage UM = 60 V is not exceeded if connections are
established to non-intrinsically safe external circuits, intrinsic safety is still given.
If the installation is changed from type of protection "e" to "i" or vice versa, the device must be checked in accordance with the instructions
contained in section 6.4 "Changing the type of protection".
4.3 Temperature data for operation in Zone 1 / Div. 1 Table 2: Fluid temperature (Ex data) for ProcessMaster models FEP315, FEP515
Model name Surface temperature Ambient temperature
FEP315 / FEH315 70 °C (158 °F) (- 40 °C)1) - 20 °C ... + 40 °C (- 40 °C)1) - 20 °C ... + 50 °C (- 40 °C)1) - 20 °C ... + 60 °C
FEP515 / FEH515
FEP325 / FEP525 85 °C (185 °F) Not thermally Thermally Not thermally Thermally Not thermally Thermally
insulated insulated insulated insulated insulated insulated
FET325 / FET525 70 °C (158 °F)
Gas & Gas & Gas & Gas & Gas & Gas &
Gas Gas Gas Gas Gas Gas
dust dust dust dust dust dust
The surface temperature depends on the fluid temperature.
With increasing fluid temperature > 70 °C (158 °F) or > 85 °C (185 °F) the surface temperature also increases to the level of the fluid NT 130 °C 90 °C 30 °C 80 °C 40 °C
T1
temperature. HT 180 °C 120 °C 20 °C 120 °C 20 °C
NT 130 °C 90 °C 30 °C 80 °C 40 °C
T2
Note HT 180 °C 120 °C 20 °C 120 °C 20 °C
The maximum permissible fluid temperature depends on the lining and flange material, and is limited by the operating values in Table 1 and the NT 130 °C 90 °C 30 °C 80 °C 40 °C
T3
explosion protection specifications in Tables 2 ... n. HT 180 °C 120 °C 20 °C 120 °C 20 °C
NT 120 °C 90 °C 30 °C 80 °C 40 °C
T4
HT 120 °C 120 °C 20 °C 120 °C 20 °C
Table 1: Fluid temperature as a function of lining and flange material
NT 85 °C 70 °C 30 °C 80 °C 40 °C
T5
Models FEP315 / FEP325, FEP515 / FEP525 HT 85 °C 85 °C 20 °C 85 °C 20 °C
Materials Fluid temperature (operating values) NT 70 °C 70 °C 30 °C 70 °C 40 °C
T6
HT 70 °C 70 °C 20 °C 70 °C 20 °C
Lining Flange Minimum Maximum
NT 130 °C 90 °C 30 °C 80 °C 40 °C
-10 °C (14 °F) 90 °C (194 °F) T1
Hard rubber Steel HT 180 °C 120 °C 20 °C 120 °C 20 °C
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
NT 130 °C 90 °C 30 °C 80 °C 40 °C
-15 °C (5 °F) 90 °C (194 °F) T2
Hard rubber Stainless steel HT 180 °C 120 °C 20 °C 120 °C 20 °C
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
NT 130 °C 90 °C 30 °C 80 °C 40 °C
Soft rubber Steel -10 °C (14 °F) 60 °C (140 °F) T3
HT 180 °C 120 °C 20 °C 120 °C 20 °C
Soft rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F)
NT 125 °C 90 °C 30 °C 80 °C 40 °C
PTFE Steel -10 °C (14 °F) 130 °C (266 °F) T4
HT 125 °C 120 °C 20 °C 120 °C 20 °C
PTFE Stainless steel -25 °C (-13 °F) 130 °C (266 °F)
NT 90 °C 90 °C 30 °C 80 °C 40 °C
PFA Steel -10 °C (14 °F) 180 °C (356 °F) T5
HT 90 °C 90 °C 20 °C 90 °C 20 °C
PFA Stainless steel -25 °C (-13 °F) 180 °C (356 °F)
NT 75 °C 75 °C 30 °C 75 °C 40 °C
Thick PTFE Steel -10 °C (14 °F) 180 °C (356 °F) T6
HT 75 °C 75 °C 20 °C 75 °C 20 °C
Thick PTFE Stainless steel -25 °C (-13 °F) 180 °C (356 °F)
ETFE Steel -10 °C (14 °F) 130 °C (266 °F) 1) Low-temperature version (option)
ETFE Stainless steel -25 °C (-13 °F) 130 °C (266 °F)
NT: standard sensor design, Tmedium maximum 130 °C (266 °F),
1) Only China production site
HT: high-temperature sensor design, Tmedium maximum 180 °C (356 °F)
Not thermally insulated: The flowmeter sensor is not surrounded by pipe insulation material.
Models FEH315, FEH515 Thermally insulated: The flowmeter sensor is surrounded by pipe insulation material.
Lining Process connection Material Fluid temperature (operating values)
Minimum Maximum Note
The standard version includes explosion protection for gases and dust. Explosion protection for dust is only available for devices featuring a
PFA Flange Stainless steel -25 °C (-13 °F) 180 °C (356 °F)
transmitter in a dual-compartment housing.
PFA Wafer type - -25 °C (-13 °F) 130 °C (266 °F)
• If the installation location for the device is classified as a potentially explosive area for gases and dust, the temperature data
PFA Variable process connection Stainless steel -25 °C (-13 °F) 130 °C (266 °F)
in the "Gas & dust" columns in the table must be taken into consideration.
• If the installation location for the device is classified as a potentially explosive area for gases only, the temperature data in
the "Gas" column in the table must be taken into consideration.
Table 3: Fluid temperature (Ex data) for ProcessMaster models FEP325, FEP525 Table 4: Fluid temperature (Ex data) for HygienicMaster models FEH315, FEH515
Ambient temperature Ambient temperature
(- 40 °C)1) - 20 °C ... + 40 °C (- 40 °C)1) - 20 °C ... + 50 °C (- 40 °C)1) - 20 °C ... + 60 °C (- 40 °C)1) - 20 °C ... + 40 °C (- 40 °C)1) - 20 °C ... + 50 °C (- 40 °C)1) - 20 °C ... + 60 °C
Not thermally Thermally Not thermally Thermally Not thermally Thermally Not thermally Thermally Not thermally Thermally Not thermally Thermally
insulated insulated insulated insulated insulated insulated insulated insulated insulated insulated insulated insulated
Gas & Gas & Gas & Gas & Gas & Gas & Gas & Gas & Gas & Gas & Gas & Gas &
Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas Gas
dust dust dust dust dust dust dust dust dust dust dust dust
NT 130 °C 110 °C 110 °C 110 °C 110 °C NT 130 °C 110 °C 20 °C 80 °C 40 °C
T1 T1
HT 180 °C 160 °C 150 °C 160 °C 150 °C HT 180 °C 120 °C 20 °C 120 °C 20 °C
NT 130 °C 110 °C 110 °C 110 °C 110 °C
T2 NT 130 °C 110 °C 20 °C 80 °C 40 °C
HT 180 °C 160 °C 150 °C 160 °C 150 °C T2
NT 130 °C 110 °C 110 °C 110 °C 110 °C HT 180 °C 120 °C 20 °C 120 °C 20 °C
T3
HT 180 °C 160 °C 150 °C 160 °C 150 °C NT 130 °C 110 °C 20 °C 80 °C 40 °C
T3
NT 120 °C 110 °C 110 °C 110 °C 110 °C HT 180 °C 120 °C 20 °C 120 °C 20 °C
T4
HT 120 °C 120 °C 120 °C 120 °C 120 °C NT 120 °C 110 °C 20 °C 80 °C 40 °C
NT 85 °C 85 °C 85 °C 85 °C 85 °C T4
T5 HT 120 °C 120 °C 20 °C 120 °C 20 °C
HT 85 °C 85 °C 85 °C 85 °C 85 °C
NT 70 °C 70 °C 70 °C 70 °C 70 °C NT 85 °C 85 °C 20 °C 80 °C 40 °C
T6 T5
HT 70 °C 70 °C 70 °C 70 °C 70 °C HT 85 °C 85 °C 20 °C 85 °C 20 °C
NT 130 °C 110 °C 110 °C 110 °C 110 °C NT 70 °C 70 °C 20 °C 70 °C 40 °C
T1 T6
HT 180 °C 160 °C 150 °C 160 °C 150 °C HT 70 °C 70 °C 20 °C 70 °C 20 °C
NT 130 °C 110 °C 110 °C 110 °C 110 °C
T2
HT 180 °C 160 °C 150 °C 160 °C 150 °C 1) Low-temperature version (option)
NT 130 °C 110 °C 110 °C 110 °C 110 °C
T3
HT 180 °C 160 °C 150 °C 160 °C 150 °C NT standard version, Tmedium maximum 130 °C (266 °F).
NT 125 °C 110 °C 110 °C 110 °C 110 °C
T4 HT high temperature version, Tmedium maximum 180 °C (356 °F).
HT 125 °C 125 °C 125 °C 125 °C 125 °C
NT 90 °C 90 °C 90 °C 90 °C 90 °C Not thermally insulated: The flowmeter sensor is not surrounded by pipe insulation material.
T5 Thermally insulated: The flowmeter sensor is surrounded by pipe insulation material.
HT 90 °C 90 °C 90 °C 90 °C 90 °C
NT 75 °C 75 °C 75 °C 75 °C 75 °C
T6 Note
HT 75 °C 75 °C 75 °C 75 °C 75 °C
1) Low-temperature version (option) transmitter in a dual-compartment housing.
• If the installation location for the device is classified as a potentially explosive area for gases and dust, the temperature data in the "Gas &
NT: standard sensor design, Tmedium maximum 130 °C (266 °F). dust" columns in the table must be taken into consideration.
HT: high-temperature sensor design, Tmedium maximum 180 °C (356 °F). • If the installation location for the device is classified as a potentially explosive area for gases only, the temperature data in the "Gas" column
Not thermally insulated: The flowmeter sensor is not surrounded by pipe insulation material. in the table must be taken into consideration.
Thermally insulated: The flowmeter sensor is surrounded by pipe insulation material.
Note
The standard version includes explosion protection for gases and dust.
the "Gas" columns in the table must be taken into consideration.
Ex relevant specifications for operation in zones 2, 21 and 22 Ex relevant specifications for operation in zones 2, 21 and 22
5 Ex relevant specifications for operation in zones 2, 21 and 22 5.2 Electrical data for operation in zones 2, 21, 22 / Div. 2
5.1 Electrical connection 5.2.1 Devices with HART protocol
5.1.1 Flowmeter sensor and transmitter in zone 2, or transmitter outside the hazardous area correct current output design (active/passive), see the marking contained in the device's terminal box.
FEP315 / FEP515, FEH315 / FEH515, FEP325 / FEP525, FEH325 / FEH525 flowmeter FET321 / FET521 transmitter outside the
sensors and FET325 / FET525 transmitters (Zone 2) hazardous area Model: FEP315, FEH315 / FEP515, FEH515 or FET325 / FET525
Operating values Type of protection Ex n/NI
Signal inputs and outputs Ui [V] Ii [mA] Ui [V] Ii [mA]
Current / HARToutput, active/passive (terminals 31/32)
30 30 30 30
Load: 250 Ω ≤ R ≤ 650 Ω
Digital output DO1, active/passive (terminals 51/52) 30 220 30 220
Digital output DO2, passive (terminals 41/42) 30 220 30 220
Digital input DI (terminals 81/82) 30 10 30 10
All inputs and outputs are electrically isolated from each other and from the supply power.
5.2.2 Devices with PROFIBUS PA or FOUNDATION fieldbus

correct design (PROFIBUS PA or FOUNDATION fieldbus), see the marking contained in the device's terminal box.
For devices in Zone 2 / Div. 2 the bus termination must conform to the FNICO model or the explosion protection regulations, respectively.
Model: FEP315, FEH315 / FEP515, FEH515 or FET325 / FET525

Operating values Type of protection Ex n, NI and FNICO
Inputs and outputs UN IN Ui Ii Pi Ci CiPA Li
A = Transmitter, B= Sensor
[V] [mA] [V] [mA] [mW] [nF] [nF] [µH]
Fig. 14: HART, PROFIBUS PA and FOUNDATION fieldbus protocol
Digital output DO2, passive (terminals 41/42) 30 220 - - - - - -
Power supply connections Output connections Fieldbus (terminals 97/98) 32 30 32 500 1) 7000 1) 1 1 5
AC power supply Terminal Function / Notes
1) Single-channel or multi-channel barriers (supply isolators) with resistance characteristic must be used.
Terminal Function / Notes 31 / 32 Current / HART output
L Live / Phase The current output is available in "active" or "passive"
N Neutral mode. 5.3 Temperature data for operation in Zone 2 / Div. 2
PE / Protective earth (PE) 97 / 98 Digital communication
Model name Surface temperature
PROFIBUS PA (PA+ / PA-) or FOUNDATION
fieldbus (FF+ / FF-) in acc. with IEC 61158-2. FEP315 / FEH315 70 °C (158 °F)
DC power supply FEP515 / FEH515
51 / 52 Digital output DO1 active / passive
Terminal Function / Notes
Function can be configured locally as „Pulse Output" FEP325 / FEH325 85 °C (185 °F)
1+ +
or „Digital Output". Factory setting is „Pulse Output". FEP525 / FEH525
2- -
81 / 82 Digital input / contact input FET325 / FET525 70 °C (158 °F)
PE / Protective earth (PE) Function can be configured locally as „External
output switch-off“, „external totalizer reset“, „external
Sensor cable terminal connections totalizer stop“ or „other“. The surface temperature depends on the fluid temperature.
Only on remote mount design. With increasing fluid temperature > 70 °C (> 158 °F) or > 85 °C (> 185 °F) the surface temperature also increases to the level of the fluid
41 / 42 Digital output DO2 passive
temperature.
Function can be configured locally as „Pulse Output"
Terminal Function / Notes Wire color or „Digital Output". Factory setting is „Digital Output",
M1 Magnet coil Brown flow direction signaling. Note
The maximum permissible fluid temperature depends on the lining and flange material, and is limited by the operating values in Table 1 and the
M2 Magnet coil Red PA Potential Equalization (PA)
explosion protection specifications in Tables 2 ... n.
D1 Data line Orange Functional ground
D2 Data line Yellow (only for transmitter outside the hazardous area)
/ SE Shield -
E1 Signal line Violet Note
1S Schield for E1 - The housing for the transmitter and flowmeter sensor must be
connected to the potential equalization PA. The operator must ensure
E2 Signal line Blue that when connecting the protective conductor (PE) no potential
2S Schield for E2 - differences can occur between protective conductor and potential
3 Measurement potential Green equalization (PA).
A temperature of 70 °C (158 °F) at the cable entry is assumed for the
Ex calculations. Therefore, the cables used for the supply power and
the signal inputs and outputs must have a minimum specification of
70 °C (158 °F).
Ex relevant specifications for operation in zones 2, 21 and 22 Ex relevant specifications for operation in zones 2, 21 and 22
Table 1: Fluid temperature as a function of lining and flange material Table 3: Fluid temperature (Ex data) for ProcessMaster models FEP325, FEP525 and HygienicMaster models FEH325,
Models FEP315 / FEP325, FEP515 / FEP525 FEH525
Materials Fluid temperature (operating values) Ambient temperature
Lining Flange Minimum Maximum - 20 °C ... + 40 °C - 20 °C ... + 50 °C - 20 °C ... + 60 °C
-10 °C (14 °F) 90 °C (194 °F) - 40 °C ... + 40 °C 1) - 40 °C ... + 50 °C 1) - 40 °C ... + 60 °C 1)
Hard rubber Steel
-5 °C (23 °F) 1) 80 °C (176 °F) 1) Not thermally Thermally Not thermally Thermally Not thermally Thermally
-15 °C (5 °F) 90 °C (194 °F) insulated insulated insulated insulated insulated insulated
Hard rubber Stainless steel
-5 °C (23 °F) 1) 80 °C (176 °F) 1)
Soft rubber Steel -10 °C (14 °F) 60 °C (140 °F) Gas & Gas & Gas & Gas & Gas & Gas &
dust dust dust dust dust dust
Soft rubber Stainless steel -15 °C (5 °F) 60 °C (140 °F)
PTFE Steel -10 °C (14 °F) 130 °C (266 °F) 110 °C 2)
NT 130 °C 130 °C --- --- 130 °C 130 °C --- --- 110 °C --- ---
PTFE Stainless steel -25 °C (-13 °F) 130 °C (266 °F) T1 120 °C 3)
PFA Steel -10 °C (14 °F) 180 °C (356 °F) HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C
PFA Stainless steel -25 °C (-13 °F) 180 °C (356 °F)
110 °C 2)
Thick PTFE Steel -10 °C (14 °F) 180 °C (356 °F) NT 130 °C 130 °C --- --- 130 °C 130 °C --- --- 110 °C --- ---
T2 120 °C 3)
Thick PTFE Stainless steel -25 °C (-13 °F) 180 °C (356 °F)
ETFE Steel -10 °C (14 °F) 130 °C (266 °F) HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C
ETFE Stainless steel -25 °C (-13 °F) 130 °C (266 °F) 110 °C 2)
NT 130 °C 130 °C --- --- 130 °C 130 °C --- --- 110 °C --- ---
T3 120 °C 3)
1) Only China production site
HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C
110 °C 2)
Models FEH315 / FEH325, FEH515 / FEH525 NT 130 °C 130 °C --- --- 130 °C 130 °C --- --- 110 °C --- ---
T4 120 °C 3)
Lining Process connection Material Fluid temperature (operating values) HT 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C
Minimum Maximum NT 95 °C 95 °C --- --- 95 °C 95 °C --- --- 95 °C 95 °C --- ---
PFA Flange Stainless steel -25 °C (-13 °F) 180 °C (356 °F) T5
HT 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C 95 °C
PFA Wafer type - -25 °C (-13 °F) 130 °C (266 °F)
NT 80 °C 80 °C --- --- 80 °C 80 °C --- --- 80 °C 80 °C --- ---
PFA Variable process connection Stainless steel -25 °C (-13 °F) 130 °C (266 °F) T6
HT 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C 80 °C
Table 2: Fluid temperature (Ex data) for ProcessMaster models FEP315, FEP515 and HygienicMaster models FEH315, 1) Low-temperature version (option)
FEH515 2) Temperature values for ProcessMaster
3) Temperature values for HygienicMaster
Ambient temperature
- 20 °C ... + 40 °C - 20 °C ... + 50 °C - 20 °C ... + 60 °C NT: standard sensor design, Tmedium maximum 130 °C (266 °F)
- 40 °C ... + 40 °C 1) - 40 °C ... + 50 °C 1) - 40 °C ... + 60 °C 1) HT: high-temperature sensor design, Tmedium maximum 180 °C (356 °F)
Not thermally Thermally Not thermally Thermally Not thermally Thermally Not thermally insulated: The flowmeter sensor is not surrounded by pipe insulation material.
insulated insulated insulated insulated insulated insulated Thermally insulated: The flowmeter sensor is surrounded by pipe insulation material.
Gas & Gas & Gas & Gas & Gas & Gas & Note
dust dust dust dust dust dust The standard version includes explosion protection for gases and dust.
100 °C 2) • If the installation location for the device is classified as a potentially explosive area for gases and dust, the temperature data
NT 130 °C 130 °C --- --- 130 °C --- --- 80 °C 40 °C --- --- in the "Gas & dust" columns in the table must be taken into consideration.
T1 110 °C 3)
HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 40 °C 180 °C 40 °C • If the installation location for the device is classified as a potentially explosive area for gases only, the temperature data in
the "Gas" columns in the table must be taken into consideration.
100 °C 2)
NT 130 °C 130 °C --- --- 130 °C --- --- 80 °C 40 °C --- ---
T2 110 °C 3)
HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 40 °C 180 °C 40 °C
100 °C 2)
NT 130 °C 130 °C --- --- 130 °C --- --- 80 °C 40 °C --- ---
T3 110 °C 3)
HT 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 180 °C 40 °C 180 °C 40 °C
100 °C 2)
NT 130 °C 130 °C --- --- 130 °C --- --- 80 °C 40 °C --- ---
T4 110 °C 3)
HT 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 130 °C 40 °C 130 °C 40 °C
1) Low-temperature version (option)

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

HT: high-temperature sensor design, Tmedium maximum 180 °C (356 °F)
Not thermally insulated: The flowmeter sensor is not surrounded by pipe insulation material.
Thermally insulated: The flowmeter sensor is surrounded by pipe insulation material.
Note
transmitter in a dual-compartment housing.
the "Gas" column in the table must be taken into consideration.
Commissioning Commissioning
6 Commissioning 6.3 Special features of version designed for operation in Ex zone 1 / Div. 1
6.1 Preliminary checks prior to start-up 6.3.1 Configuring the current output
The following points must be checked before commissioning: For devices designed for use in Ex Zone 1 / Div.1, the current output cannot be reconfigured
• The supply power must be switched off. subsequently.
• The supply power must match information on the name plate. The configuration required for the current output (active/passive) must be specified when the
order is placed.
• The pin assignment must correspond to the connection diagram.
For the correct current output design (active/passive), see the marking contained in the device's
• Sensor and transmitter must be grounded properly. terminal box.
• The temperature limits must be observed.
• The sensor must be installed at a largely vibration-free location.
6.3.2 Configuration of the digital outputs
• The housing cover and its safety locking device must be sealed before switching on the
supply power. For version designed for operation in Ex zone 1 / Div. 1, the digital outputs DO1 (51/52) and
DO2 (41/42) can be configured on a NAMUR switching amplifier. On leaving the factory, the
• For devices with remote mount design and an accuracy of 0.2 % of rate make sure that the device is configured with the standard wiring (non-NAMUR).
flowmeter sensor and the transmitter match correctly.
For this purpose, the final characters X1, X2, etc. are printed on the name plates of the Devices with PROFIBUS PA or FOUNDATION fieldbus only have the digital output
flowmeter sensors, whereas the transmitters are identified by the final characters Y1, Y2, DO2 (41 / 42).
etc.
Devices with the end characters X1 / Y1 or X2 / Y2, etc. fit with each other.
Important (Note)
The outputs' type of protection remains unaffected by this. The devices connected to these
• Any unused connections must be sealed in accordance with IEC 60079 prior to outputs must conform to the applicable regulations for explosion protection.
commissioning using the plugs supplied.
IMPORTANT (NOTE)
Commissioning and operation must be performed in accordance with ATEX 137 or BetrSichV
(EN60079-14). Only properly trained personnel are authorized to carry out commissioning in
Ex areas.
6.2 Notes on combining the FEP325 flowmeter sensor with the FET325 transmitter or the FEP525
flowmeter sensor with the FET525 transmitter
Fig. 15:
When combining the FEP325 flowmeter sensor with the FET325 transmitter, you must ensure
that the flowmeter sensor is assigned to the transmitter correctly.
The same is valid for combining the FEP525 flowmeter sensor with the FET525 transmitter.
The flowmeter sensor is identified by means of the suffix (X01, X02, etc.) that forms part of the
order number on the name plate.
The associated transmitter is identified by means of the suffix (Y01, Y02, etc.) that forms part of
the order number on the name plate.
Commissioning Commissioning
6.4 Changing the type of protection
The jumpers are located on the backplane in the transmitter housing.
Models FEP315 / FEP515, FEH315 / FEH515, FEP325 / FEP525, FET325 / FET525 can
provide various types of protection during operation:
• When connected to an intrinsically safe circuit in Zone 1, operated as an intrinsically safe
device (Ex ia)
• When connected to a non-intrinsically safe circuit in Zone 1, operated as a device with a
flameproof enclosure (Ex d)
• When connected to a non-intrinsically safe circuit in Zone 2, operated as a non-sparking
device (Ex nA)
If a device which is already operational is required to provide a different type of protection, the
following measures must be implemented/insulation checks must be performed in accordance
with IEC 60079-ff.
A subsequent change of the type of protection is the sole responsibility of the operator.
No. 1. Type of protection 2. Type of protection Required step/check

1 Zone 1: Zone 1: • Switch off supply power.
Ex d, non-intrinsically safe Intrinsically safe circuits Use 500 VAC or 710 VDC to take the following
circuits measurements for one minute:
Jumper terminals 31/32, 41/42, 51/52, 81/82.
Then measure all jumpers (A,B,C,D) against one
another.
HART protocol PROFIBUS PA

FOUNDATION fieldbus
Fig. 16
BR902 for digital output DO1 BR901 for digital output DO2 • Switch off supply power.
BR902 in position 1: Standard (non-NAMUR) BR901 in position 1: Standard (non-NAMUR) Use 500 VAC or 710 VDC to take the following
BR902 in position 2: NAMUR BR901 in position 2: NAMUR measurements for one minute:
Jumper terminals 31/32, 41/42, 51/52, 81/82.
Configure the digital outputs as described: Then measure against the housing.
1. Switch off the supply power and wait at least 20 minutes before the next step.
2. Open the cover safety device (4) and housing cover (1).
3. Loosen screws (3) and pull out transmitter plug-in (2).
4. Insert the jumpers in the required positions.
5. Put the transmitter plug-in (2) back into the housing and retighten the screws (3). • Visual inspection
6. Close the housing cover (1) and lock the cover by unscrewing the screw (4). Zone 2: • Special precautions/checks are not necessary.
Non-sparking (nA)
2 Zone 1: Zone 1: • Visual inspection (no damage to the threads of
Intrinsically safe circuits Ex d, non-intrinsically the cover or the cable fittings)
safe circuits
Zone 2: • Special precautions/checks are not necessary.
Non-sparking (nA)
3 Zone 2: Zone 1: • Perform the checks described under No. 1.
Non-sparking (nA) Intrinsically safe circuits
Zone 1: • Visual inspection (no damage to the threads of
Ex d, non-intrinsically the cover or the cable fittings)
safe circuits
Maintenance Maintenance
7 Maintenance 7.2 Replacing the transmitter or sensor
7.1 General information IMPORTANT (NOTE)
Repair and maintenance activities may only be performed by authorized customer service • When replacing the transmitter or flowmeter sensor make sure that they are assigned
personnel. correctly. It is not possible to operate a flowmeter sensor of the 300 series with a
transmitter of the 500 series. The series (e.g., ProcessMaster 300 or ProcessMaster 500)
When replacing or repairing individual components, original spare parts must be used. is shown on the name plate of the transmitter or flowmeter sensor.
• After replacing the transmitter, the system data must be reimported according to
DANGER - Risk of explosion! information in the operating instruction (see the chapter "Downloading the system data").
When the housing cover is open, the explosion protection is suspended.
Before opening the housing switch off the power to all connection lines and wait at least 20 7.2.1 Transmitter
minutes.
Transmitter with dual-compartment housing
WARNING – Electrical voltage risk!
When the housing is open, EMC protection is impaired and protection against contact is
suspended.
Before opening the housing, switch off power to all connecting cables for the device.
NOTICE - Potential damage to parts

The electronic components of the printed circuit board can be damaged by static electricity
(observe ESD guidelines).
Make sure that the static electricity in your body is discharged before touching electronic
components.
IMPORTANT (NOTE)
Users must also observe the information in the operating and commissioning instruction for
the device.
Transmitter with single-compartment housing

Fig. 17
Replace the transmitter plug-in as follows:
2. Release the cover safety device (4) and housing cover (1).
3. Loosen screws (3) and pull out transmitter plug-in (2).
4. Replace transmitter plug-in and retighten screws (3).
5. Close the housing cover (1) and lock the cover by unscrewing the screw (4).
Maintenance Appendix
7.2.2 Flowmeter sensor 8 Appendix
8.1 Approvals and certifications
The version of the meter in your possession meets the requirements of the
CE mark
following European directives:
- EMC directive 2014/30/EU
- Low voltage directive 2014/35/EU
- RoHS Directive 2011/65/EU
- Pressure equipment directive (PED) 2014/68/EU
- ATEX directive 2014/34/EU
Fig. 18 Explosion Identification for intended use in potentially explosive atmospheres according
Replace the flowmeter sensor as follows: Protection to:
2. Open the cover safety device (4) and housing cover (1). - ATEX directive (marking in addition to CE marking)
3. Disconnect the signal cable (if necessary, remove the sealing compound).
4. Install the new sensor according to the installation instructions.
5. Complete the electrical connection according to the connection diagram. - IEC standards
6. Close the housing cover (1) and lock the cover by unscrewing the screw (3).
- FM Approvals (US)
- cFM Approvals (Canada)
- NEPSI (China)
- GOST
IMPORTANT (NOTE)
All documentation, declarations of conformity and certificates are available in ABB's download
area.
www.abb.com/flow
A
ABB has Sales & Customer Support expertise in over 100 The Company’s policy is one of continuous product
countries worldwide. improvement and the right is reserved to modify the
information contained herein without notice.
www.abb.com/flow
Printed in the Fed. Rep. of Germany (08.2017)
© ABB 2017
3KXF231300R4801
ABB Limited ABB Inc. ABB Automation Products GmbH ABB Engineering (Shanghai) Ltd.
Measurement & Analytics Measurement & Analytics Measurement & Analytics Measurement & Analytics
Howard Road, St. Neots 125 E. County Line Road Dransfelder Str. 2 No. 4528, Kangxin Highway, Pudong New District
Cambridgeshire, PE19 8EU Warminster, PA 18974 37079 Goettingen Shanghai, 201319,
UK USA Germany P.R. China
Tel: +44 (0) 870 600 6122 Tel: +1 215 674 6000 Tel: +49 551 905-0 Tel: +86(0) 21 6105 6666
Fax: +44 (0)1480 213 339 Fax: +1 215 674 7183 Fax: +49 551 905-777 Fax: +86(0) 21 6105 6677
Mail: enquiries.mp.uk@gb.abb.com Mail: vertrieb.messtechnik- Mail: china.instrumentation@cn.abb.com
produkte@de.abb.com
22/7/2019 HN 2140
TRO MONITORS
OWNER’S MANUAL
Chlorine and Total Residual Oxidant Monitor
For Use in Hazardous Environments
And Extended Reagent Life
Model A28031
HF scientific
3170 Old Metro Parkway
Ft. Myers, FL 33916
Phone: 239-337-2116
Toll Free: 888-203-7248
Fax: 239-332-7643
Email:hf.info@wattswater.com
Website: www.hfscientific.com
Catalog No 29146
Rev 1.94 (4/18)
Table of Contents
Section Page
Specifications ....................................................................................................1
DECLARATION OF CONFORMITY
1.0 Overview ...........................................................................................................2
Ex px IIC T4 Gb 0°C ≤ Ta ≤ 55°C 1.1 Unpacking and Inspection of the Instrument and Accessories .............2
IECEx Certificate #IECEx LC 14.0005 1.2 The Display ...........................................................................................3
To the following standards: 1.3 The Touch Pad ......................................................................................3
1.4 Orientation ............................................................................................4
Explosive Atmospheres – Part 0: Equipment – General Requirements, IEC 60079-0: 20011
Explosive Atmospheres –Part 2: Equipment Protection by Pressurized Enclosure “p”, IEC 60079-2: 2007-02 2.0 Safety .................................................................................................................5
2.1 Symbols Used In CLX-Ex .....................................................................5
Emissions & Immunity – Tested and passed EN61326: 2006 2.2 Use in Explosive Environments Safety..................................................5
3.0 Theory of Operation ........................................................................................6

Manufacturer’s Name: HF scientific inc. 3.1 The Measurement...................................................................................6
3.2 The Air Sentinel Controller ...................................................................7
Manufacturer’s Address: 3170 Old Metro Parkway, Fort Myers, Florida 33916-7597 3.3 Remote Standby ....................................................................................8
3.4 The Reagents .........................................................................................8
Importer’s Name: 3.5 The Reagent Cooler ..............................................................................8
Importer’s Address: 4.0 Installation and Commissioning ....................................................................9

4.1 Mounting & Site Selection.....................................................................9
Type of Equipment: TRO Monitor 4.2 Plumbing ............................................................................................10
4.3 Air Supply ..........................................................................................10
Model: CLX-Ex 4.4 Electrical Connections ........................................................................11
4.4.1 RS-485 ...................................................................................11
I, the undersigned, hereby declare that the equipment specified above conforms to the above Directive and 4.4.2 Relay ......................................................................................11
Standard 4.4.3 4-20 mA ..................................................................................12
4.4.4 Remote Standby Connections ..................................................12
4.4.5 RS-485/4-20 mA cable Ferrite .................................................12
Place: Fort Myers, Florida USA 4.5 Installing Reagents ..............................................................................12
(Signature)
Date: 1 January 2015 Mike Trammell, 5.0 Purge Air Sentinel Controller Operation ...................................................13
Vice President of Product Development, 5.1 Start Up ...............................................................................................13
Watts Water Quality 5.2 Indicator Lamps ...................................................................................13
5.3 Maintenance Bypass Operation ...........................................................14
6.0 Operation .......................................................................................................15

6.1 Routine Measurement .........................................................................15
6.2 Routine Measurement with Remote Standby ......................................15
6.3 Security Access Feature .......................................................................16
6.4 The White LED ....................................................................................17
7.0 Instrument Calibration ................................................................................18

7.1 Slope (gain) Calibration Procedure .....................................................18
7.2 Zero (offset) Calibration Procedure ....................................................19
7.3 Restore Factory Settings ......................................................................19
Catalog #29146 (4/18)

REV 1.94
Table of Contents (continued)
Section Page
8.0 Instrument Configuration (CONFIG mode) ...............................................20 Specifications

8.1 Setting the 4-20 mA .............................................................................20 Measurement Range 0.00 – 10.00 mg/L (PPM)
8.2 Configuring the Error Level.................................................................21 ±5% of reading or ±0.03 mg/L (PPM) whichever is greater for range of
Accuracy
8.3 Configuring the RS-485 Port ..............................................................21 0-6.0 mg/L(PPM) ±10% of reading from 6.01-10.00 mg/L (PPM)
8.4 Configuring the Alarm .........................................................................21
8.4.1 Alarm1 .....................................................................................22 Resolution 0.01 mg/L (PPM)
8.5 Enabling the Security Access...............................................................22
Cycle Time Adjustable; 60 seconds to 10 minutes (600 seconds)
8.6 Extended Settings.................................................................................22
8.7 Units of Measurement ..........................................................................23 Display Multi-Line Liquid Crystal Backlit Display
8.8 Averaging and Filtering .......................................................................23
Alarms One NO relay contact 120-240VAC 2A
8.9 LCD Backlight Brightness ...................................................................23
8.10 RS- 485 Parameters..............................................................................24 Analog Output Powered 4-20 mA, 600 W drive, isolated
8.11 Cycle Time ..........................................................................................24
Communications Port Bi-directional RS-485 with Modbus
8.12 Water Conservation ............................................................................24
8.13 4 mA Adjustment .................................................................................25 Water Pressure Integral pressure regulator 0.34 bar (5.0 PSI) to 10.3 bar (150 PSI.)
8.14 20 mA Adjustment ...............................................................................25 200 – 400 ml/min.
Flow Rate to Waste
9.0 Additional Features and Options ................................................................26 Operating Temperature 0°C – 55°C (32°F – 131°F)
9.1 RS-485 Output .....................................................................................26 Wetted Materials ®
PVC, Borosilicate Glass, Reslyn (FFKM), Viton (FKM),
9.1.1 Simple Communication ...........................................................26 ®
9.1.2 Modbus Communication ..........................................................26 Polypropylene, 316 Stainless Steel, Acetal, Noryl , Silicone
9.2 Remote Panel Meter .............................................................................26 Sample Temperature Range 0°C – 55°C (32°F – 131°F)
10.0 Troubleshooting .............................................................................................27 Power Supply 100 to 240VAC, 47-63 Hz, 250VA
10.1 CLX-Ex Fault Detection ......................................................................27 Insulation Rating Double Insulated, Pollution Degree 2, Overvoltage Category II
10.2 Setting Flow Rate .................................................................................28
10.3 Clearing Faults .....................................................................................28 Environmental Conditions Altitude up to 2000 meters
10.4 Reagent Clogs .....................................................................................28 Up to 95 % RH (non-condensing)
10.5 Diagnostic Chart .................................................................................29
10.6 Technical and Customer Assistance ...................................................29 IECEx Hazloc Rating Ex px IIC T4 Gb 0°C ≤ Ta ≤ 55°C
Compressed Air Water and oil free, -40oF (-40oC) Dew Point, Particles <5u, ISA Grade
11.0 Routine Maintenance .....................................................................................30 Hydrocarbon Free. Full time clean dry air at 5.5 - 7 bar (80-101.5 PSI)
11.1 Maintenance Schedule ........................................................................30 @35 SLPM (1.2 SCFM) @ 20oC (68oF) Max
11.2 Replacing or Installing the Reagents ...................................................33
11.3 Indicator Reagent Preparation .............................................................33 Regulatory Compliance CE Approved, ETL listed to UL 61010-1 Issued May 11 2012 3 rd Ed &
11.4 Check Valve Flushing Kit ...................................................................34 ETL certified to CSA 22.2 No. 61010.1 issued May 11 2012
And Certifications
11.5 Instrument Storage ..............................................................................34 EN61326:2006
11.6 Cleaning the CLX-Ex .........................................................................34
Shipping Weight 27.2 kg (60 lbs.) Reagents are Shipped Separately
12.0 Accessories and Replacement Parts List .....................................................35 Shipping Dimensions 93 cm X 62 cm X 32 cm (36½” X 24½” X 12½”)
13.0 IECEx Certificate .........................................................................................37
14.0 Limited Warranty .........................................................................................41
CLX-Ex (4/18) Page 1

REV 1.94
1.0 Overview 1.2 The Display
The CLX-Ex Online Chlorine Monitor allows for the reading of chlorine levels of process Figure 1 illustrates all the items that can appear on the display. The upper row of the
water on-line. The CLX-Ex has been designed to meet the design criteria specified by display (1) is used for reporting the chlorine levels and to provide user guidance in the
Standard Methods for the Examination of Water and Wastewater (21th Edition) Method customer setting routine. The lower row of the display (2) is used to communicate error
4500-Cl G. DPD Colorimetric Method. The CLX-Ex uses a 515nm LED as the messages (message queue) and provide user guidance. The display has two icons (3) that are
measurement light source. used to indicate the use of access code and offset mode. In addition, mode arrows (4) are
used to indicate the current instrument operating mode; AUTO (normal operation), CAL
This instrument has been designed to operate in explosive atmospheres and meets the (calibration) and CONFIG (configuration).
IECEx rating as stated in the specifications. The instrument uses an approved
purge/pressurization controller called the Air Sentinel. Please refer to the companion
manual Cat. No. 28749 for all information on:
· Operation of the Air Sentinel.
· Electrical power connections.
· Purge Air Connection.
In addition this instrument has vortex cooling. This instrument will automatically control a
connected compressed air line to lower the temperature of one of the reagents, allowing the
reagent an operating life of up to 3 months.
Every effort has been made to ensure the accuracy of this manual. Due to the continuous Figure 1: Display used in the instrument.
development and improvement of all instrumentation, there may be slight differences
between this manual and the instrument received. Therefore, no legal claims can be made
against any discrepancies herein.
1.3 The Touch Pad
Figure 2 illustrates the touch pad. The touch pad has six buttons: PRIME, SERVICE,
1.1 Unpacking and Inspection of the Instrument and Accessories MODE/EXIT, , p and q
The MODE/EXIT button is used to cycle between the three operational modes of the
The table below indicates the items in the shipment. instrument: CAL, CONFIG, and AUTO (Measurement) mode. The button enters the
Item Quantity option or mode that is highlighted or chosen. The p and q buttons are used to change
settings.
CLX -Ex Monitor 1
The PRIME and SERVICE buttons are dedicated controls. The PRIME will start 75
Owner’s Manual 1 reagent pump pulses to prime the tubing after a change or addition of reagent bottles. The
SERVICE button will drain the instrument and hold all operations until either the
Tubing/Cuvette Kit: 8 black pump tubes, 2 different Cap Assemblies, 1 SERVICE button is pushed again or the power is reset. This button should be used while
1 replacement cuvette changing the tubing, the measurement cuvette or reagent bottles.
Check Valve Flushing Kit 1
Remove the instrument from the shipping crate. Carefully inspect all items to ensure that no
visible damage has occurred during shipment. If the items received do not match the order,
please immediately contact the local distributor or the HF scientific Customer Service
Department.
Figure 2: The CLX-Ex touch pad.
CLX-Ex (4/18) Page 2 CLX-Ex (4/18) Page 3

REV 1.94 REV 1.94
1.4 Orientation
2.0 Safety
From the diagram below the major components can be located. Note that two reagents are
required the buffer and the indicator. The reagents are discussed in the Routine Maintenance This manual contains basic instructions that must be followed during the commissioning,
section 11.0. operation, care and maintenance of the instrument. The safety protection provided by this
equipment may be impaired if it is commissioned and/or used in a manner not described in
this manual. Consequently, all responsible personnel must read this manual prior to
working with this instrument.
In certain instances “Notices”, or helpful hints, have been highlighted to give further
clarification to the instructions. Refer to the Table of Contents to easily find specific topics
and to learn about unfamiliar terms.
This manual is intended to be used in conjunction with No. 28749 for more
information on the connection and operation of the Air Sentinel.
2.1 Symbols Used in this manual
This Symbol identifies hazards

which, if not avoided, will result in
death or serious injury.
This symbol identifies hazards

which, if not avoided, could result
in minor or moderate injury or
damage to the equipment.
This symbol identifies important

information, practices or actions.
This pictorial alert you to the need

read the manual, possibly at a
different section.
This pictorial alerts you to

electricity, electrocution and
shock hazards.
2.2 Use in Explosive Environments Safety

In the interests of safety the operator must ensure the atmosphere where the instrument is
located is safe from gases, vapors, dust or other flammable conditions whenever the
instrument is opened for service or maintenance. At all other times the door must be kept
closed with purge air connected the purge system operating with the all GREEN lamps lit
Figure 3: The CLX-Ex with Cover Open indicating safe operation.

REV 1.94 REV 1.94
3.0 Theory of Operation
3.1 The Measurement 3.2 The Air Sentinel Controller
The CLX-Ex has two solenoid valves, one for sample water (FLOW) and one for draining The Air Sentinel controller governs the power to the instrument. For normal instrument
of the cuvette (PURGE). A third solenoid, along with four check valves forms a reagent operation air needs to passes through fitting on the base of the main enclosure and
pump. Sample water flow is controlled by the FLOW solenoid valve. The PURGE solenoid constantly purge any vapors that could build-up. All GREEN lamps indicate a safe operating
valve is used to empty the cuvette in the measurement chamber. condition. Only when this condition is reached will power be applied to the measurement
portion of the instrument.
The measurement chamber consists of a sample inlet, a purge drain, and an overflow. The
reagent is added from the check valves integrated into the lower portion. A green LED Start-up
provides the 515 nm source lamp, a red LED is used for sample level and flow At start-up with the enclosure door open, the Purge Control will display a RED
measurement. A single detector is located 180º from the green LED. A replaceable glass PRESSURE lamp on the visual indicator indicates that the system is not pressurized and no
cuvette separates the LEDs from the detector and maintains the measurement path length. power is sent to the instrument.
Sample water flows in the inlet at the bottom, through the measurement cuvette and out
through an overflow drain. This flow is used to both fill the cuvette and flush the system. Closing the door with the air pressure applied, will cause the Air Sentinel to display a
GREEN PRESSURE lamp and RED TIMER lamp. During this time the enclosure will
The reagents are dispensed from two replaceable bottles. One bottle has a buffer to control
undergo an automatic dilution purge period of at least 5 minutes where at least 5 volumes of
the pH; the second has an indicator that contains the DPD, which produces color when
free space inside the enclosure will be exchanged with clean purge air. No power is applied
chlorine is present in the sample. The degree of color is dependant on the amount of
to the rest of the instrument during this time.
chlorine in the sample water.
The measurement chamber is open to view operations. A white LED backlights the chamber After the enclosure air has gone through this purge period the Air Sentinel will display all
for a clearer view. The white LED will flash to attract attention in the case of a warning or GREEN lamps. At this time the instrument is deemed safe and power is applied to rest of
failure. Most warnings and failures are also displayed on the screen. To prevent interference, the instrument.
the white LED is turned off during measurements.
WARNING: Do not apply power to the Air Sentinel controller unless the area has been
During normal operation the CLX-Ex will run through a timed cycle. A simplified cycle properly tested and is known not to contain explosive materials.
will consist of the following sequences:
· Flushing – continuous sample flow Bypass Key
· Purging – PURGE valve opens WARNING: Use of the bypass key disables the safety features and safe operation of
· Zeroing – no flow with cuvette full this instrument. It is imperative that this operation be performed only after the area
· Adding Reagents – one pulse of the reagent pump has been tested and known to be safe.
· Mixing with sample – sample flow pulses in Assuming the area has been tested and is known not to contain explosive materials; a bypass
· Reading resulting sample – no flow with cuvette full service key is provided and can be used. In this operating mode power will be retained to the
· Purging – PURGE valve opens to remove reacted sample
rest of the instrument even though the door is open. It is imitative that this mode is only
The cycle above is simplified and does not describe all the actions and testing that occurs. used after area is known to be safe. This operation disables the safe operation of this
The CPU continuously diagnoses the entire system for correct operation and sample water instrument.
flow. If an error occurs, a message is posted to the message queue on the LCD screen.
Upon turning the key, the indicator will display the RED BYPASS & TIMER lamps. This
The reagent is added by a single pulse of the reagent solenoid. When the reagents require is an indication of the maintenance mode. Power is retained to the instrument. The key
replacement, the PRIME button is pushed to bring new reagents into the system. During cannot be removed in this mode of operation.
PRIME the reagent solenoid is pulsed several times to draw fluid from the two reagent
bottles and fill the tubes with new reagent. A complete PRIME takes less than a minute. After maintenance has been performed the door should be closed and latched. Air pressure
will once again pressurize the enclosure. The maintenance key can now be turned and
The SERVICE button empties the cuvette, stops the flow of sample water, and clears any removed and the key cover replaced. The purge controller will display the GREEN
errors. This provides a convenient way to replace reagents and the measurement cuvette. If PRESSURE & BYPASS lamps indicating a safe operation and power is kept applied to the
more extensive servicing is performed, all power to the CLX-Ex should be removed. If the instrument. The TIMER lamp will be GREEN immediately. No purge time is required
CLX-Ex is to be turned off, it is recommended that the instrument be placed in SERVICE since door was opened under a non-hazardous condition.
mode before removing power. This ensures that the cuvette is emptied and the flow is off.

REV 1.94 REV 1.94
3.3 Remote Standby 4.0 Installation and Commissioning
This feature will allow for remotely placing the instrument into a standby mode. This can be Prior to use for the first time, one of the reagents (the indicator) will have to be mixed. Refer
done to lower reagent usage while not performing ballasting or de-ballasting operations. The to section 11.2 Replacing or Installing the Reagents.
last operation of each cycle is a flush and hold. Whenever the instrument not being used
(standby), it is stored such that the optics is clean & dry. 4.1 Mounting & Site Selection
The instrument is designed for wall mounting. Choose a location that is easily accessible for
Dry contact are provided as feedback as to the operation of the instrument (operating or operation and service and ensure that the Purge Control lamp is about eye level.
standby). For more information on this feature refer to sections 4.4.4 Remote Standby Consideration must be made for the plumbing and electrical conduit connections. The
Connections and 6.2 Routine Measurement with Remote Standby. overall mounting dimensions of the instrument are shown in Figure 4.
3.4 The Reagents

The indicator reagent reacts with any oxidant, generally chlorine, to create a pink color
which the instrument measures and compares with a sample of water without reagents.
The buffer reagent is required to control the sample pH to bring the sample to neutral.
The reagents are provided already hydrated and require little operator preparation.
The indicator reagents are packaged a plastic box. Each 125 mL indicator will require the
addition and mixing of the DPD powder contained in the small brown bottle. This activates
the indicator reagent. The indicator reagents should be changed out on a 90 day basis even if
they are not fully used.
The 500 ml buffer does not require any preparation and is good for one year.
After one year all the reagents will have been consumed and replacement reagent set will be
required. This can be ordered through agent Catalog No.09991. This set will include a new
plastic box with four sets of Indicator reagents plus one 500 mL bottle of Buffer.
3.5 The Reagent Cooler

A reagent cooler is provided for the 125 ml indicator reagent.
For proper operation power must be applied by the Purge Air Sentinel controller to the
cooling chamber temperature controller. Clean dry compressed air must also be provided at
pressures between 5.5 and 7 bar (80 to 101.5 PSI).
The cooling chamber temperature controller governs the solenoid which controls air flow to
the vortex cooling unit. The air flow is turned on or off as required to maintain the
indicating reagent temperature at 20-25˚C. This extends the life of the reagent up to 90 days.
To provide this extended reagent life, power to the cooling power supply and air pressure
must be supplied full time.
Figure 4: Overall Mounting Dimensions of the Instrument
Be sure that the instrument be mounted as close as possible to the sampling point to ensure a
quick response time (within 2-3 meters (6-10 ft) of the sampling point).

REV 1.94 REV 1.94
4.2 Plumbing and between the instrument and other peripheral devices.
The instrument is designed to require very little head pressure to operate, but will need All terminals are designed to accept wires in the range of 14-28 AWG. All wires should be
around 0.34 bar (5 PSI). The maximum pressure for proper operation should not exceed stripped to a length of 6 mm (¼”).
10.3 bar (150 PSI). The maximum allowable fluid temperature is 55°C (131°F).
For line power connections refer to the companion manual Catalog No. 28749
The fluid waste from drain connection of this instrument contains reagents with large 4.4.1 RS-485
quantities of sample water. HF scientific recommends that operators check with local The RS-485 half-duplex (2-wire) digital interface operates with differential levels
authorities concerning proper disposal of waste diluted fluids. This waste fluid must that are not susceptible to electrical interferences. This is why cable lengths up to
NEVER be reintroduced into the incoming water stream. 3000 ft can be implemented. The last device on each bus may require terminating
with a 120 ohm resistor to eliminate signal reflection on the line. Do not run RS-485
All plumbing connections are intended to be made through stainless steel connections.
cables in the same conduit as power. Set-up of the RS-485 is covered in 8.3
The water sample inlet requires 6 mm OD stainless steel tubing. The fitting is a compression Configuring the RS–485 Port
fitting so the installer need only place the supplied the nut and feral over tubing and tighten.
To prevent damage to the instrument, ensure that
The water drain requires 12 mm OD stainless steel tubing. This fitting is also a compression power is disconnected prior to making connections.
fitting so the installer need only place the supplied the nut and feral over tubing and tighten. For ease of connecting, remove the plug-in terminal
block. Connections are labeled beside this
Properly installed and sealed connections are required to ensure the water tightness and termination on the PC board. The recommended
ratings of the instrument. cable is 22 AWG shielded twisted pair. The grey
terminal block is removable to assist in making
The drain must be open to the Atmosphere for proper operation. connections.
4.3 Air Supply 4.4.2 Relay
This instrument requires water and oil free air, -40 oC (-40oF) Dew Point, Particles <5u, ISA One relay alarm connections labeled ALM COM &
Grade Hydrocarbon free. The air needs to be provided at between 5.5 and 7 bar (80-101.5 ALM NO is provided. Please note that this is a fail-
PSI) with a volume of 35 SLPM (1.2 SCFM) as measured at 5.5 bar (80 PSI). This air safe so the “normal” condition is power to the CLX-
supply must be provided continuously from a known safe area. Ex on and no alarm condition. The relay is rated
240VAC 2A. Operation of this alarm is covered in
The air connection requires 6 mm stainless steel tubing. A compression type fitting is section 8.4 Configuring the Alarm.
supplied on the base of the main enclosure that simply requires the installer to slip the
supplied nut and feral over the tubing and then tighten the nut.
4.4.3 4-20 mA
4.4 Electrical Connections
All electrical connections must pass through the three compression grommets on the left The 4-20 mA output is driven by a 15 VDC power
side of the instrument. Cabling must be selected to ensure that these connections are tight. source and can drive recorder loads up to 600 ohms.
The grommets can accept cabling from 11 to 21 mm diameter. One grommet is supplied for Transformer isolation is provided on the CLX-Ex. Do not run 4-20 mA cables in the
system power and two are supplied for low voltage I/O connections. These grommets must same conduit as power. Operation of this output is covered in section 8.1 Setting the
be tightened to maintain cabinet air pressure. 4-20 mA.
To prevent damage to the instrument, and for general safety ensure that power is
The electrical power for the protective gas supply (blower, compressor, etc.) should be
disconnected to the CLX-Ex prior to making any connections. Polarities of the
either taken from a separate power source or taken from the supply side of the electrical
connections are labeled beside this termination on the PC board.
isolator for the pressurized enclosure.
The recommended cable is 22 AWG shielded twisted pair. To prevent ground loops,
Most of the low voltage electrical communication connections to the instrument are made at
connect the shield at either the CLX-Ex or at its destination, but not both. The grey
the termination area which is located on the left side of the instrument. Remove the access
terminal block is removable to assist in making connections.
cover by loosening the captive screw. The connections are labeled and are self-descriptive.
Please follow all government recommendations for installation of electrical connections to The 4-20mA is factory calibrated. An adjustment is available on the 4-20mA in

REV 1.94 REV 1.94
sections 8.12 and 8.13. In addition to making adjustments, these menus output
continuous 4 mA or 20 mA and can be used as a signal test. Remember that the 5.0 Air Sentinel Controller Operation
configuration mode will timeout after 15 minutes. The Air Sentinel controller is mounted on the side of the main enclosure. This controller
4.4.4 Remote Standby Connections will ensure proper safe operation of the CLX-Ex. If of all the required conditions are met,
the controller will act as a power governor. It does this by monitoring the pressurization of
The instrument operates on user control software, where an external control initiates the main enclosure with clean dry air. Should this air supply pressure fail the PRESSURE
each cycle. This control line is called the RSI short for Remote Standby Input. lamp on the Air Sentinel unit will turn RED and power to the rest of the instrument is
The CLX-Ex will indicate the current status on another line called RSO or Remote disconnected.
Standby Output. These connections are a relay contact that is closed when busy and
open during when in standby mode. WARNING: Do not apply power to the Air Sentinel controller unless the area has been
properly tested and is known not to contain explosive materials.
The connections are labeled RSI and RSO. The RSI has + and – polarity connection
associate with it and expects a 24VDC control signal.
The RSO is simply a relay contact and is not polarized. 5.1 Start Up
When power is applied to the CLX-Ex for the first time, ensure that the air supply is
4.4.5 RS-485/4-20 mA cable Ferrite
connected as stated in section 4.3 and the cabinet is closed and locked. Once power is
To meet IEC requirements for RF radiated immunity a clamp-on type ferrite is applied, the Air Sentinel will go through a purge period of 5 minutes where at least five
supplied in the accessory kit. It should be placed on the RS-485 or 4-20 mA cable volumes of the enclosure are pushed through the CLX-Ex and out the Air Sentinel vent.
outside, as close as possible to the CLX-Ex. If both outputs will be used, an During the purge period the TIMER lamp Air Sentinel will be RED indicating the purge is
additional ferrite will be needed and can be ordered from HF scientific Catalog in process and no power is applied to the rest of the CLX-Ex.
number 24560.
4.4.6 Modbus Control At the complete of the purge, the TIMER lamp will go GREEN and power will be applied
to the rest of the system. As long as the proper air supply conditions are met the CLX-Ex
In addition to the above mentioned Remote Standby Connections, the same control will continue to operate.
can be achieved using Modbus control. Two special Modbus addresses are
provided. 5.2 Indicator Lamps
The reading cycle is initiated using the coil 00005 with default at False (0). Setting The indicator lamps are a very quick way to determine to operation of the controller and
this address to True (1) initiates the reading cycle. thus the safety condition of the CLX-Ex.
At any time the standby status can be check at Modbus Coil Address 00005 or Lamp Color Matrix Meaning Power to rest of CLX-Ex
Modbus Input Address 10005. False (0) indicates standby and True (1) indicates the
measurement cycle is taking place. Control is only available from the Coil Address All lamps GREEN Safe Operation Power ON
00005. TIMER lamp RED Instrument purging or Bypass Power OFF
operation
4.5 Installing Reagents PRESSURE lamp RED Unsafe Operation Power OFF
BYPASS lamp RED Bypass Key Operating Power ON
The CLX-Ex will require that two reagents be installed prior to operation. These are a buffer
No Lamps on No power applied to CLX-Ex No power applied everything off.
and an indicator. For reagent preparation refer to section 11.2 Replacing and Installing the
Reagents.
Using the table above, you can quickly determine the operating condition of the instrument.
Under normal operation all GREEN lamps should appear.

REV 1.94 REV 1.94
6.0 Operation
5.3 Maintenance Bypass Operation Under normal operation the Air Sentinel controller lamps will all be GREEN indicating
safe operation. If the lamps are GREEN, correct this condition first. Please refer to section
Use of the bypass key disables the safety features and safe operation of this instrument. 5.0 Air Sentinel Controller Operation.
It is imperative that this operation be performed only after the area has been tested
and known to be safe. The CLX-Ex Online Chlorine Monitor allows for the measurement of the chlorine of
process water on-line. The chlorine value of the process water is usually reported in
When shipped from the factory the bypass key is shipped on the strap securing the key milligrams per Liter (mg/L), these units are equivalent to Parts Per Million (PPM).
cap. Once the commissioning of the system has been done the key should be moved to a
known secure location. It is not advised that they be left on the strap. Readings above 10.00 mg/L are outside the range of this instrument. Although the CLX-Ex
may display above 10.0 mg/L, these readings will not be within the stated accuracy. As the
To perform some maintenance operations on the CLX-Ex it is necessary to have the entire reagents degrade due to aging, readings above 10.0 mg/L may decrease in value.
instrument powered up while the enclosure door is open. Under these conditions normally 6.1 Routine Measurement
the Air Sentinel controller would determine that the enclosure is not pressurized and power First, ensure that all plumbing and electrical connections are complete before continuing.
will be removed to the measurement section of the CLX-Ex. To allow for this situation, a
The following steps describe how to measure the value of chlorine of a sample using this
special maintenance bypass key is supplied.
instrument:
Located on the right side of the Air Sentinel controller is a hex cap. Removing this cap 1. Apply power to the instrument and allow the unit to warm up. The instrument may
reveals the key slot. Insert the key and turn it clockwise to engage the bypass operation. The have to re-calibrate to the water level sense detector. This WCAL or water
TIMER & BYPASS lamps will turn RED to indicate the bypass mode. Assuming the area calibration will take few minutes to perform.
around the CLX-Ex has been tested and known to be safe, the enclosure door can now be 2. When a continuous process stream is flowing through the instrument, the instrument
safely opened and power will remain on to the entire system. The key cannot be removed will display the measured chlorine level of the sample by displaying it on the LCD
while operating in the maintenance bypass mode. screen. In addition, the equivalent signal is provided on the analog (4-20 mA)
output, or the digital (RS-485) output, depending on the options selected.
Do not operate the CLX-Ex for long periods of time in the bypass mode. This is 6.2 Routine Measurement With Remote Standby
intended only for maintenance operations. First, ensure that all plumbing and electrical connections are complete before continuing.
Do not operate the CLX-Ex in the bypass mode unattended. The following steps describe how to measure the value of chlorine of a sample using this
instrument:
To return the instrument to normal, safe operation, close the enclosure door. Ensure that the 1. Apply power to the instrument. The instrument will perform a water calibration
air supply is connected turn the key counter-clockwise and remove. Replace the key cover. (WCAL). During this time the RSO contact will be closed, indication the system is
If the pressure in the cabinet has built up to a normal acceptable level the Air Sentinel will busy. This automatic calibration is necessary and will only be performed once on
show all GREEN lamps and the system will continue to run. power up.
2. When the system has completed the WCAL, the RSO contacts will open indicating
that it is in standby mode and is ready to take a measurement.
3. Application of 24VDC to the RSI+ will initiate a read cycle. The RSO contacts will
close to indicate the system is busy.
4. At the completion of the cycle, the RSO contacts will open & the measured chlorine
level of the sample will be displayed on the LCD screen. In addition, the equivalent
signal is provided on the analog (4-20 mA) output, or the digital (RS-485) output,
depending on the options selected.
The system is ready to take another measurement
As mentioned previously the same control can be performed via Modbus. Setting Coil
00005 to a 1 will start a cycle. See 4.4.6 Modbus Control.
REV 1.94 REV 1.94
Please note that these operating screens cannot be seen except with the cabinet door 6.4 The White LED
open and the instrument in maintenance bypass mode. See section 5.3 for more A white LED is used to illuminate the measurement cuvette for easy viewing of the
information on this. instrument operations. During the Zeroing portion of the cycle and the Measurement portion
of the cycle, when the green LED is active, the white LED is turned off to lower
interference. This is normal operation for the instrument and does not represent an error or
problem.
During normal operation, the instrument will have the
arrow beside AUTO highlighted with the current scale The white LED is also used to draw attention to a problem as described in section 10.1
displayed on the lower row of the display and the CLX-Ex Fault Detection. In these instances the white LED blinks at a constant rate
measured reading on the upper row of the display (see dependant on the severity of the problem, but is still turned off as described above. Please
screen shown). note that any fault is always posted to message queue on the lower portion of the LCD.
The screen depicted indicates that the system has just

been started or just entered AUTO mode from Service
mode and no readings have been taken yet.
Please note that calibrations will not be allowed until a reading is posted.
6.3 Security Access Feature

The instrument is equipped with a security access code feature that can be activated in the
configuration mode. If the security feature is enabled, the screen shown in the illustration
below will appear when the MODE/EXIT button is pressed.
The security code (333) must be entered to gain access to CAL or CONFIG menus. Notice
that the first number in the code is flashing. The flashing indicates that this is the number to
be changed. Use the p or q arrows to select the first
of the three numbers in the code and then press the
button to accept the first number of the code. Now
enter the second number in the code. Proceed as with
the first number followed by . Then repeat the process
for the third number in the access code, and finish with
the button.
If the valid access code has been selected, the instrument will be directed to the calibration
mode. If the wrong access code is selected, the instrument will return to the AUTO mode.
Refer to section 8.4 Enabling the Security Access for more information.

REV 1.94 REV 1.94
7.0 Instrument Calibration 7.2 Zero (offset) Calibration Procedure
Generally this calibration is only required if readings are expected to be below 1 mg/L or if
The instrument was tested prior to leaving the factory. The instrument operates from a pre- it is required by a regulatory authority. To perform this calibration, the water supply to the
determined calibration curve for high accuracy of residual oxidant concentration. It is not CLX-Ex must be changed to chlorine free water such as de-ionized water. This chlorine free
necessary to recalibrate to maintain accuracy specifications. water must be run through the instrument for at least 5 minutes prior to using the following
If re-calibration is required by a regulatory authority, this can easily be performed if procedure.
required. The method is by comparison against another instrument, such as a laboratory or
hand held photometer (such as HF scientific’s Chlorine Pocket Photometer). 1. On the CLX-Ex, press the MODE/EXIT button once. The screen is shown
below.
There are two points of calibration. The slope or gain and the zero (offset). To perform the
zero calibration, the instrument must be plumbed to a sample of known chlorine free water,
such as de-ionized water for a zero adjustment.
7.1 Slope (gain) Calibration Procedure
It is important that the chlorine level be quite stable to use this method. The comparison will
be made against a trusted measurement such as a chlorine photometer, spectrophotometer,
or an amperometric titration.
1. Obtain a grab sample of the flow prior entering the instrument. 2. Press either the p or qbuttons to get the following screen.
2. Measure the value of the sample with one of the methods shown above.
3. On the CLX-Ex, press the MODE/EXIT button once. The screen is shown below.
3. Press to enter the zero calibration screen.
4. Press to enter the calibration adjustment.
4. The screen will show the current reading on the CLX-Ex. Since there is no
chlorine, the only reading may be a slight offset due to the absorbance of the
reagents. There should be no pink color developed.
5. Press to perform a Zero calibration. When the calibration has completed the
instrument will return to AUTO measurement mode automatically.
There is a limit of ±0.20 mg/L total adjustment available. A ZERO Cal. greater than
this will cause a CAL warning and no calibration will have occurred. Enter SERVICE
5. The screen will show the current reading on the CLX-Ex. Using the p & q buttons mode to clear this error.
adjust the reading to agree with the laboratory method or portable photometer.
6. Press to accept the calibration adjustment and return to AUTO measurement 7.3 Restore Factory Settings
mode. If the CLX-Ex displays a CAL error or the calibration was incorrectly performed, it may be
There is a limit to the size of the change that can be made to a current reading. The preferred to restore the factory calibration. All factory defaults settings including the factory
upper limit is the current reading times 1.5. The lower limit is the current reading calibration can be reset by holding down the p button and then pressing and releasing the 8
divided by 1.5. button then releasing the p button.
Ensure a reading is posted to the display before calibrating to avoid a nOnE error.
REV 1.94 REV 1.94
8.0 Instrument Configuration (CONFIG mode) 8.2 Configuring the Error Level
In case of an error in the CLX-Ex, the 4-20 mA reading
Please note that these operating screens cannot be seen except with the cabinet door can be used to indicate a problem by sending the current
open and the instrument in maintenance bypass mode. See section 5.3 for more to either 4.00 mA, 2.00 mA or 0 mA. The factory
information. default setting is OFF. Select the desired ERLV by using
the p and q buttons then press the button to accept
the desired error response.
If changes to the configuration have to be performed, you will need to enter the maintenance
bypass mode see section 5.3 for more information. 8.3 Configuring the RS–485 Port
The instrument is equipped with an RS 485 port which
operates in Simple bus or Modbus. Prompts will appear
The instrument has been designed to provide the ability to customize the instrument for setting the baud rate, the address and the Modbus
according to needs at any time during normal operation. This mode has been split into sub- transmission mode (RTU or ASCII).
menus to facilitate instrument configuration. This section describes how to use each of the
sub-menus to configure the instrument. While in the configuration mode, the instrument has Select the correct baud rate (1200, 2400, 4800, 9600, or
a time-out feature that automatically returns the system operation to the AUTO mode after a 19200) for operation of the I/O port by pressing the p or q buttons to change the displayed
fifteen (15) minute period of no button pushes. baud rate.
Enter the CONFIG mode of the instrument by pressing the MODE/EXIT button until the Press the button to continue on and select the desired
arrow beside CONFIG is illuminated, then press the button to scroll through the sub- instrument address using the p or q buttons. Once the
menus. selection is satisfactory, press the button.
To exit the CONFIG mode, press the MODE/EXIT button any changes that were made
will be saved. To use the Modbus mode, select ASCII or RTU. See
section 9.1.2.
8.1 Setting the 4-20 mA Output
8.4 Configuring the Alarm
The first configuration selection is 4-20 for the 4-20 mA
One relay is provided that are designed to operate as an independent programmable alarm or
output. Select the either On or OFF using the p and q
as a system problem alarm. Please note that changes to the alarm will not be recognized
buttons. Once the desired output has been set, press the
until the start of the next cycle. Two settings must be selected to fully program the alarm:
button to accept it. The next prompts will depend on the
output selected. Also see sections 8.12 & 8.13. 1. The alarm function (HI, LO, OFF or Error)
2. The alarm set point (level at which the alarm activates)
If the 4-20 mA output was turned On, prompts to set the
These items are described below:
4mA (4MA) and 20mA (20MA) chlorine limits will be
displayed. There will also be a menu to adjust the error Alarm Function: The alarm can either be turned OFF or selected to operate in one of three
level (ERLV). The first prompt will be the chlorine limit different manners:
assigned to the 4 mA output level: 1. HI alarm: the relay changes state when the measured chlorine level is higher than the
Select the chlorine level to assign to the 4MA using the programmed alarm level (set point).
p and q buttons. 2. LO alarm: the relay changes state when the measured chlorine level is lower than the
Once the desired level has been set, press the button to accept it. programmed alarm level (set point).
The 4MA can be set higher than 20MA level to invert the output current if required. 3. Error alarm: If there is a system fault or problem the alarm will change states.
This may be required to control a dosing pump. Alarm Set Point: The level at which the alarm activates is called the alarm set point. On
The next prompt will be the chlorine level assigned to the the instrument, the alarm set point is designated as “S/P”. The set point is adjustable to any
20MA. Select the chlorine level using the p and q valid chlorine level over the range of the instrument in steps of 0.01 mg/L. This setting is
buttons. Once the desired level has been set, press the not available if the Error function is chosen
button to accept it.
REV 1.94 REV 1.94
8.4.1 Alarm 1 8.7 Units of Measurement
Alarm 1 Function: The ALM1 is displayed and the display indicates the current The unit of measure can be set to either mg/L (milligrams per liter) or PPM (parts per
function of alarm 1 (HI, LO, OFF, or Error). Use the p or q buttons to cycle million). The factory setting is mg/L. Select the desired UNIT using the p and q buttons
through and select the desired function. Press the button to accept the selection. and press the button to accept it.
If the alarm was turned OFF, a prompt will appear to set up alarm 2.
Alarm 1 Set Point: This prompt is used to select the set point for this alarm; this is
indicated by “S/P” shown on the lower row of the display. Select the desired alarm
level by using the p and q buttons. Once the desired set point has been set, press
the button to accept it.
mg/L screen PPM screen
8.8 Averaging and Filtering
The Remote Standby limits the relays to a single normally open connection. The CLX-Ex can display and output averaged readings to help smooth out the response and
Although the alarm 2 menu may display, this alarm can be used. eliminate large reading variation in rapidly changing processes. There are 5 settings for the
averaging feature:
Due to the cyclic nature of the instrument, relay chatter is not an issue. There is 1 = No averaging, each reading is in “real time”.
no need for alarm delays or hysteresis. 2 = The current reading and previous reading are averaged.
3 = The current reading and previous 2 readings are averaged.
8.5 Enabling the Security Access
The instrument is equipped with a security access. If this option is turned on, the user is The factory setting is averaging of 2. Select the desired AVG using the p and q buttons
required to input the access code into the instrument to and press the button to accept it.
get to any mode other than AUTO. The only code is
333. This code may not be changed. See section 6.3 for In addition to averaging, the CLX-Ex has a software filter that limits the change between
more information on this security feature. The security consecutive readings to 20%. For example, the reading following a reading of 1.00 ppm
key icon will be visible and flashing on the display could not be displayed as higher than 1.20 ppm or lower than 0.80 ppm. This filter also
whenever the access option is selected using the p or q helps smooth out large changes and eliminate reading
buttons. (On or OFF). spikes. After 3 consecutive readings, it is assumed that
the large change in the readings is "real", and the filter
will be disabled. For example, the change between
8.6 Extended Settings reading 1 & 2, and readings 2 & 3 will be limited to
The last settings are grouped together to prevent them 20%, but the change between readings 3 & 4 will not be
from being adjusted by accident. To gain access to the limited.
extended settings, select On using the p or q buttons
and press the button. Note: This software filter is completely disabled when the averaging (AVG) is set to 1.
8.9 LCD Backlight Brightness

If extended settings are set to OFF, pressing the button will save all settings and the The LCD backlight brightness may need to be adjusted. This is of particular interest if
CLX-Ex will automatically return to the normal AUTO mode of the instrument. multiple instruments are located in the same area and it is desired for the entire group to
have the same appearance. Ten levels are available. The
factory setting brightness is 8.
Change the brightness by pressing the p or q button.
When the desired brightness has been selected, press the
button.

REV 1.94 REV 1.94
8.10 RS-485 Parameters
These menus will only appear if the RS-485 is enabled (see 8.3). The factory setting is 8 Bit, 8.13 4mA Adjustment
no (nOnE) Parity, 1 Stop Bit. If the 4-20 mA setting is turned ON (8.1 Setting the 4-20 mA Output), the following two
menus will appear. The first menu outputs a constant 4
Make selections using the p and q buttons then press the button to move to the next mA while allowing for a small amount of adjustment.
menu. The adjustment can be made using the and buttons.
This adjustment will allow the operator to make the
CLX-Ex agree with a PLC or SCADA system. The
adjustment limits are ± 200 counts or about ± 0.2 mA.
This setting will be slightly different on each instrument as each CLX-Ex will be factory set
to 4.00mA. Press the button when adjustments are complete to save this setting and move
on to the 20mA adjustment.
8.11 Cycle Time

The cycle time can be changed using this menu. Please note that changing this menu will 8.14 20mA Adjustment
directly affect the volume of reagent that will be consumed. This menu operates similar to the previous menu. This menu outputs a constant 20 mA
while allowing for a small amount of adjustment. The adjustment can be made using the p
and q buttons. The adjustment limits are ± 1000 counts or about ± 1 mA.
Make selections using the p and q buttons then press
the button. Allowable setting is from 60 to 600 This setting will be slightly different on each instrument
seconds (10 minutes). as each CLX-Ex will be factory set to 20.00mA.
The indicator reagent has a defined life after being mixed regardless of the cycle time
setting. If the reagent is kept in the powered cooling chamber the life is 90 days.
8.12 Water Conservation

To conserve water, the flush time can be adjusted use as little water as possible. When complete with the 20mA adjustment, press the Ώ button to exit to AUTO mode and
save all configuration settings.
This feature is generally not used in ballast water applications and should be set to
OFF.
The instrument requires 110 seconds to complete its

normal operations, when the WCON is turned On, at the
factory cycle time the instrument sits idle for about 40
seconds. This results in about a 25% water savings. The
actual amount of water conservation is dependent on the
incoming water pressure and the cycle time setting.
The use of this option may result in some slight loss of accuracy. The factory setting for this
option is OFF.
Make selections using the p and q buttons then press the button to exit to AUTO mode
and save all configuration settings. If the 4-20 mA in section 7.1 is turned ON, there are two
additional menus that will appear before returning to AUTO mode.

REV 1.94 REV 1.94
9.0 Additional Features and Options 10.0 Troubleshooting
9.1 RS-485 Outputs 10.1 CLX-Ex Fault Detection

The CLX-Ex has the capability to operate in two different RS-485 modes. Included are a
simple communication mode and Modbus communications. Both modes will automatically Please note that these operating screens cannot be seen except with the cabinet door
configure and do not require any changes or selections open and the instrument in maintenance bypass mode. See section 5.3 for more
information on this.
9.1.1 Simple Communication The CLX-Ex performs continuous diagnostic monitoring. In the CLX-Ex, there are 4
severity levels of fault detection. Level 4, 3 & 2 will allow normal operation, but warn of the
The CLX-Ex can provide basic communications over simple programs such as the
problem. Level 1 is an instrument failure and the instrument will not operate. Any faults are
Hilgraeve HyperTerminal that is included with most Microsoft Windows packages.
displayed in a queue form in the bottom row of the LCD.
The user could also use Visual Basic or other programs. The factory setting
communication parameters are 8 bits, no parity and 1 stop bit. These can be changed
A level 4 fault is simply a screen indication that one of the alarm levels has been activated.
in the Extended CONFIG menus 8.9 RS-485 Parameters.
This fault level will not affect the 4-20 mA and will only affect the alarm activated. The
The master computer will send out: sample back light blinks at a rate of once every 4 seconds.
· Byte #1 the attention character “:” in ASCII or 3A Hex
· Byte #2 the address of the CLX-Ex being queried A level 3 fault indicates a failure or a problem that usually can be corrected by the operator.
· Byte #3 & 4 CR LF or 0D 0A in hex Refer to the chart below. If any of these errors occur, the instrument will still display
The CLX-Ex will respond with: readings and probably will operate correctly. These faults will self-clear when the problem
The CLX-Ex will respond with: is corrected. If any of these faults occur, they may affect the 4-20mA and any alarm
dependent on the detection setting (Error). See sections 8.2 & 8.4.1 for error settings. The
· The same attention character “:” in ASCII or 3A Hex sample back light blinks at a rate of once every 2.5 seconds to indicate these faults.
· The address of the CLX-Ex
· The Reading Level 3 (Self-Clearing) fault conditions
· The Unit (mg/L) Message Description of Fault Corrective Action
A sample communication would look like this: MA 4-20 mA enabled & loop open Check 4-20 mA wiring or turn off 4-
(Master computer requesting a report from address #1) :1 CRLF 20mA if not used
CAL Calibration invalid – not accepted Recalibrate if needed
(CLX-Ex set to address #1 Response) :001 0.0249mg/L WATR No water flowing Check water flow
FAST Intake water flow too fast Set flow rate (see section 10.2)
9.1.2 Modbus Communication SLOW Sample cuvette filling too slowly Set flow rate (see section 10.2)
Modbus protocol communication is included with this instrument. The Modbus PURG Sample cuvette has slow purge Check drain lines
address list is available from HF scientific or online at www.hfscientiifc.com. NPRG Sample cuvette not purging Check drain lines
ISOL Problem with intake solenoid Check wiring, check for clogged solenoid
9.2 Remote Panel Meter (Catalog # 19609)
PSOL Problem with purge solenoid Check wiring, check for clogged solenoid
The remote panel meter allows for remote indication of the mg/L reading using the 4-20 mA
GLAS Dirty cuvette Replace or clean cuvette
loop of the CLX-Ex. No external power is required, as the meter is run off of the 4-20 mA
WCAL Water Level Calibration Invalid Clear fault (see section 10.3)
source of the CLX-Ex.
A level 2 fault indicates a severe problem that will usually require technical assistance from
HF scientific customer service (see section 10.6). The queued display will show POST. If
this fault occurs it will affect the 4-20mA and any alarm set for fault detection (Error). The
sample back light blinks at rate of once every 1 second.

REV 1.94 REV 1.94
A level 1 fault is a system fault. This is NOT a problem that the operator can correct, and 10.5 Diagnostic Chart
the unit must be returned to the factory for service (see section 10.6). These failures consist
of failures in the CPU, A/D, EEPROM or other devices internal to the instrument. The Symptom Cause Cure
queued display will show FAIL, the upper display will show a four or five digit fault code. Lower display shows MA 4-20 mA loop open Check wiring. See sections
If this fault occurs, it will affect the 4-20mA and any alarm set for fault detection (Error). 4.4.4 and 8.1
The instrument will not operate with this fault. The sample back light blinks at rate of once Lower display shows FAIL Major system fault Refer to section 10.1
every 0.4 seconds. Readings are erratic (1) Bubbles in solution (1) See above
(2) Debris in flow (2) Install T strainer at inlet
If any fault condition occurs, the message indicating the fault will be shown on the lower (3) Bad or sticky check (3) Flush check valves as
row of the display. valves described in section 10.4 or
replace the valves.
10.2 Setting Flow Rate Readings are lower than expected (1) Condensate or leaky (1) Install desiccant cartridge
measurement cuvette kit
The flow rate on the CLX-Ex was factory adjusted and usually should not need adjustment.
(2) Measurement cuvette (2) Replace or clean cuvette
Installation variances may affect the flow. The optimal flow rate through the CLX-Ex may
dirty
be adjusted if needed. The flow is adjusted by removing regulator vinyl cap and turning the (3) Replace reagents
(3) Reagents bad or expired
adjustment screw on the pressure regulator. To assist in this adjustment follow the procedure
(4) Buffer reagent not being
shown below: (4) Check buffer lines and
dispensed
1. Press the SERVICE button. check valves.
2. Wait for the display to read HOLd, then press Mode/ Exit. Upper display flashes Sample Over-Range Check sample. Sample may be
3. Display will show FLOW with the number 0. Press either the p or q button. too high to read.
4. CLX-Ex will drain, and then pulse in water while a count is displayed on the screen. Upper display shows nOnE while No current reading displayed Wait for CLX-Ex to post a
5. The display will show one of three messages HI, LO or Good. attempting to calibrate reading
The flow test determines if the flow rate is suitable for proper operation. Loosen the locking
nut then adjust the pressure regulator using a coin or a large flat blade screwdriver. Press
10.6 Technical and Customer Assistance
either the p or q button while in the FLOW routine to display a new flow rate. Please note
that only ¼ turn incremental adjustments should be made to the regulator on each attempt. If for any reason assistance is needed regarding this instrument please do not hesitate to
contact either the HF scientific Technical Service Department or the HF scientific Customer
If the message is LO, turn the regulator control clockwise. If the message is HI, turn the
Service Department:
regulator counterclockwise. The optimal setting is when the number of counts is adjusted to
8-10. Once completed, tighten the locking nut after adjustment and replace the regulator
vinyl cap. To return to normal operation, press the button.
HF scientific
10.3 Clearing Faults Fort Myers, Florida 33916-7597
Every time SERVICE mode is exited, all faults are cleared. If the original fault or a new Phone: (239) 337-2116
fault occurs, it will be posted. Toll Free (888) 203-7248
Fax: (239) 332-7643
In the case of WCAL, it is possible the power was enabled before a water sample was
Email: hf.info@wattswater.com
available. Ensure a water sample is available and then press PRIME to force another Water
www.hfscientific.com
Calibration (WCAL).
10.4 Reagent Clogs

If reagents fail to flow or Prime it may be due to a clog in either the tubing or at a check
valve. To alleviate this you may have to flush the system with Chlorine Free water,
preferably Deionized water. See section11.4 Check Valve Flushing Kit.

REV 1.94 REV 1.94
11.0 Routine Maintenance After a PRIME the CLX-Ex will perform a water calibration (WCAL). It will take a
few minutes to complete this procedure.
Please note that to perform these maintenance operations the cabinet door must be
open and the instrument in maintenance bypass mode. See section 5.3 for more *The 1 year buffer and 90 day indicator reagent life is primarily used on ballast water
information on this. applications. The assumption is based on the factory default of a 60 second cycle and up to
60 hours total operation per month.
11.1 Maintenance Schedule Pump Tubing Replacement

The recommended schedule is shown below. It is important to replace the reagents to get The black pump tubes may need replacement more often due to the fact that they are subject
reliable accurate readings from the CLX-Ex. The Buffer supplied can last for up to one year. to wear. The inline check valves should not need to be replaced and should be saved. Please
Each mixed indicator reagent will last for up to 90 days* when kept in the special cooling note that the check valves are directional as shown below.
chamber. The one year kit includes one buffer bottle and four sets of indicator reagents. The
Buffer reagent is mounted in a clip and is further held with a Velcro strap. The indicator
reagent is in a 125ml bottle that is placed inside the cooling chamber. See section 11.2 for
more information on the reagents.
The CLX-Ex is shipped with one CLX-Ex Tubing/Cuvette kit, HF scientific Catalog #
09950EX. The kit consists of the following: Figure 5: Inline check valve
Qty Part Steps:

1 Spare Buffer Cap Assembly 1 Flush the system as described above to reduce personal contact with the reagents.
1 Spare Indicator Cap Assembly 2 Press SERVICE to stop the flow of sample water and drain the cuvette.
8 Pump Tubes 3 Remove and retain the thumb screw on top of the pump; pull the pump hammer and
1 Spare Cuvette spring up and out of the way. There is no need to completely remove the hammer and
spring.
Two replacement sets of reagent cap/tubing assemblies are supplied with the CLX-Ex; one 4 Working on one reagent side at a time. Replace the black tubing between optics inlet
for the buffer and one for the indicator. and the check valve OUTLET. Discard the old tubing.
5 Ensure the check valve is placed into its seat.
Additional kits can be ordered from your local HF scientific distributor or representative. It 6 Repeat steps 4 & 5 for the other reagent.
is recommended to keep one kit on hand at all times. 7 Replace the hammer and spring back into place and secure with the thumb screw.
8 Check the drawing on the following page to ensure correct installation.
Generally, both pump tubes should be replaced annually. Spare cap assemblies for both the 9 Return to operation as described.
buffer and the indicator are supplied and can be replaced when needed.
Cap Assembly Replacement
When the Cap Assemblies needs to be changed follow the procedure shown below. It is
Every 90 days recommended that both assemblies are changed at the same time.
1. The indicator reagent required for operating this instrument must be changed at least
every 90 days. The buffer reagent can be used up to one year.
Steps:
2. The internal strainer should be checked and cleaned if necessary.
1 Flush the system as described above to reduce personal contact with the reagents.
3. The glass cuvette should be inspected. Check for excessive debris on the inside surface
2 Press SERVICE to stop the flow of sample water and drain the cuvette.
of the glass. It is suggested to keep a spare cuvette to replace when required. The old
3 Replace the buffer cap (blue or black cap) assembly.
cuvette may be cleaned, if possible, for future replacement.
4 Repeat step 3 above, for the indicator side (white cap).
5 Replace reagents, prime and return to service.
Flushing the System
Press the SERVICE button to stop the water flow. Remove old reagents and discard. Place
the suction tubes in a small container of clean water. Press SERVICE to return to operation
mode, press PRIME and then 8 to flush the system with water. Remove the suction tubes
from the water Press PRIME and then 8 to remove most of the water.

REV 1.94 REV 1.94
Cuvette Replacement 11.2 Replacing or Installing the Reagents
Check the condition of cuvette and change if it appears badly soiled or discolored. Follow
Reagent kits are available from HF scientific. Refer to section 12.0 Replacement Parts and
the steps below.
Accessories for the appropriate Catalog number. There are two reagents required for the
Steps:
instrument to operate; the buffer and the indicator.
1. Replace the two Cap Assemblies.
2. Turn the knurled top on the optics system counterclockwise (as viewed for the top) The reagents are provided “wet” and the buffer is ready to use and will last up to one year.
until the cuvette just “pops” out, but do not remove the top. The smaller indicator reagent does require the addition of the DPD power to activate it.
3. When the cuvette “pops” out, move the retaining o-ring & remove the cuvette. You Once activated it starts to oxidize. This process is slowed by keeping it in the cooling
may need a stiff wire such as a bent paper clip to grasp the cuvette. Retain this cuvette chamber.
for future use if it can be cleaned.
4. Install the new cuvette by pushing it firmly in place and turning the knurled top
clockwise until the cuvette is held securely. When commissioning the CLX-Ex it is recommended to follow the procedure in section
5. Check the drawing on the following page to ensure correct installation. 11.4. This procedure only needs to be done once when the instrument first
6. Return to operation as described. commissioned.
T-Strainer Cleaning
The T-strainer is integral to the instrument and must be checked 11.3 Indicator Reagent Preparation
occasionally. When necessary it must be removed and cleaned. The
Remove the cap of the small liquid indicator reagent and add the contents of the DPD
strainer screen may require replacement after a period of time.
powder bottle (small brown bottle). Cap and shake to fully dissolve the powder.
Steps:
1. Press SERVICE to stop the flow of sample water and drain the
cuvette. Once mixed the indicator has an expected life of 90 days if kept in the powered cooling
2. Ensure the source water is turned off. chamber. Write the mixing date on the reagent bottle labels in the area provided.
3. The T-strainer is clamped to the intake regulator. The removal Dispose of expired reagents correctly.
requires the use of a flat blade screwdriver as shown in the photo.
Once the two clamps are opened the T-strainer can be removed.
4. Disconnect the top of the T-strainer and regulator from the tubing To replace the reagents, press the SERVICE button; this will empty the cuvette and stop
and clear of the enclosure. any flow of water. Remove the cap on both bottles replace with the cap supplied with the
5. Remove and clean the screen and then reassemble. CLX-Ex. The buffer is installed on the left and the indicator is installed in the cooling
6. Be sure to tighten the bowl of the strainer. chamber. The suction tube for both reagents will reach the bottom of the bottles.
7. Be certain the clamps are tightened fully and the tubing
To complete the replacement procedure, press the PRIME button and then the 8 button.
connections are complete. You may require pliers to close
This will draw enough of each reagent to completely prime the tubes and replace any old
the clamps.
solution. The system will automatically return to normal operation after it has primed.
8. Turn source water back on.
9. Return to normal operation.
10. Check for any leaks. Use caution when changing the reagents as they are corrosive. These reagents may
stain clothing. After changing the reagents, operators should wash their hands.
Return to Normal Operation
Press the SERVICE button to return sample flow to the system. Check for leaks. If a leak
occurs press SERVICE again, repair leak and try again. Once the system is operating
correctly, return or replace reagents and press PRIME and then 8 one time to restart reagent
flow. The system will automatically return to normal operation.
Tubes may darken due to contact with the reagent. This condition does not affect the
performance of these parts.

REV 1.94 REV 1.94
11.4 Check Valve Flushing Kit 12.0 Accessories and Replacement Parts List
Sometimes upon initial commissioning, the check valves stick and require manual priming. The items shown below are recommended accessories and replacement parts.
This should not be needed after commissioning. Be careful when using this kit to use only
chlorine free water. Complete instructions are included in the kit. Accessory Catalog Number Photo
Reagent Kit – Total Chlorine 12 09991

month supply
Purge Manual CLX-Ex (Air 28749 N/A

Sentinel)
Operating Manual CLX-Ex 29146 N/A
Tubing/Cuvette Kit 09950EX
Replacement Cuvette 25018S

Figure 6: Check Valve Flushing
11.5 Instrument Storage

If the CLX-Ex is relocated or will be inactive for long periods of time (several months),
remove the reagents. Flush the reagent system as describe in 11.1 Maintenance Schedule.
Place the instrument in Service mode to drain the system then remove power by
disconnecting the mains power plug. It is usually a good idea to disconnect or shut off the
source water.
Check Valve Kit 25017S
11.6 Cleaning the CLX-Ex
Flush the system as mentioned in section 11.1 Maintenance Schedule. When the flushing is
finished, press the SEVICE button wait until the display reads HOLd.
As a matter of safety, always disconnect any power source to the CLX-Ex prior to
attempting any cleaning. It is recommended that the source water is also shut off.
Isopropyl alcohol (rubbing alcohol) on a soft cotton cloth works very well in removing Ferrite for 4-20mA or RS-485 24560
reagent stains from plastic parts, the key pad and the display. Use care when cleaning
around electrical components. Do not use any harsh cleaning agents as these may cause
damage to the instrument components.
Ensure that the system is dry prior to applying power.

REV 1.94 REV 1.94
13.0 IECEx Certificate
A copy of the certificate is shown below for convenience but it should be noted that the certificate
is only valid while online at iecex.com. Use the following
Check Valve Flushing Kit 25096 link:http://iecex.iec.ch/iecex/iecexweb.nsf/fc034777969a786bc1256d42005bd791/4d2622fa4eb3
7677c1257d790082e91e?OpenDocument
T-Strainer/ Pressure Regulator 25357

Assembly
Replacement T-Strainer Screen 28625
Water Intake Assembly 28411
To order any accessory or replacement part, please contact the HF scientific Customer Service
Department. If for any reason technical assistance is needed regarding this instrument, please
do not hesitate to contact the HF scientific Technical Services Department.
HF scientific
Fort Myers, Florida 33916-7597
Phone: (239) 337-2116
Toll Free: (888) 203-7248
Fax: (239) 332-7643
www.hfscientific.com

REV 1.94 REV 1.94
REV 1.94 REV 1.94
14.0 Limited Warranty
H.F. Scientific, Inc. (the "Company") warrants each product to be free from defects in material and
workmanship under normal usage for a period of twenty-four (24) months from first use or thirty-
six (36) months from shipment, whichever occurs first. In the event of defects within the warranty
period, the Company will, at its option, replace or recondition the product without charge. Parts,
which by their nature are normally required to be replaced periodically, consistent with normal
maintenance, specifically reagent, desiccant, sensors, electrodes and fuses are excluded. Also
excluded are accessories and supply type items.
Proof of purchase (invoice or paid order confirmation) and/or first use (commissioning) must be
provided when making a product warranty claim.
THE WARRANTY SET FORTH HEREIN IS GIVEN EXPRESSLY AND IS THE ONLY
WARRANTY GIVEN BY THE COMPANY WITH RESPECT TO THE PRODUCT. THE
COMPANY MAKES NO OTHER WARRANTIES, EXPRESS OR IMPLIED. THE COMPANY
HEREBY SPECIFICALLY DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR
IMPLIED, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
The remedy described in the first paragraph of this warranty shall constitute the sole and exclusive
remedy for breach of warranty, and the Company shall not be responsible for any incidental, special
or consequential damages, including without limitation, lost profits or the cost of repairing or
replacing other property which is damaged if this product does not work properly, other costs
resulting from labor charges, delays, vandalism, negligence, fouling caused by foreign material,
damage from adverse water conditions, chemical, or any other circumstances over which the
Company has no control. In addition, the Company shall not be responsible for any costs incidental
to the Company’s warranty response efforts, including, without limitation, costs associated with the
removal and replacement of systems, structures or other parts of facilities, de-installation,
decontamination and re-installation of products, or transportation of products to and from the
Company. This warranty shall be invalidated by any abuse, misuse, misapplication, improper
installation or improper maintenance or alteration of the product.
Some States do not allow limitations on how long an implied warranty lasts, and some States do not
allow the exclusion or limitation of incidental or consequential damages. Therefore the above
limitations may not apply to you. This Limited Warranty gives you specific legal rights, and you
may have other rights that vary from State to State. You should consult applicable state laws to
determine your rights. SO FAR AS IS CONSISTENT WITH APPLICABLE STATE LAW, ANY
IMPLIED WARRANTIES THAT MAY NOT BE DISCLAIMED, INCLUDING THE IMPLIED
WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE,
ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF ORIGINAL
SHIPMENT.
HF scientific, inc.
Fort Myers, Florida 33916-7597
Phone: (239) 337-2116
Fax: (239) 332-7643
Toll free: 888-203-7248
Website: www.hfscientific.com
REV 1.94 REV 1.94
Notes
22/7/2019 HN 2140
DOSING PUMP(S)
GRUNDFOS INSTRUCTIONS
English (GB) Installation and operating instructions
Original installation and operating instructions 6.4.4 Batch (pulse-based) 25
6.4.5 Dosing timer cycle 26
CONTENTS 6.4.6 Dosing timer week 27
SMART Digital XL - DDA Page 6.5
6.6
Analog output
SlowMode
28
28
1. General information 3
From 60 to 200 l/h 1.1 Symbols used in this document 3
6.7 FlowControl 29
6.8 Pressure monitoring 30
1.2 Qualification and training of personnel 3
Installation and operating instructions 1.3 Safety instructions for the operator/user 3
6.8.1 Pressure setting ranges 30
6.8.2 Calibration of pressure sensor 30
1.4 Safety of the system in the event of a
failure in the dosing pump 4 6.9 Flow measurement 31
1.5 Dosing chemicals 4 6.10 AutoFlowAdapt 31
1.6 Diaphragm leakage 4 6.11 Auto deaeration 31
1.6.1 Diaphragm leakage detection (optional) 4 6.12 Diaphragm leak. detect. 31
6.13 Key lock 32
2. Product introduction 5
6.13.1 Temporary deactivation 32
2.1 Applications 5
6.13.2 Deactivation 32
2.2 Improper operating methods 5
6.14 Display setup 32
2.3 Symbols on the pump 6
6.14.1 Units 32
2.4 Nameplate 6
6.14.2 Additional display 32
2.5 Type key 7
6.15 Time+date 33
2.6 Product overview 8 6.16 Bus communication 33
3. Technical data / Dimensions 9 6.16.1 GENIbus communication 33
3.1 Technical data 9 6.16.2 Possible industrial bus types 33
3.2 Dimensions 11 6.16.3 Activate communication 33
4. Assembly and installation 12 6.16.4 Setting the bus address 34
4.1 Pump assembly 12 6.16.5 Characteristics of bus communication 34
4.1.1 Requirements 12 6.16.6 Deactivate communication 34
4.1.2 Aligning and installing the mounting plate 12 6.16.7 Communication faults 34
4.1.3 Installing the pump on the mounting plate 12 6.17 Inputs/Outputs 35
4.1.4 Adjusting the control cube position 12 6.17.1 Relay outputs 35
4.2 Hydraulic connection 13 6.17.2 External stop 36
4.3 Electrical connection 14 6.17.3 Empty and Low level signals 36
6.18 Basic settings 36
5. Startup 16
5.1 Preparing the pump for startup 16 7. Service 37
5.2 Starting up the pump 16 7.1 Regular maintenance 37
5.3 Setting the menu language 17 7.2 Cleaning 37
5.4 Deaerating the pump 18 7.3 Service system 37
5.5 Calibrating the pump 18 7.4 Perform service 38
5.5.1 Calibration process - example for DDA 19 7.4.1 Dosing head overview 38
60-10 7.4.2 Dismantling the diaphragm and valves 39
6. Operation 20 7.4.3 Reassembling the diaphragm and valves 39
6.1 Control elements 20 7.5 Resetting the service system 39
6.2 Display and symbols 20 7.6 Diaphragm leakage 40
6.2.1 Navigation 20 7.6.1 Dismantling in case of diaphragm 40
leakage
6.2.2 Operating states 20
7.6.2 Dosing liquid in the pump housing 40
6.2.3 Sleep mode (energy-saving mode) 20
7.7 Repairs 41
Further languages 6.2.4 Overview of display symbols 21
6.3 Main menus 22 8. Faults 41
6.3.1 Operation 22 8.1 List of faults 42
http://net.grundfos.com/qr/i/98767821 8.1.1 Faults with error message 42
6.3.2 Info 22
6.3.3 Alarm 22 8.1.2 General faults 44
6.3.4 Setup 23 9. Disposal 44
6.4 Operation modes 23
6.4.1 Manual 23
6.4.2 Pulse 24
6.4.3 Analog 0/4-20 mA 24
2
1.2 Qualification and training of personnel 1.4 Safety of the system in the event of a To avoid any danger resulting from diaphragm
Prior to installation, read this document. leakage, observe the following:
Installation and operation must comply The personnel responsible for the installation, failure in the dosing pump
with local regulations and accepted codes operation and service must be appropriately • Perform regular maintenance. See section
The dosing pump was designed according to the
of good practice. qualified for these tasks. Areas of responsibility, 7.1 Regular maintenance.
latest technologies and is carefully manufactured
levels of authority and the supervision of the and tested. • Never operate the pump with blocked or soiled
personnel must be precisely defined by the operator. drain opening.
1. General information If necessary, the personnel must be trained
If it fails regardless of this, the safety of the overall
system must be ensured. Use the relevant – If the drain opening is blocked or soiled,
These installation and operating instructions contain appropriately. proceed as described in section
monitoring and control functions for this.
general instructions that must be observed during 7.6.1 Dismantling in case of diaphragm
Risks of not observing the safety instructions
installation, operation and maintenance of the pump. Make sure that any chemicals that are leakage.
It must therefore be read by the installation engineer Non-observance of the safety instructions may have
dangerous consequences for the personnel, the released from the pump or any damaged • Take suitable precautions to prevent harm to
and the relevant qualified operator prior to lines do not cause damage to system parts
environment and the pump and may result in the loss health and damage to property from escaping
installation and startup, and must be available at the and buildings.
of any claims for damages. dosing liquid.
installation location at all times.
It may lead to the following hazards: The installation of leak monitoring • Never operate the pump with damaged or loose
1.1 Symbols used in this document solutions and drip trays is recommended. dosing head screws.
• Personal injury from exposure to electrical,
mechanical and chemical influences. 1.6.1 Diaphragm leakage detection (optional)
WARNING 1.5 Dosing chemicals
• Damage to the environment and personal injury Applies to DDA-AR control variant.
Indicates a hazardous situation which, if from leakage of harmful substances. Before switching the supply voltage back on, the
dosing lines must be connected in such a way that Pumps with diaphragm leakage detection (DLD)
not avoided, could result in death or have a special dosing head with a special diaphragm
serious personal injury. 1.3 Safety instructions for the any chemicals in the dosing head cannot spray out
and put people at risk. and a pressure switch. The pressure switch is fitted
operator/user and connected to the pump on delivery.
CAUTION The dosing medium is pressurised and can be
The safety instructions described in these harmful to health and the environment. For pumps with diaphragm leakage detection the
Indicates a hazardous situation which, if instructions, existing national regulations on health pressure differential between inlet and outlet side
When working with chemicals, the accident
not avoided, could result in minor or protection, environmental protection and for accident must be at least 2 bar / 29 psi.
prevention regulations applicable at the installation
moderate personal injury. prevention and any internal working, operating and
site should be applied (e.g. wearing protective
safety regulations of the operator must be observed.
The text accompanying the three hazard symbols clothing and safety goggles).
DANGER, WARNING and CAUTION is structured in Information attached to the pump must be observed.
Observe the chemical manufacturer's safety data
the following way: Leakages of dangerous substances must be sheets and safety instructions when handling
disposed of in a way that is not harmful to the chemicals!
SIGNAL WORD personnel or the environment.
A deaeration hose, which is routed into a container,
Description of hazard Damage caused by electrical energy must be e.g. a drip tray, must be connected to the deaeration
Consequence of ignoring the warning. prevented, see the regulations of the local electricity valve.
- Action to avoid the hazard. supply company.
1.6 Diaphragm leakage
WARNING
A blue or grey circle with a white graphical If the diaphragm leaks or is broken, dosing liquid
symbol indicates that an action must be Electric shock escapes from the drain opening on the dosing head. Fig. 1 Diaphragm leakage detection
taken. Death or serious personal injury See fig. 4, pos. 16. Observe section 7.6 Diaphragm
- Keep liquids away from the power leakage.
supply and electrical components. Pos. Components
If these instructions are not observed, it
may result in malfunction or damage to the
WARNING
Before starting work on the pump, the 1 Pressure switch
equipment. Danger of explosion, if dosing liquid
pump must be in the "Stop" operating state has entered the pump housing! 2 Dosing head
or be disconnected from the power supply.
Death or serious personal injury 3 Drain opening
The system must be pressureless.
Tips and advice that make the work easier. Operation with damaged diaphragms can
lead to dosing liquid entering the pump 4 Dosing medium
The mains plug is the separator separating housing. D1 Working diaphragm
the pump from the mains. - In case of diaphragm leakage,
immediately separate the pump from D2 Signal diaphragm (intermediate layer)
the power supply! D3 Protective diaphragm
Only original accessories and original spare parts - Make sure the pump cannot be put back
should be used. into operation by accident!
- Dismantle the dosing head without
connecting the pump to the power
supply and make sure no dosing liquid
has entered the pump housing. Proceed
as described in section
7.6.1 Dismantling in case of diaphragm
leakage.
3 4
In case of a leak in the working diaphragm: Areas of application 2.3 Symbols on the pump
• Dosing medium (4) penetrates between working • Drinking water treatment
diaphragm (D1) and protective diaphragm (D3) • Wastewater treatment Symbol Description
and is transferred to the pressure switch (1)
• Boiler water treatment
through the signal diaphragm (D2).
• Cooling water treatment Indication of universally dangerous spot.
• On the next discharge stroke the increasing
pressure activates the pressure switch (1). • Process water treatment
• The pump indicates an alarm and stops. • CIP (Clean-In-Place)
The pump provides two relay outputs, which can be • Swimming pool water treatment In case of emergency and prior to all maintenance work and repairs, take the mains plug out
used to trigger an external alarm, for example. • Chemical industry of the power supply!
Replace the diaphragm as soon as possible after a • Ultrafiltration process and reverse osmosis
diaphragm leakage was detected. • Food and beverage industry
The device complies with electrical safety class I.
• Paper and pulp industry
Replace the pressure switch, if the
diaphragm of the pressure switch is • Irrigation
damaged. 2.4 Nameplate
2.2 Improper operating methods
If both the working diaphragm (D1) and the The operational safety of the pump is only
protective diaphragm (D3) are damaged, dosing guaranteed if it is used in accordance with section
liquid escapes from the drain opening (3) on the 2.1 Applications.
dosing head.
Other applications or the operation of pumps in
Immediately separate the pump from the ambient and operating conditions, which are not
power supply. Observe section approved, are considered improper and are not
1.6 Diaphragm leakage. permitted. Grundfos cannot be held liable for any
damage resulting from incorrect use.
2. Product introduction The pump is NOT approved for operation Fig. 2 Nameplate
The DDA dosing pump is a self-priming diaphragm in potentially explosive areas, automotive
pump. It consists of a housing with PMS (Permanent applications or marine applications.
Pos. Description Pos. Description
Magnet Synchronous) motor and electronics, a
dosing head with double PTFE diaphragm and Frequent disengagement from the mains 1 Type designation 6 Enclosure class
valves, and the control cube. voltage, e.g. via a relay, can result in
2 Voltage 7 Marks of approval
Excellent dosing features of the pump: damage to the pump electronics and in the
breakdown of the pump. The dosing 3 Frequency 8 Country of origin
• Optimal intake even with degassing media, as accuracy is also reduced as a result of
the pump always works at full suction stroke internal start procedures. 4 Power consumption 9 Max. operating pressure
volume.
Do not control the pump via the mains 5 Max. dosing flow 10 Model
• Continuous dosing, as the medium is sucked up voltage for dosing purposes!
with a short suction stroke, regardless of the
current dosing flow, and dosed with the longest Only use the "External stop" function to
possible dosing stroke. start and stop the pump!
2.1 Applications
The pump is suitable for liquid, non-abrasive,
non-flammable and non-combustible media.
Observe the technical data of the product. See
section 3.1 Technical data.
Observe the freezing and boiling points of the dosing
medium.
Make sure that parts in contact with the dosing
medium are resistant to the dosing medium under
operating conditions. See data booklet:
http://net.grundfos.com/qr/i/99021865.
Should you have any questions regarding the
material resistance and suitability of the pump for
specific dosing media, please contact Grundfos.
A sunscreen is required for outdoor installation.
5 6
2.5 Type key 2.6 Product overview
Valve type See
The type key is used to identify the precise pump Pos. Description
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG section
and is not used for configuration purposes.
Example: DDA 60-10 FCM-PVC/V/C-F-31U3U3FG 1 Standard 1 Control cube
2 Spring-loaded
Type 2 Graphic LC display 6.2.2
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG 3 Click wheel 6.1

Connection, inlet / outlet
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG 4 [100%] key 6.1
Max. flow [l/h] 5 Signal inputs/outputs 4.3
U3U3 2x Union nut G5/4
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG 6 Mounting plate
2x Hose connector 19/20 mm
2x Hose clamp 7 Mains connection
Max. pressure [bar]
2x Pipe connector 25 mm 8 [Start/stop] key 6.1
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG
A7A7 2x Union nut G5/4 9 Dosing head
Control variant 2x Inlay external thread 3/4" NPT 10 Valve, outlet side
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG A1A1 2x Union nut G5/4 (SS)
11 Deaeration valve
AR Alarm relay 2x Inlay internal thread Rp3/4" (SS)
12 Connection, deaeration hose
FCM AR + FlowControl function A3A3 2x Union nut G5/4 (SS)
Pressure switch of diaphragm
2x Inlay internal thread 3/4" NPT (SS) 13 leakage detection (optional for
Dosing head variant DDA-AR)
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG Mains plug FlowControl sensor plug (only
14
PVC Polyvinyl chloride DDA 60-10 FCM-PVC/V/C-F-31U3U3FG DDA-FCM)
PV PVDF F EU (Schuko) Fig. 3 Front view of the pump 15 Valve, inlet side
SS Stainless steel 1.4401 B USA, Canada Drain opening in case of
16
G UK diaphragm leakage
PVC + integrated diaphragm leakage
PVC-L
detection I Australia, New Zealand, Taiwan Signal connection (FlowControl
17
PV + integrated diaphragm leakage E Switzerland or diaphragm leakage detection)
PV-L
detection J Japan
SS + integrated diaphragm leakage L Argentina
SS-L
detection
Design / approval
Gasket material
G Grundfos red
E EPDM
A Grundfos green
V FKM
B Grundfos black
T PTFE
X Neutral / black
Valve ball material R EAC approval
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG C China approval
C Ceramics
Special variant Fig. 4 Dosing head
SS Stainless steel 1.4401
DDA 60-10 FCM-PVC/V/C-F-31U3U3FGC3
Control cube Standard
DDA 60-10 FCM-PVC/V/C-F-31U3U3FG C3 Inspection certificate 3.1 (EN 10204)
Front mounted (change to left or right is

F
possible)
Supply voltage
3 100-240 V 50/60 Hz single phase
7 8
3. Technical data / Dimensions
Data 60-10 120-7 200-4
3.1 Technical data Voltage [V] 100-240 V ± 10 %, 50/60 Hz
Length of mains cable [m] 1.5
Data 60-10 120-7 200-4
Max. inrush current for 2 ms (100 V) [A] 35
Turn-down ratio (setting range) [1:X] 800 800 800 Max. inrush current for 2 ms (240 V) [A] 70
Electrical
[l/h] 60 120 200 data Max. power consumption P 1 [W] 62
Max. dosing capacity
[gph] 15.8 32 52.8 Enclosure class IP65, Nema 4X
[l/h] 30 60 100 Electrical safety class I
Max. dosing capacity with SlowMode 50 %
[gph] 7.9 16 26.4 Pollution degree 2
[l/h] 15 30 50 Max. load for level input 12 V, 5 mA
Max. dosing capacity with SlowMode 25 %
[gph] 3.95 8 13.2 Max. load for pulse input 12 V, 5 mA
[l/h] 0.075 0.15 0.25 Max. load for External stop input 12 V, 5 mA
Min. dosing capacity
[gph] 0.0197 0.04 0.066 Min. pulse length [ms] 5
[bar] 10 7 4 Signal input Max. pulse frequency [Hz] 100
Max. operating pressure (backpressure)
[psi] 145 101 58 Impedance at 0/4-20 mA analog input [Ω] 15
[strokes/
Max. stroke frequency 1) 196 188 188 Accuracy of analog input (full-scale value) [%] ± 0.5
min]
Min. resolution of analog input [mA] 0.02
Stroke volume [ml] 5.56 11.58 19.3
Max. loop resistance in external circuit [Ω] 150
Accuracy of repeatability 5) [%] 1.5 SP + 0.1 FS 5)
2) Max. resistive load on relay output [A] 0.5
Max. suction lift during operation [m] 3
Max. voltage on relay/analog output [V] 30 VDC / 30 VAC
Max. suction lift when priming with wet
[m] 1.5
valves 2) Signal Max. loop resistance in external circuit of the
[Ω] 500
output 0/4-20 mA analog output
Min. pressure difference between inlet and [bar] 1 6)
outlet side Accuracy of analog output (full-scale value) [%] ± 0.5
Mechanical [psi] 14.5 6)
data Min. resolution of analog output [mA] 0.02
[bar] 2
Max. inlet pressure, inlet side Weight (PVC, PVDF) [kg] 6.7 7.9 8.9
[psi] 29
Weight/size Weight (stainless steel) [kg] 7.2 8.3 9.1
Max. viscosity in SlowMode 25 % with [mPas]
3000 3000 2000
spring-loaded valves 3) (= cP) Diaphragm diameter [mm] 74 97 117
Max. viscosity in SlowMode 50 % with [mPas] Sound
2000 1500 1000 Max. sound pressure level [dB(A)] 80
spring-loaded valves 3) (= cP) pressure
Max. viscosity without SlowMode with [mPas]
1000 1000 500 Approvals CE, CSA-US, NSF61, EAC, ACS, RCM
spring-loaded valves 3) (= cP)
[mPas] 1)
Max. viscosity without spring-loaded valves 3) 100 The maximum stroke frequency varies depending on calibration
(= cP) 2)
Data is based on measurements with water
Min. internal hose/pipe diameter inlet/outlet 3)
[mm] 19 Maximum suction lift: 1 m, dosing capacity reduced (approx. 30 %)
side 2), 4)
4)
Min. internal hose/pipe diameter inlet/outlet Length of inlet line: 1.5 m, length of outlet line: 10 m (at max. viscosity)
[mm] 19
side (high viscosity) 4) 5)
FS = Full-scale (maximum actual dosing flow), SP = Setpoint
Min. / Max. liquid temperature (PVDF, SS) [°C] 0 / 50 6)
For FCM control variant and for pumps with diaphragm leakage detection the pressure difference must be
Min. / Max. liquid temperature (PVC) [°C] 0 / 40 at least 2 bar / 29 psi.
Min. / Max. ambient temperature [°C] 0 / 45

Min. / Max. storage temperature (PVDF, SS) [°C] -20 / 70
Min. / Max. storage temperature (PVC) [°C] -20 / 45
Max. relative humidity (non-condensing) [%] 90
Max. altitude above sea level [m] 2000
9 10
3.2 Dimensions 4. Assembly and installation 4.1.4 Adjusting the control cube position
The control cube is fitted to the front of the pump on
4.1 Pump assembly delivery. It can be turned by 90 ° so that the user can
select to operate the pump from the right or left side.
Install the pump in such a way that the
plug can easily be reached by the operator Install the control cube correctly to ensure
during operation. This will enable the the enclosure class (IP65 / Nema 4X) and
operator to separate the pump from the shock protection.
power supply quickly in case of
emergency. 1. Switch off the power supply.
2. Carefully remove both protective caps on the
4.1.1 Requirements control cube using a thin screwdriver.
• The installation location must be protected from 3. Loosen the screws.
rain, humidity, condensation, direct sunlight and 4. Carefully lift off the control cube only so far from
dust. the pump housing that no tensile stress is
• The installation location must have sufficient produced on the flat band cable.
lighting to ensure safe operation. – Make sure no liquid enters the housing.
• Observe the permissible ambient conditions. See 5. Turn the control cube by 90 ° and re-attach.
section 3.1 Technical data.
– Make sure the O-ring is placed correctly.
• The mounting surface must be stable and must
not vibrate. 6. Push down the cube and tighten the screws
using a torque wrench.
• The mounting plate must be mounted horizontally
e.g. on a tank. – Torque [Nm]: 1.3 (± 0.2)
• Dosing must flow upwards vertically. 7. Attach the protective caps observing the correct
orientation.
4.1.2 Aligning and installing the mounting plate
The mounting plate can be used as a drill template,
please see fig. 5 for drill hole distances.
1. Indicate drill holes.
2. Drill holes.
3. Secure mounting plate using four screws on a
bracket or a tank.
4.1.3 Installing the pump on the mounting plate
Fig. 5 Dimensional sketch 1. Remove the locking screws from their transport
position on the mounting plate.
2. Place the pump on the mounting plate support
Dosing head A A1 A2 B C D clamps and slide it in as far as possible.
Pump type
material [mm] [mm] [mm] [mm] [mm] [mm]
– The mounting plate moves into the final
DDA 60-10 PVC/PV 410 374 26 263 112 45 position when you tighten the locking screws.
3. Carefully screw in and tighten the locking screws
DDA 60-10 SS 405 364 - 263 112 45
using a torque wrench.
DDA 120-7 PVC/PV 410 374 26 276.5 97 45 – Torque [Nm]: 2.5 (+ 0.5)
DDA 120-7 SS 405 364 - 276.5 97 45
DDA 200-4 PVC/PV 410 374 26 287.5 88 45
DDA 200-4 SS 405 364 - 287.5 88 45
Fig. 7 Adjusting control cube
Fig. 6 Installing the pump on the mounting

plate
11 12
4.2 Hydraulic connection Hose connection, type U3U3 Pipe connection, type U3U3
For details on connection types, see section For details on connection types, see section
WARNING 2.5 Type key. 2.5 Type key.
Chemical hazard 1. Make sure the system is pressureless. 1. Make sure the system is pressureless.
Death or serious personal injury 2. Install hose connector (1) with union nut (2) at 2. Push union nut (2) across pipe (3).
- Observe the material safety data sheet inlet and outlet valve. 3. For PVC pipe:
of the dosing medium. – Make sure the gasket at the valve is placed Glue inlay (1) to end of pipe (3) according to pipe
- Wear protective clothing (gloves and correctly. manufacturer's specification.
goggles) when working on the dosing
– Tighten union nuts manually. Do not use tools. 4. For PVDF pipe:
head, connections or lines.
3. If using PTFE gaskets, retighten union nuts after Weld inlay (1) to end of pipe (3) according to pipe
The dosing head may contain water from the factory 2-5 operating hours. manufacturer's specification. Fig. 10 Hydraulic connection, type A7A7
check. When dosing media which should not come 5. Install pipe with union nut (2) at inlet and outlet
4. Push hose clamp (3) across hose (4).
into contact with water, another medium must be valve.
dosed beforehand. 5. Push hose (4) completely onto hose connector
(1) and tighten hose clamp (3). – Make sure the gasket at the valve is placed
Faultless function can only be guaranteed in correctly.
conjunction with lines supplied by Grundfos. 6. Attach a deaeration hose to the corresponding
connection (see fig. 4, pos. 12) and run it into a – Tighten union nuts manually. Do not use tools.
The lines used must comply with the pressure limits
suitable container or collecting tray. 6. If using PTFE gaskets, retighten union nuts after
as per section 3.1 Technical data.
2-5 operating hours.
Important information on installation 7. Attach a deaeration hose to the corresponding
• Observe suction lift and line diameter, see connection (see fig. 4, pos. 12) and run it into a
section 3.1 Technical data. suitable container or collecting tray.
• Shorten hoses and pipes at right angles.
Fig. 11 Hydraulic connection, type A1A1, A3A3
• Ensure that there are no loops or kinks in the
hoses. 4.3 Electrical connection
• Keep inlet line as short as possible.
The mains plug is the separator separating the pump
• Route inlet line up towards the inlet valve. from the mains.
• Installing a filter in the inlet line protects the Fig. 8 Hydraulic connection All electrical connections must be carried out by a
entire installation against dirt and reduces the qualified electrician in accordance with local
risk of leakage. regulations.
• Install a pressure-relief valve in the outlet line to The pump can start automatically when the power
provide protection against impermissibly high supply is switched on.
pressure. Fig. 9 Hydraulic connection
• We recommend the installation of a pulsation CAUTION
damper downstream the pump: Pipe connection, types A1A1, A3A3, A7A7
Automatic startup
– for pipe installations. For details on connection types, see section Minor or moderate personal injury
2.5 Type key. - Make sure the pump has been correctly
– for hose installations where the pump is
operated with ≥ 75 % of its dosing capacity. 1. Make sure the system is pressureless. installed and is ready to be started
2. Push union nut (2) across pipe (3). before you switch on the power supply.
• Only control variant DDA-FCM:
For discharge quantities < 1 l/h we recommend 3. Apply appropriate sealing material to thread of The enclosure class (IP65 / Nema 4X) is only
the use of an additional spring-loaded valve inlay (1). guaranteed if plugs or protective caps are correctly
(approx. 2 bar) on the outlet side for the safe 4. Screw inlay (1) into end of pipe (3). installed.
generation of the necessary differential pressure. Do not manipulate mains plug or cable.
5. Install pipe with union nut (2) at inlet and outlet
Pressure differential between inlet and valve. The rated voltage of the pump must conform to local
outlet side must be at least 1 bar / 14.5 psi. – Make sure the gasket at the valve is placed conditions. See section 2.4 Nameplate.
correctly.
For control variant FCM and for pumps
with diaphragm leakage detection the – Tighten union nuts manually. Do not use tools.
pressure differential between inlet and 6. If using PTFE gaskets, retighten union nuts after
outlet side must be at least 2 bar / 29 psi. 2-5 operating hours.
7. Attach a deaeration hose to the corresponding
connection (see fig. 4, pos. 12) and run it into a
suitable container or collecting tray.
13 14
Signal connections signal connection (DDA-FCM) 5. Startup
WARNING 5.1 Preparing the pump for startup
Electric shock
Death or serious personal injury CAUTION
- Electric circuits of external devices Chemical hazard
connected to the pump inputs must be
Minor or moderate personal injury
separated from dangerous voltage by
- Observe the material safety data sheet
means of double or reinforced
of the dosing medium.
insulation!
- Wear protective clothing (gloves and
goggles) when working on the dosing
head, connections or lines.
- Collect and dispose of all chemicals in a
way that is not harmful to persons or the
environment.
The pump can start automatically when the power
Fig. 13 FlowControl signal connection supply is switched on.
DLD signal connection (optional for DDA-AR) CAUTION

Automatic startup
Minor or moderate personal injury
- Make sure the pump has been correctly
installed and is ready to be started
before you switch on the power supply.
Tighten the dosing head screws with a

torque wrench before startup and every
time the dosing head has been opened.
After 48 operating hours, retighten the
dosing head screws using a torque
wrench. Torque [Nm]: 6 (+ 1).
• Make sure the pump has been connected
electrically by a qualified person.
• Make sure the power supply specified on the
Fig. 14 DLD signal connection nameplate matches the local conditions.
• Check that all pipe or hose connections have
been tightened properly and tighten them, if
necessary. See section 4.2 Hydraulic connection.
Fig. 12 Wiring diagram of the electrical connections 5.2 Starting up the pump
1. Read section 5.1 Preparing the pump for startup.
2. Switch on the power supply.
Symbol Function Pin assignment
3. Proceed according to sections:
1/brown 2/white 3/blue 4/black
– 5.3 Setting the menu language
Analog GND/(-) mA (+) mA – 5.4 Deaerating the pump
External stop GND X – 5.5 Calibrating the pump.
Pulse GND X
1 2 3 4
Low-level signal X GND
Empty signal X GND
1/brown 2/white 3/blue 4/black 5/yellow/green
Analog output (+) mA GND/(-) mA
1 2/brown 3/blue 4 5/black
GENIbus RS-485 A RS-485 B GND
1/brown 2/white 3/blue 4/black

Relay 1 X X
Relay 2 X X
15 16
5.3 Setting the menu language 5.4 Deaerating the pump
For description of control elements, see section 6. 1. Read section 5.1 Preparing the pump for startup.
2. Open the deaeration valve by approximately half
1. Turn click wheel to highlight the cog symbol.
Operation a turn.
60.0 l/h
WARNING
Pressurised dosing medium
Manual Death or serious personal injury
- Do not open the deaeration valve by
more than one full turn.
3. Press the [100%] key and hold it down until liquid
2. Press the click wheel to open the "Setup" menu. Operation flows out of the deaeration hose continuously
and without any bubbles.
60.0 l/h 4. Close the deaeration valve.
Manual
Press the [100%] key and simultaneously
turn the click wheel clockwise to increase
the duration of the process to up to 300
seconds. After setting the seconds, do not
3. Turn the click wheel to highlight the "Language"
menu.
Setup press the key any longer.
Language English >
Operation mode Manual > 5.5 Calibrating the pump
Analog output Actual flow > The pump is calibrated in the factory for media with a
SlowMode Off > viscosity similar to water at maximum pump
FlowControl active ❑ backpressure. See section 3.1 Technical data.
If the pump is operated with a backpressure that
4. Press the click wheel to open the "Language"
menu.
Setup deviates or if dosing a medium whose viscosity
deviates, the pump must be calibrated.
Language English > For pumps with FCM control variant, it is not
Operation mode Manual > necessary to calibrate the pump if there is deviating
Analog output Actual flow > or fluctuating backpressure as long as the
SlowMode Off > "AutoFlowAdapt" function has been enabled. See
FlowControl active ❑ section 6.10 .
During calibration the pump performs 100

5. Turn the click wheel to highlight the desired
language.
Language strokes/minute as a standard. If the
SlowMode function is activated, the
English
Deutsch number of strokes is 60 at 50 % and 30 at
❑
Francais 25 %.
❑
Espanol ❑ Requirements
Italiano ❑ • The hydraulics and electrics of the pump are
connected. See section 4. Assembly and
6. Press the click wheel to select the highlighted
language.
Language installation.
• The pump is integrated into the dosing process
English under operating conditions.
Deutsch ❑
Francais • The dosing head and inlet hose are filled with
❑
Espanol dosing medium.
❑
Italiano ❑ • The pump has been deaerated.
7. Press the click wheel again to confirm the "Confirm

settings?" prompt and apply the setting.
Language
Confirm
settings?
Fig. 15 Set menu language
17 18
5.5.1 Calibration process - example for DDA 60-10 6. Operation 6.2 Display and symbols
1. Fill a measuring beaker with dosing medium. 6.2.1 Navigation
6.1 Control elements
Recommended filling volumes V 1: In the "Info", "Alarm" and "Setup" main menus, the
The pump control panel includes a display and the options and submenus are displayed in the rows
– DDA 60-10: 2.5 l
following control elements. below. Use the "Back" symbol to return to the higher
– DDA 120-7: 5 l
– DDA 200-4: 8 l V1 = 2.5 l menu level. The scroll bar at the right edge of the
display indicates that there are further menu items
which are not shown.
The active symbol (current cursor position) flashes.
2. Read off and note down the fill volume V1 (e.g. Press the click wheel to confirm your selection and
2.5 l). open the next menu level. The active main menu is
3. Place the inlet hose in the measuring beaker. displayed as text, the other main menus are
displayed as symbols. The position of the cursor is
highlighted in black in the submenus.
When you position the cursor on a value and press
the click wheel, a value is selected. Turning the click
wheel clockwise increases the value, turning the
click wheel counter-clockwise reduces the value.
Fig. 16 Control panel When you now press the click wheel, the cursor will
be released again.
Pos. Description 6.2.2 Operating states
4. Start the calibration process in the "Setup > The operating state of the pump is indicated by a
Calibration" menu. Calibration 1 Graphical LC display
symbol and display colour.
[Start/stop] key:
2
0 START Starting and stopping the pump. Display Fault Operating state
Strokes:
Click wheel:
STOP Stop Standby
The click wheel is used to navigate through White -
Calibrat. volume: 0.0000ml the menus, select settings and confirm
them. Turning the click wheel clockwise Running
3 Green -
moves the cursor clockwise in increments
5. The pump executes 200 dosing strokes and
displays the factory calibration value (e.g. 1.05 l). Calibration in the display. Turning the click wheel
counter-clockwise moves the cursor Yellow Warning
Stop Standby Running
counter-clockwise.
Strokes: 200 START
STOP 4
[100%] key:
The pump doses at maximum flow
Red Alarm
Stop Standby
regardless of the operation mode. 6.2.3 Sleep mode (energy-saving mode)

Calibrat. volume: 1.05l
If in the "Operation" main menu the pump is not
operated for 30 seconds, the header disappears.
6. Remove the inlet hose from the measuring After two minutes, the display brightness is reduced.
beaker and check the remaining volume V 2 (e.g.
1.39 l). V 2 = 1.39 l If in any other menu the pump is not operated for two
minutes, the display switches back to the
"Operation" main menu and the display brightness is
7. From V 1 and V2, calculate the actual dosed reduced. This state will be cancelled when the pump
volume Vd = V 1 - V 2 (e.g. 2.5 l - 1.39 l = 1.11 l). is operated or a fault occurs.
V d = V 1 - V2 = 1.11 l
8. Set and apply V d in the calibration menu.

• The pump is calibrated. Calibration
START
Strokes:
200 STOP
Calibrat. volume: 1.11 l
Actual dosed volume V d
19 20
6.2.4 Overview of display symbols 6.3 Main menus
The following display symbols may appear in the menus. The main menus are displayed as symbols at the top The "Info > Counters" menu contains the following
of the display. The currently active main menu is counters:
displayed as text.
Top row with main menus (Sect. 6.3)
Counters Resettable
Operation Back 6.3.1
Status information such as the dosing flow,
Info Yes
selected operation mode and operating state Total dosed volume [l] or US gallons
Alarm Run display is displayed in the "Operation" main menu.
Setup Running - rotates when pump is dosing No

Accumulated operating hours (pump
Blocked drive - flashing symbol Operation switched on) [h]
Operation
59.6 l/h
Accumulated motor runtime [h]
No
59.6 Manual 59.6l/h

l/h
Accumulated number of dosing No
Manual 59.6l/h strokes
6.3.2
You can find the date, time and information Accumulated frequency of switching No
about the active dosing process, various mains voltage on
Activated functions Additional display (Sect. 6.14.2) counters, product data and the service system status
AR variant: Target flow in the "Info" main menu. The information can be 6.3.3
SlowMode (Sect. 6.6) accessed during operation.
FCM variant: Actual flow You can view errors in the "Alarm" main
FlowControl (Sect. 6.7) The service system can also be reset from here. menu.
Remaining batch volume (Batch/Timer)
Key lock (Sect. 6.13) Input current (Analog)
Bus (Sect. 6.16) Info Alarm
Time until next dosing process (Timer)
Auto deaeration (Sect. 6.11) Th 16.02.2017 12:34 1 12.02.2017 12:34
Total dosed volume Backpressure 10.0bar Empty
Counters >
Actual backpressure 2 12.02.2017 12:34
Service -
Low level
Operation mode ServiceKit
Reset service system
Manual (Sect. 6.4.1) Signal/error display Software rev. Vx.xx
Motor Control Vx.xx Delete alarm
Pulse (Sect. 6.4.2) External stop (Sect. 6.17.2) messages
Hardware rev. Vx.xx ❑
Analog 0/4-20 mA (Sect. 6.4.3) Empty signal (Sect. 6.17.3) Serial no.:
Product no.: Up to 10 warnings and alarms, together with their
Batch (Sect. 6.4.4) Low-level signal (Sect. 6.17.3)
Type Key: date, time and cause, are listed in chronological
Timer (Sect. 6.4.5, 6.4.6) Cable break (Sect. 6.4.3) order. If the list is full, the oldest entry will be
overwritten, see section 8. Faults.
Operating state (Sect. 6.2.2) and dosing CIU (Sect. 6.16)
flow Service (Sect. 7.)
Running Diaphragm leak. (Sect. 6.12)
Standby Overheating (Sect. 8.1)
Stop Overload (Sect. 8.1)
Deaerating Disch. valve leak (Sect. 8.1)
Diaphragm position "out" (Sect. 7.)
Diaphragm position "in" (Sect. 7.)
Fig. 17 Overview of display symbols
21 22
6.3.4 6.4 Operation modes 6.4.2 6.4.3 Analog 0/4-20 mA
The "Setup" main menu contains menus for Six different operation modes can be set in the In this operation mode, the pump doses the In this operation mode, the pump doses
pump configuration. These menus are "Setup > Operation mode" menu. set dosing volume for each incoming (potential-free) according to the external analog signal. The
described in the following sections. pulse, e.g. from a water meter. The pump dosing volume is proportional to the signal input
• Manual, see section 6.4.1
Check all pump settings after any change in the automatically calculates the optimum stroke value in mA.
• Pulse, see section 6.4.2 frequency for dosing the set volume per pulse.
"Setup" menu.
• Analog 0-20mA, see section 6.4.3 The calculation is based on: Operation Input value Dosing flow
Analog 4-20mA, see section 6.4.3 mode [mA] [%]
Setup Section • Batch (pulse-based), see section 6.4.4
• the frequency of external pulses
• the set dosing volume/pulse. ≤ 4.1 0
Language English > 5.3 • Dosing timer cycle, see section 6.4.5 4-20 mA
Operation mode Pulse > 6.4 • Dosing timer week, see section 6.4.6 ≥ 19.8 100
Pulse memory* ❑ 6.4.2
6.4.1
Operation ≤ 0.1 0
Analog scaling > 6.4.3 0-20 mA
Batch volume*
Dosing time[mm:ss]*
35.0 l
46:30
6.4.4
6.4.4
In this operation mode, the pump constantly
doses the dosing flow set with the click wheel. 18.4 ml/
≥ 19.8 100
Dosing timer cycle* > 6.4.5 The dosing flow is set in l/h or ml/h in the "Operation" Pulse 6.62l/h If the input value in operation mode 4-20 mA falls
Dosing timer week* > 6.4.6 menu. The pump automatically switches between the below 2 mA, an alarm is displayed and the pump
Analog output Actual flow > 6.5 units. Alternatively, the display can be reset to US stops. A cable break or signal transmitter error has
SlowMode Off > 6.6 units (gph). See section 6.14 Display setup. occurred. The "Cable break" symbol is displayed in
FlowControl active* 6.7 Fig. 19 Pulse mode the "Signal and error display" area of the display.
❑
FlowControl* > 6.7
Pressure monitoring* > 6.8 Operation The dosing volume per pulse is set in ml/pulse in the
"Operation" menu using the click wheel. The setting
AutoFlowAdapt* 6.10
38.4
❑ range for the dosing volume depends on the pump
Auto deaeration ❑ 6.11 l/h type:
Calibration > 5.5
Diaphragm leak. detect.* ❑ 6.12 Manual 38.4l/h
Key lock Off > 6.13 Type Setting range [ml/pulse]
Display > 6.14 DDA 60-10 0.0111 - 111
Time+date > 6.15
Fig. 18 Manual mode DDA 120-7 0.0232 - 232
Bus > 6.16
Inputs/Outputs > 6.17 The setting range depends on the pump type: DDA 200-4 0.0386 - 386
Basic settings > 6.18
Setting range* The frequency of incoming pulses is multiplied by the Fig. 20 Analog scaling
Type set dosing volume. If the pump receives more pulses
* These submenus are only displayed for specific
[l/h] [gph] than it can process at the maximum dosing flow, it
default settings and control variants. The
runs at the maximum stroke frequency in continuous
contents of the "Setup" menu also vary
depending on the operation mode.
DDA 60-10 0.075 - 60 0.02 - 15 operation. Excess pulses will be ignored if the
memory function is not enabled.
Operation
51.4
DDA 120-7 0.15 - 120 0.04 - 32
Memory function l/h
DDA 200-4 0.25 - 200 0.065 - 52
When the "Setup > Pulse memory" function is 0-20mA 17.14mA
* When the "SlowMode" function is active, the enabled, up to 65,000 unprocessed pulses can be
maximum dosing flow is reduced, see section saved for subsequent processing.
3.1 Technical data.
Subsequent processing of saved pulses Fig. 21 Analog operation mode
can cause local increase in concentration!
The contents of the memory will be deleted by:

• Switching off the power supply
• Changing the operation mode
• Interruption (e.g. alarm, External stop).
23 24
Set analog scaling Set analog scaling in the " " menu The batch volume (e.g. 75.0 l) is set in the "Setup > 6.4.5
Analog scaling refers to the assignment of the Analog scaling can also be modified after a security Batch volume" menu. The minimum dosing time In this operation mode, the pump doses the
current input value to the dosing flow. prompt directly in the "Operation" menu. This is how required for this (e.g. 1 hour, 16 minutes) is set batch volume in regular cycles. Dosing
the dosing flow is directly modified for the current displayed and can be increased. starts when the pump is started after a singular start
Changes of analog scaling affect also the analog
output signal. See section 6.5 . flow input value. Please observe that changes also delay. The setting range for the batch volume
have a direct effect on point I 2/Q 2 (see fig. 24). corresponds to the values in section 6.4.4
Analog scaling passes through the two reference Setup .
points (I1/Q 1 ) and (I2/Q 2 ), which are set in the "Setup
> Analog scaling" menu. The dosing flow is Operation mode Batch >
(I2 /Q 2) (I2/Q 2) When time or date is changed in
controlled according to this setting. Batch volume 75.0l
"Time+date" menu, timer dosing and timer
new Dosing time[h:mm] 1:16
Example 1 (DDA 60-10) relay output functions (Relay 2) are
Analog output Input >
Analog scaling with positive gradient: stopped!
SlowMode Off >
Timer dosing and timer relay output
Fig. 26 Batch mode functions must be restarted manually!
(I2/Q 2 ) (I1 /Q 1) Changing time or date can cause increase
Signals received during a batch process or an or decrease in concentration!
interruption (e.g. alarm, External stop) will be
actual mA ignored. If the pump is restarted following an
interruption, the next batch volume is dosed on the Batch volume
Fig. 24 Set analog scaling ("Operation" menu)
next incoming pulse.
(I1 /Q 1 ) 6.4.4
In this operation mode, the pump doses the
set batch volume in the set dosing time (t 1). A
Operation
t1 t1
Fig. 22 Analog scaling with pos. gradient

batch is dosed with each incoming pulse.
75.0 l
t2
Batch volume Batch 74.5l
In example 1, the reference points I1 = 6 mA, Q 1 = 20 t3
l/h and I 2 = 16 mA, Q2 = 60 l/h have been set.
From 0 to 6 mA analog scaling is described by a line Fig. 27 Batch mode Fig. 28 Dosing timer cycle diagram
that passes through Q = 0 l/h, between 6 mA and 16 t1 t1
mA it rises proportionally from 20 l/h to 60 l/h and In the "Operation" menu, the total batch volume (e.g.
from 16 mA onwards it passes through Q = 60 l/h. Time 75.0 l) and the remaining batch volume still to be t1 Dosing time
Example 2 (DDA 60-10) dosed (e.g. 74.5 l) are shown in the display.
t2 Start delay
Analog scaling with negative gradient (Operation Pulse Pulse
t3 Cycle time
mode 0-20 mA):
Fig. 25 Batch (pulse-based)
In the event of an interruption (e.g. interruption of the
The setting range depends on the pump type: mains voltage, External stop), the dosing will be
(I 1/Q 1) stopped while the time continues running. After
Setting range per batch suspending the interruption, the pump will continue
to dose according to the actual timeline position.
Type
Resolution* The following settings are required in the "Setup >
from [ml] to [l]
[ml] Dosing timer cycle" menu:
(I2/Q 2)
DDA 60-10 5.56 999 0.694
DDA 120-7 11.6 999 1.45 Timer
DDA 200-4 19.3 999 2.41
Batch volume 6.83l
Fig. 23 Analog scaling with neg. gradient Dosing time[mm:ss] 7:12
* Thanks to the digital motor control, dosing
quantities with a resolution of up to 1/8 of the Cycle time[mm:ss] 9:00
In example 2, the reference points I1 = 2 mA, Q 1 = 60
dosing stroke volume can be dosed. Start delay[s] 12.0
l/h and I 2 = 16 mA, Q2 = 18 l/h have been set.
From 0 to 2 mA analog scaling is described by a line
that passes through Q = 0 l/h, between 2 mA and 16 Fig. 29 Dosing timer cycle
mA it drops proportionally from 60 l/h to 18 l/h and
from 16 mA onwards it passes through Q2 = 18 l/h. The batch volume to be dosed (e.g. 6.83 l) is set in
the "Setup > Dosing timer cycle" menu. The dosing
time required for this (e.g. 7:12) is displayed and can
be changed.
25 26
The total batch volume (e.g. 6.83 l) and the If several procedures overlap, the process with the 6.5 6.6
remaining batch volume still to be dosed are higher dosing flow has priority.
When the "SlowMode" function is enabled, the
displayed in the "Operation" menu. During breaks in In the event of an interruption (e.g. disconnection of pump slows down the suction stroke. The function is
dosing, the time until the next dosing process (e.g. the mains voltage, External stop), the dosing is Analog out enabled in the "Setup > SlowMode" menu and is
11 seconds) is displayed. stopped while the time continues running. After Output = Input used to prevent cavitation in the following cases:
suspending the interruption, the pump continues to Actual flow ❑ • for dosing media with a high viscosity
Operation dose according to the actual timeline position.
The following settings are required in the "Setup >
Backpressure
Bus control
❑ • for degassing dosing media
❑
6.83 l
Dosing timer week" menu for each dosing procedure: • for long inlet lines
• for large suction lift.
Timer 11.0s
Timer Fig. 34 Configure analog output In the "Setup > SlowMode" menu, the speed of the
suction stroke can be reduced to 50 % or 25 %.
Procedure 1 The analog output of the pump is parametrised in the
Batch volume 986ml "Setup > Analog output" menu. The following Enabling the 'SlowMode' function reduces
Fig. 30 Dosing timer cycle Dosing time[mm:ss] 1:00 settings are possible: the maximum dosing flow of the pump to
Start time[hh:mm] 05:00 the set percentage value!
6.4.6
Variant
In this operation mode, up to 16 dosing M❑ T W❑ T F❑ S❑ S Description of output
Setting
procedures are defined for a week. These
dosing procedures may take place regularly on one
Fig. 32 Setting the timer signal
SlowMode
or several week days. The setting range for the The batch volume (e.g. 986 ml) is set in the "Setup > Off
batch volume corresponds to the values in section Analog feedback signal SlowMode (50% max.) ❑
Dosing timer week" menu. The dosing time required
6.4.4 . (not for master-slave SlowMode (25% max.) ❑
for this (e.g. 1 minute, 0 seconds) is displayed and Output =
application). The analog X X
can be changed. Input
When time or date is changed in input signal is mapped
"Time+date" menu, timer dosing and timer In the "Operation" menu, the total batch volume (e.g. 1:1 to the analog output.
relay output functions (Relay 2) are 986 ml) and the remaining batch volume to be dosed
is displayed. During breaks in dosing, the time (e.g. Current actual flow Fig. 35 SlowMode menu
stopped!
1 day, 2 hours) until the next dosing is displayed. • 0/4 mA = 0 %
Timer dosing and timer relay output Actual
• 20 mA = 100 % X X*
functions must be restarted manually! flow**
see section 6.9 Flow
Changing time or date can cause increase Operation measurement
or decrease in concentration!
986
Timer
ml
Backpressure, measured
in the dosing head
1:02d • 0/4 mA = 0 bar
Backpre
• 20 mA = Max. X
ssure
operating pressure
see section 6.8
Fig. 33 Weekly timer dosing (break in dosing)
Enabled by command in
Bus
Bus control, see section X X
control
6.16 Bus communication
MO TU WE TH FR SA SU * Output signal is based on motor speed and pump

status (target flow).
Fig. 31 Example for Dosing timer week function ** Signal has same analog scaling as the current
analog input signal. See 6.4.3 Analog 0/4-20 mA.
Wiring diagram see section 4.3 Electrical
connection.
In all operation modes, the analog output

has a range of 4-20 mA. Exception:
Operation mode 0-20 mA. Here, the
analog output range is 0-20 mA.
27 28
6.7 FlowControl works with a maintenance-free sensor 6.8.2 Calibration of pressure sensor
in the dosing head. During the dosing process, the The "Delay" parameter is used to define the time The pressure sensor is calibrated in the factory. As a
Applies to DDA-FCM control variant.
sensor measures the current pressure and period until an error message is generated: "short", rule, it does not need to be re-calibrated. If specific
This function is used to monitor the dosing process. continuously sends the measured value to the "medium" or "long". The delay depends on the set circumstances (e.g. pressure sensor exchange,
Although the pump is running, various influences microprocessor in the pump. An internal indicator dosing flow and therefore cannot be measured in extreme air pressure values at the location of the
e.g. air bubbles, can cause a reduced flow or even diagram is created from the current measured values strokes or time. pump) necessitate a calibration, the sensor can be
stop the dosing process. In order to guarantee and the current diaphragm position (stroke length). calibrated as follows:
optimum process safety, the enabled "FlowControl" Causes for deviations can be identified immediately Air bubbles
function directly detects and indicates the following 1. Set pump to "Stop" operating state.
by aligning the current indicator diagram with a The "FlowControl" function identifies air bubbles >
errors and deviations: calculated optimum indicator diagram. Air bubbles in 60 % of the stroke volume. After switching to "Air 2. Make system pressureless and flush.
• Overpressure the dosing head reduce e.g. the discharge phase bubble" warning status, the pump adapts the stroke 3. Dismantle inlet line and inlet valve.
• Damaged outlet line and consequently the stroke volume (see fig. 36). frequency to approximately 30-40 % of max. stroke
Requirements for a correct indicator diagram are: frequency, and starts a special motor drive strategy. Calibrating when the inlet valve is installed
• Air in the dosing chamber produces incorrect calibration and can
The adaptation of the stroke frequency allows the air
• Cavitation • FlowControl function is active cause personal injuries and damage to
bubbles to rise from inlet to outlet valve. Due to the
• Inlet valve leakage > 70 % • pressure difference between inlet and outlet side special motor drive strategy the air bubbles are property!
is > 2 bar displaced from the dosing head into the outlet line. Only carry out a calibration if this is
• Outlet valve leakage > 70 %.
• No interruption/pause in discharge stroke If the air bubbles have not been eliminated after a technically required!
The occurrence of a fault is indicated by the "eye"
symbol flashing. The faults are displayed in the • Pressure sensor and cable are functioning maximum of 60 strokes, the pump returns to the 4. Proceed as described below to calibrate:
"Alarm" menu. See section 8. Faults. properly normal motor drive strategy.
• No leakage > 50 % in inlet or outlet valve
6.8 Plug in pressure sensor plug or select "Setup >
If one of these requirements is not met, the indicator FlowControl active" menu
diagram cannot be evaluated. Applies to DDA-FCM control variant.
A pressure sensor monitors the pressure in the
Pressure dosing head. If the pressure during the discharge
phase falls below 2 bar, a warning is generated Prompt:
(pump continues running). If in the "Setup > "Activate FlowContr.?"
Pressure monitoring" menu the function "Min.
pressure alarm" is activated, an alarm is generated FlowControl not
and the pump is stopped. activated
Trouble-free dosing stroke
Faulty dosing stroke: Air If the pressure exceeds the "Max. pressure" set in Prompt:
bubbles in the dosing the "Setup > Pressure monitoring" menu, the pump "Sensor calibration?"
head is shut down, enters the standby state and indicates
an alarm. FlowControl active,
Sensor not calibrated.
The pump restarts automatically once the Prompt:
backpressure falls below the set "Max. "Suction valve removed?"
pressure"!
6.8.1 Pressure setting ranges Sensor not calibrated.
Fixed min. Adjustable max. Calibration error

Type pressure pressure OK
Stroke length [bar] [psi] [bar] [psi] Message: Message:
DDA 60-10 <2 < 29 3-11 44-165 " " "Sensor calib. failed!"
Fig. 36 Indicator diagram " X "Repeat?"
DDA 120-7 <2 < 29 3-8 44-115 bar"
1 Compression phase DDA 200-4 <2 < 29 3-5 44-73
In "Sensitivity" the deviation in stroke volume, which
2 Discharge phase will result in an error message, is set in percent.
The pressure measured in the dosing head
3 Expansion phase is slightly higher than the actual system
Deviation Sensor not calibrated.
4 Suction phase pressure.
low approx. 70 % Therefore the "Max. pressure " should be If a calibration is not successfully possible, check
Setting set at least 1 bar higher than the system plug connections, cable and sensor and replace
medium approx. 50 %
The "FlowControl" function is set using the two pressure. defective parts where necessary.
parameters "Sensitivity" and "Delay" in the "Setup > high approx. 30 %
FlowControl" menu.
29 30
6.9 Flow measurement Example of " " 6.13 6.14.2 Additional display
Applies to DDA-FCM control variant. Pressure fluctuations The key lock is set in the "Setup > Key lock" The additional display provides additional
The dosing volume decreases as backpressure menu by entering a four-digit code. It protects the information about the current pump status. The value
The pump accurately measures the actual flow and
increases and conversely the dosing volume pump by preventing changes to settings. Two levels is shown in the display with the corresponding
displays it. Via the 0/4-20 mA analog output, the
increases as the backpressure decreases. of key lock can be selected: symbol.
actual flow signal can easily be integrated into an
external process control without additional The "AutoFlowAdapt" function identifies pressure In "Manual" mode the "Actual flow" information can
measuring equipment. See section 6.5 fluctuations and responds by adjusting the stroke Level Description be displayed with Q = 31.9 l/h (see fig. 37).
. frequency. The actual flow is thus maintained at a
constant level. All settings can only be changed by
The flow measurement is based on the indicator
diagram as described in section 6.7 . Settings
entering the lock code. Operation
6.11 The [Start/stop] key and the [100%]
The accumulated length of the discharge phase
multiplied by the stroke frequency produces the
displayed actual flow. Faults e.g. air bubbles or
Dosing degassing media can result in air
pockets in the dosing head during breaks in Settings +
key are not locked.
The [Start/stop] key and the [100%]
32.0 l/h
Manual 31.9l/h
backpressure that is too low result in a smaller or dosing. This can result in no medium being dosed keys key and all settings are locked.
larger actual flow. When the "AutoFlowAdapt" when restarting the pump. The "Setup > Auto
function is activated (see section deaeration" function performs pump deaeration It is still possible to navigate in the "Alarm" and "Info"
6.10 ), the pump compensates for automatically at regular intervals. main menu and reset alarms. Additional display
these influences by correction of the stroke Software-controlled diaphragm movements 6.13.1 Temporary deactivation Fig. 37 Display with additional display
frequency. encourage any bubbles to rise and gather at the
outlet valve so that they can be removed on the next If the "Key lock" function is activated but settings
Strokes which cannot be analysed (partial strokes, The additional display can be set as follows:
dosing stroke. need to be modified, the keys can be unlocked
pressure differential which is too low) are
temporarily by entering the deactivation code. If the
provisionally calculated based on the setpoint value The function works: code is not entered within 10 seconds, the display Setting Description
and displayed. • when the pump is not in the "Stop" operating automatically switches to the "Operation" main
state menu. The key lock remains active. Depending on the operation mode:
6.10
• during breaks in dosing (e.g. External stop, no Actual flow (Manual/Pulse) 1), 2)
Applies to DDA-FCM control variant. 6.13.2 Deactivation
incoming pulses, etc.).
The "AutoFlowAdapt" function is activated in the The key lock can be deactivated in the "Setup > Key Target flow (Pulse)
The diaphragm movements can displace small
"Setup" menu. It detects changes in various lock" menu via the "Off" menu point. The key lock is Default
volumes into the outlet line. When dosing strongly
parameters and responds accordingly in order to deactivated after the general code "2583" or a display Input current (analog)
degassing media, this is however virtually
keep the set target flow constant. pre-defined custom code has been entered.
impossible. Remaining batch volume
6.14 Display setup (Batch, Timer)
Dosing accuracy is increased when 6.12
Use the following settings in the "Setup > Display" Period until next dosing (Timer)
"AutoFlowAdapt" is activated. Applies to DDA-AR control variant.
menu to adjust the display properties: Dosed Dosed vol. since last reset (see
This function is only available if the pump is
This function processes information from the • Units (metric/US) volume on page 22)
equipped with a special dosing head for leakage
pressure sensor in the dosing head. Errors detected detection. See section 2.5 Type key. • Display contrast Actual flow Current actual flow 1), 2)
by the sensor are processed by the software. The The "Diaphragm leak. detect." function is activated in • Additional display.
pump responds immediately regardless of the Current backpressure in the
the "Setup" menu. It detects diaphragm leakages. Backpressure
operation mode by adjusting the stroke frequency or 6.14.1 Units dosing head 1)
When a leakage is detected, the pump stops and an
where necessary compensating for the deviations alarm is displayed. Metric units (litres/millilitres/bar) or US units (US 1)
with a corresponding indicator diagram. gallons/PSI) can be selected. According to the only control variant DDA-FCM
See also sections: operation mode and menu, the following units of 2)
only if indicator diagram can be evaluated (see
If the target flow cannot be achieved by the
adjustments, a warning is issued. • 1.6.1 Diaphragm leakage detection (optional) measurement are displayed: 6.7 )
"AutoFlowAdapt" operates on the basis of the • 6.2.4 Overview of display symbols
following functions: • 8.1 List of faults Operation mode /
Metric units US units
function
• FlowControl: malfunctions are identified. See
section 6.7 . Manual control ml/h or l/h gph
• Pressure monitoring: pressure fluctuations are
Pulse control ml/ ml/
identified. See section 6.8 .
• Flow measurement: deviations from the target 0/4-20 mA Analog
ml/h or l/h gph
flow are identified. See section 6.9 Flow control
measurement. Batch (pulse- or
ml or l gal
timer-controlled)
Calibration ml ml
Volume counter l gal
Pressure monitoring bar psi
31 32
6.15 6.16.2 Possible industrial bus types 6.16.4 Setting the bus address 6.16.6 Deactivate communication
The time and date can be set in the "Setup > The pump can be connected to a Grundfos CIU unit 1. Enter "Setup > Bus" menu and set desired bus After deactivating the bus control function, the pump
Time+date" menu. (CIU = Communication Interface Unit) equipped with address: can start automatically.
one of the following CIM modules (CIM =
The conversion between summer and winter time
Communication Interface Module): Bus type Address range CAUTION
does not take place automatically.
• CIM150 Profibus Automatic startup
When time or date is changed in Profibus ® DP 0-126
• CIM200 Modbus Minor or moderate personal injury
"Time+date" menu, timer dosing and timer • CIM270 GRM Modbus RTU 1-247 - Before deactivating the bus control
relay output functions (Relay 2) are function, set the pump to operating state
stopped! • CIM500 Ethernet 2. The pump needs to be restarted to initialise the "Stop".
Timer dosing and timer relay output For internal communication between the CIU and the new bus address. Switch off the power supply of
dosing pump, GENIbus is used. the pump and wait for approximately 20 seconds. Bus control function can be deactivated in the "Setup
functions must be restarted manually! > Bus" menu. After deactivation all submenus in
Changing time or date can cause increase 3. Switch on the power supply of the pump. "Setup" menu are available.
The maximum cable length for GENIbus
or decrease in concentration! connection is 3 m and must not be The pump is initialised with the new bus address. The "Bus" symbol in the display disappears at next
exceeded. 6.16.5 Characteristics of bus communication restart of the pump, after the CIU plug was
6.16 Bus communication Prior to installation and startup, read the disconnected.
To start and stop the pump via bus, it needs to be in
The bus communication enables remote documentation delivered with the CIU unit. operating state "Running". When the pump is
monitoring and setting of the pump via a remotely stopped from bus, the "External stop" After disconnecting any plug, always refit
fieldbus system. 6.16.3 Activate communication
symbol is displayed and the pump switches to protective cap.
Further manuals, functional profiles and support files 1. Set the pump to operating state "Stop" with the operating state "Standby".
(e.g. GSD-files) are available on the CD delivered [Start/stop] key.
While bus control function is activated, the "Setup" 6.16.7 Communication faults
with the interface hardware and on 2. Switch off the power supply of the pump. menu only shows the "Bus" and "Key lock"
www.grundfos.com. 3. Install and connect the CIU as described in the Faults are only detected, if the respective
submenus. The other main menus, the "External
respective separate installation and operating "BusWatchDog" (see functional profile on CIM/CIU
6.16.1 GENIbus communication stop" function and the keys are still available.
instructions. product CD) is activated.
The pump is supplied with an integrated module for All operation modes (see section 6.4 Operation
4. Switch on the power supply of the pump. After a communication fault is repaired, the pump
GENIbus communication. The pump identifies the modes) can still be used when bus control is
can start automatically, depending on current bus
bus control after connecting to the corresponding The "Activate communication?" prompt is displayed. activated. This allows to use the bus control only for
control and pump settings.
signal input. The "Activate communication?" prompt After confirmation, the "Bus" symbol appears in the monitoring and setting the pump. In this case the
is displayed. After confirmation, the corresponding respective "BusWatchDog" (see functional profile on
"Activated functions" area of the "Operation" menu, CAUTION
symbol appears in the "Activated functions" area in no matter if the prompt was accepted or refused. CIM/CIU product CD) should be deactivated in bus
the "Operation" menu. control, because otherwise faults in communication Automatic startup
If the prompt has been accepted, the bus control can stop the pump. Minor or moderate personal injury
In the "Setup > Bus" menu the GENIbus address can function is activated. If the prompt has been refused, - Before repairing any fault, set the pump
be set from 32 to 231 and bus control can be bus control function can be activated in "Setup >
To change any settings manually, the bus to operating state "Stop".
deactivated. Bus" menu.
control function must be deactivated In case of bus communication faults (e.g.
temporarily.
communication cable break), the pump stops dosing
Bus Profibus and switches to operating state "Standby"
Bus control active approximately 10 seconds after the fault was
Bus control active
Bus address 231 detected. An alarm is triggered, detailing the cause
Bus address 126
of the fault. See section 8. Faults.
Fig. 38 Bus menu Fig. 39 Example of submenu for Profibus ®
The maximum cable length for GENIbus

connection is 3 m and must not be
exceeded.
33 34
6.17 6.17.1 Relay outputs ( ) 6.17.3 and signals
In the "Setup > Inputs/Outputs" menu, you can The pump can switch two external signals using For the "Relay 2 > Timer Cycle" function, set the In order to monitor the filling level in the
configure the two outputs "Relay 1+Relay 2" and the installed relays. The relay outputs are potential-free. following parameters: tank, a dual-level sensor can be connected to the
signal inputs "External stop", "Empty signal" and The connection diagram of the relays is shown in • On (t1) pump. The pump responds to the signals as follows:
"Low-level signal". section 4.3 Electrical connection. Both relays can be
• Start delay (t2 )
allocated with the following signals: Sensor signal Pump status
• Cycle time (t3).
In/Output Description
• Display is yellow
signal signal Low level • Flashes
Relay 1 >
Relay 2 > • Pump continues running
Display red, pump
External stop NO • Display is red
Alarm* Alarm stopped (e.g. empty
Empty signal NO signal, etc.) Empty • Flashes
Low-level signal NO t1 t1
• Pump stops
Display yellow, pump is
Fig. 40 Inputs/Outputs menu Warning* Warning running (e.g. low-level t2
signal, etc.)
t3 When the tank is filled up again, the pump
When time or date is changed in Stroke Stroke restarts automatically.
Each full stroke
"Time+date" menu, timer dosing and timer signal signal
Fig. 41 Diagram
relay output functions (Relay 2) are Pump Pump Both signal inputs are allocated to the normally open
stopped! Pump running and dosing contact (NO) in the factory. They can be re-allocated
dosing dosing* ( )
Timer dosing and timer relay output This function saves up to 16 relay on-times for a in the "Setup > Inputs/Outputs" menu to normally
Pulse Pulse Each incoming pulse closed contact (NC).
functions must be restarted manually! week. The following settings can be made for each
input** input** from pulse input
Changing time or date can cause increase relay switching operation in the "Relay 2 > Timer
or decrease in concentration! Bus Bus Activated by a command Week" menu: 6.18
control control in the bus communication All settings can be reset to the settings default upon
• Procedure (No.)
Timer delivery in the "Setup > Basic settings" menu.
See following sections • On time (duration)
Cycle Selecting "Save customer settings" saves the current
• Start time
configuration to the memory. This can then be
Timer • Weekdays.
See following sections activated using "Load customer settings".
Week
6.17.2 The memory always contains the previously saved
Contact type The pump can be stopped via an external configuration. Older memory data is overwritten.
NO* NO* Normally open contact contact, e.g. from a control room. When activating
the external stop signal, the pump switches to
NC NC Normally closed contact operating state "Standby". The corresponding
symbol appears in the "Signal/error display" area of
* Factory setting the display.
** The correct transmission of incoming pulses can
only be guaranteed up to a pulse frequency of 5 Frequent disengagement from the mains
Hz. voltage, e.g. via a relay, can result in
damage to the pump electronics and in the
breakdown of the pump. The dosing
accuracy is also reduced as a result of
internal start procedures.
Do not control the pump via the mains
voltage for dosing purposes!
Only use the "External stop" function to
start and stop the pump!
The contact type is factory-set to normally open
contact (NO). In the "Setup > Inputs/Outputs >
External stop" menu, the setting can be changed to
normally closed contact (NC).
35 36
7. Service 7.3 Service system 7.4 Perform service 7.4.1 Dosing head overview
In order to ensure a long service life and dosing According to the motor runtime or after a defined Only spare parts and accessories from Grundfos
accuracy, wearing parts such as diaphragms and period of operation, service requirements will should be used for maintenance. The usage of
valves must be regularly checked for signs of wear. appear. Service requirements appear regardless of non-original spare parts and accessories renders
Where necessary, replace worn parts with original the current operating state of the pump and do not any liability for resulting damages null and void.
spare parts made from suitable materials. affect the dosing process.
Should you have any questions, please contact your
CAUTION
Grundfos service partner. Motor Chemical hazard
Time interval
Service requirement runtime Minor or moderate personal injury
[months]*
[h]* - Observe the material safety data sheet
Maintenance work must only be carried out
of the dosing medium.
by qualified staff. Service soon! 7500 23
- Wear protective clothing (gloves and
Service now! 8000 24 goggles) when working on the dosing
7.1 Regular maintenance head, connections or lines. Fig. 44 DDA 60-10
* Since the last service system reset - Collect and dispose of all chemicals in a
way that is not harmful to persons or the
Interval Task environment.
Check, if liquid leaks from the drain
opening on the dosing head and if the Service soon! Before starting work on the pump, the
drain opening is blocked or soiled. Please exchange pump must be in the "Stop" operating state
See fig. 44-45, pos. 8. diaphragm and valves! or be disconnected from the power supply.
If so, follow the instructions given in Service kit: The system must be pressureless.
section 7.6 Diaphragm leakage. 97xxxxxx
Check, if liquid leaks from the dosing
head or valves. Fig. 42 Service soon!
If necessary, tighten dosing head
Daily
screws with a torque wrench. Torque
[Nm]: 6 (+ 1).
If necessary, tighten valves and cap
Service now! Fig. 45 DDA 120-7 / DDA 200-4
nuts, or perform service. See section
7.4 Perform service. Please exchange
diaphragm and valves!
Check, if a service requirement is Service kit: Pos. Components
present at the pump display. If so, 97xxxxxx
1 Extension piece
follow the instructions given in
section 7.3 Service system. Fig. 43 Service now! 2 Flange
Clean all pump surfaces with a dry 2a O-ring
Weekly For media which result in increased wear, the service
and clean cloth.
interval must be shortened. 2b Screws
Check dosing head screws. The service requirement signals when the 2c Intermediate ring
If necessary, tighten dosing head replacement of wearing parts is due and displays the
Every 3
screws with a torque wrench. Torque number of the service kit. Press the click wheel to 2d O-ring
months
[Nm]: 6 (+ 1). Replace damaged temporarily hide the service prompt. 3 Diaphragm
screws immediately.
When the "Service now!" message appears
4 Valve on outlet side
(displayed daily), the pump must be serviced
7.2 Cleaning 5 Dosing head
immediately. The symbol appears in the
If necessary, clean all pump surfaces with a dry and "Operation" menu. 6 Screws
clean cloth. The number of the service kit required is also
displayed in the "Info" menu. 7 Valve on inlet side
8 Drain opening
9 Alignment pin
10 Safety diaphragm
37 38
7.4.2 Dismantling the diaphragm and valves 7.4.3 Reassembling the diaphragm and valves 7.6 Diaphragm leakage 7.6.1 Dismantling in case of diaphragm leakage
The pump must only be reassembled, if nothing If the diaphragm leaks or is broken, dosing liquid
If the diaphragm is possibly damaged, indicates that dosing liquid has entered the pump
don't connect the pump to the power escapes from the drain opening on the dosing head. Do not connect the pump to the power
housing. Otherwise proceed as described in section See fig. 4, pos. 16. supply!
supply! Proceed as described in section 7.6.2 Dosing liquid in the pump housing.
7.6 Diaphragm leakage. In case of diaphragm leakage, the safety diaphragm
This section refers to fig. 44-45. (fig. 44-45, pos. 10) protects the pump housing This section refers to fig. 44-45.
This section refers to fig. 44-45. 1. DDA 60-10: against ingress of dosing liquid. 1. Make system pressureless.
1. Set pump to "Stop" operating state using the – Place new O-rings (2a, 2d) in the grooves at When dosing crystallising liquids the drain opening
[Start/stop] key. 2. Take suitable steps to ensure that the returning
flange (2) and make sure they are seated can be blocked by crystallisation. If the pump is not liquid is safely collected.
2. Make system pressureless. correctly. taken out of operation immediately, a pressure can
3. Empty dosing head and flush it if necessary.
3. Take suitable steps to ensure that the returning – Attach flange (2) observing alignment pin (9). build up between the diaphragm (fig. 44-45, pos. 3)
liquid is safely collected. and the safety diaphragm. The pressure can press 4. Dismantle inlet, outlet and deaeration lines.
2. DDA 120-7 / DDA 200-4:
4. Empty dosing head and flush it if necessary. dosing liquid through the safety diaphragm into the 5. Unscrew valves on inlet and outlet side (4, 7).
– Retighten screws (2b) using a torque wrench. pump housing.
5. Press the [Start/stop] and [100%] keys at the 6. Disconnect FlowControl or DLD signal
Torque [Nm]: 6 (+ 1).
same time to put the diaphragm into "out" Most dosing liquids don't cause any danger when connection, if present. See fig. 13-14.
– Attach intermediate ring (2c) to flange (2) entering the pump housing. However a few liquids
position. 7. Remove screws (6).
observing the alignment pin. can cause a chemical reaction with inner parts of the
– Symbol must be displayed (see fig. 17). 8. Remove dosing head (5).
3. Screw on the new diaphragm (3) clockwise. pump. In the worst case, this reaction can produce
6. Dismantle inlet, outlet and deaeration lines. explosive gases in the pump housing. 9. Unscrew diaphragm (3) counter-clockwise and
– Make sure the diaphragm is screwed on
7. Unscrew valves on inlet and outlet side (4, 7). remove it.
completely and fully resting on extension piece
8. Disconnect FlowControl or DLD signal (1). WARNING 10. DDA 60-10:
connection, if present. See fig. 13-14. 4. Press the [Start/stop] and [100%] keys at the Danger of explosion, if dosing liquid – Remove flange (2) together with O-rings (2a,
9. Remove screws (6). same time to put the diaphragm into "in" position. has entered the pump housing! 2d).
10. Remove dosing head (5). – Symbol must be displayed (see fig. 17). Death or serious personal injury 11. DDA 120-7 / DDA 200-4:
Operation with damaged diaphragm can – Remove intermediate ring (2c).
11. Unscrew diaphragm (3) counter-clockwise and 5. Attach dosing head (5).
lead to dosing liquid entering the pump
remove it. – DDA 60-10: Observe alignment pin (9). 12. Make sure the drain opening (8) is not blocked or
housing.
12. DDA 60-10: soiled. Clean if necessary.
6. Install screws (6) and cross-tighten them with a - In case of diaphragm leakage,
– Remove flange (2) together with O-rings (2a, torque wrench. immediately separate the pump from 13. Check the safety diaphragm (10) for wear and
2d). the power supply! damage. If the safety diaphragm is damaged,
– Torque [Nm]: 6 (+ 1).
- Make sure the pump cannot be put back send the pump to Grundfos for repair. See
13. DDA 120-7 / DDA 200-4: 7. Connect FlowControl or DLD signal connection, if section 7.7 Repairs.
into operation by accident!
– Remove intermediate ring (2c). present. See fig. 13-14.
- Dismantle the dosing head without If nothing indicates that dosing liquid has entered the
14. Make sure the drain opening (8) is not blocked or 8. Install new valves (4, 7). connecting the pump to the power pump housing, go on as described in section
soiled. Clean if necessary. – Pay attention to the flow direction arrow. supply and make sure no dosing liquid 7.4.3 Reassembling the diaphragm and valves.
15. Check the safety diaphragm (10) for wear and 9. Perform hydraulic connection. See section has entered the pump housing. Proceed Otherwise proceed as described in section
damage. If the safety diaphragm is damaged, 4.2 Hydraulic connection. as described in section 7.6.2 Dosing liquid in the pump housing.
send the pump to Grundfos for repair. See 7.6.1 Dismantling in case of diaphragm
10. Press the [Start/stop] key to leave the service 7.6.2 Dosing liquid in the pump housing
section 7.7 Repairs. leakage.
mode.
If nothing indicates that dosing liquid has entered the To avoid any danger resulting from diaphragm Immediately separate the pump from the
pump housing, go on as described in section Tighten the dosing head screws with a leakage, observe the following: power supply!
7.4.3 Reassembling the diaphragm and valves. torque wrench before startup and every • Perform regular maintenance. See section Make sure the pump cannot be put back
Otherwise proceed as described in section time the dosing head has been opened. 7.1 Regular maintenance. into operation by accident!
7.6.2 Dosing liquid in the pump housing. After 48 operating hours, retighten the
dosing head screws using a torque • Never operate the pump with blocked or soiled If dosing liquid has entered the pump housing:
wrench. Torque [Nm]: 6 (+ 1). drain opening.
• Send the pump to Grundfos for repair, following
– If the drain opening is blocked or soiled, the instructions given in section 7.7 Repairs.
11. Deaerate the dosing pump. See section proceed as described in section
5.4 Deaerating the pump. • If a repair isn't economically reasonable, dispose
7.6.1 Dismantling in case of diaphragm
12. Observe the notes on commissioning in section of the pump observing the information in section
leakage.
5. Startup. 9. Disposal.
• Take suitable precautions to prevent harm to
health and damage to property from escaping
7.5 Resetting the service system dosing liquid.
After performing the service, the service system • Never operate the pump with damaged or loose
must be reset using the "Info > Reset service dosing head screws.
system" function.
39 40
7.7 Repairs 8. Faults 8.1 List of faults
In the event of faults in the dosing pump, a warning 8.1.1 Faults with error message
The pump housing must only be opened
or an alarm is triggered. The corresponding fault
by personnel authorised by Grundfos!
symbol flashes in the "Operation" menu, see section
Repairs must only be carried out by Display in the
8.1 List of faults. The cursor jumps to the "Alarm" Possible cause Possible remedy
authorised and qualified personnel! " " menu
main menu symbol. Press the click wheel to open the
Switch off the pump and disconnect it from "Alarm" menu and, where necessary, faults to be Empty • Dosing medium tank empty • Fill tank.
the voltage supply before carrying out acknowledged will be acknowledged. (Alarm) • Check contact setting (NO/NC).
maintenance work and repairs! A yellow display indicates a warning and the pump Low level • Dosing medium tank almost empty
After consulting Grundfos, please send the pump, continues running. (Warning)
together with the safety declaration completed by a A red display indicates an alarm and the pump is • Outlet valve blocked • Replace valve if necessary. See section
specialist, to Grundfos. The safety declaration can stopped. 7.4 Perform service.
be found at the end of these instructions. It must be The pump can start automatically when the cause of
copied, completed and attached to the pump. • Isolating valve in outlet line closed • Check flow direction of valves (arrow) and
the fault has been remedied.
correct if necessary.
The pump must be cleaned prior to CAUTION Overpressure • Open the isolating valve (on the outlet
dispatch! (Alarm) side).
Automatic startup
If dosing liquid has possibly entered the Minor or moderate personal injury • Pressure peaks due to high • Enlarge diameter of outlet line.
pump housing, state that explicitly in the - Before remedying the cause of the fault, viscosity
safety declaration! Observe section make sure the pump has been installed • Max. pressure set too low. See • Change pressure setting. See section
7.6 Diaphragm leakage. correctly and is ready to be started. section 6.8 ) 6.8 .
If the above requirements are not met, Grundfos may • Faulty diaphragm • Change the diaphragm. See section
refuse to accept delivery of the pump. The shipping Before starting work on the pump, the 7.4 Perform service.
costs will be charged to the sender. pump must be in the "Stop" operating state
or be disconnected from the power supply. • Broken outlet line • Check outlet line and repair if necessary.
Low
The system must be pressureless. • Pressure differential between inlet • Install additional spring-loaded valve
backpressure
The last 10 faults are stored in the "Alarm" main (Warning/alarm*) and outlet side too low (approx. 2 bar) on the outlet side.
menu. When a new fault occurs, the oldest fault is • Leakage in the pressure loading
deleted. valve at Q < 1 l/h
The two most recent faults are shown in the display, • Deaeration valve open • Close the deaeration valve.
you can scroll through all the other faults. The time • Broken/leaky inlet line • Check inlet line and repair if necessary.
and cause of the fault are displayed. • Provide positive inlet pressure (place
Air bubble dosing medium tank above the pump).
Alarm (Warning) • Strongly degassing medium • Enable "SlowMode". See section

6.6 .
1 12.02.2017 12:34
• Tank dosing medium empty • Fill tank.
Empty
• Blocked/constricted/squeezed • Enable "SlowMode". See section
2 12.02.2017 12:34 inlet line 6.6 .
Low level Cavitation • Blocked/constricted inlet valve • Reduce suction lift.
(Warning) • Suction lift too high • Increase inlet hose diameter.
• Viscosity too high • Check inlet line and open isolating valve if
Delete alarm necessary.
messages ❑
• Leaky/dirty inlet valve • Check valve and tighten it up.
• Flush system.
The list of faults can be deleted at the end of the list.
• Replace valve if necessary. See section
If there is a service requirement, this appears when Suct. valve leak 7.4 Perform service.
the "Alarm" menu is opened. Press the click wheel to (Warning)
• Check O-ring position.
temporarily close the service prompt. See section
• Install filter in inlet line.
7.3 Service system.
• Deaeration valve open • Close the deaeration valve.
• Considerable deviation between • Check installation.
Flow deviation target and actual flow
(Warning) • Pump not or incorrectly calibrated • Calibrate the pump. See section
5.5 Calibrating the pump.
41 42
8.1.2 General faults
Display in the
Possible cause Possible remedy
" " menu
Fault Possible cause Possible remedy
• Leaky/dirty outlet valve • Check valve and tighten it up. Replace
valve if necessary. See section Install additional spring-loaded valve (approx. 2
• Leakage in the pressure loading Inlet pressure greater than
7.4 Perform service. bar) on the outlet side.
valve backpressure
• Flush system. Dosing flow too high Increase pressure differential.
Disch. valve leak • Check O-ring position. Calibrate the pump. See section 5.5 Calibrating
(Warning) Incorrect calibration
• Install screen in inlet line. the pump.
• Install spring-loaded valve on the outlet Air in dosing head Deaerate the pump.
side.
Change the diaphragm. See section 7.4 Perform
• Deaeration valve open • Close the deaeration valve. Faulty diaphragm
service.
• Backpressure greater than • Reduce backpressure. Leakage/fracture in lines Check and repair lines.
nominal pressure
Valves leaking or blocked Check and clean valves.
• Outlet valve blocked • Replace valve if necessary. See section
7.4 Perform service. Check that the arrow on the valve housing is
• Isolating valve in outlet line closed
Valves installed incorrectly pointing in the direction of flow. Check whether all
• Check flow direction of valves (arrow) and
O-rings are installed correctly.
correct if necessary.
Overload • Open the isolating valve (on the outlet Blocked inlet line Clean inlet line/install filter.
No dosing flow or
(Alarm) side). dosing flow too low Reduce suction lift.
• Pressure peaks • Enlarge diameter of outlet line. Suction lift too high Install priming aid.
• Install a pulsation damper in the outlet line Enable "SlowMode". See section 6.6 .
close to the outlet valve.
Enable "SlowMode". See section 6.6 .
• Ambient temperature below • Adjust ambient temperature to specified
specified minimum value. See value. Viscosity too high Use hose with larger diameter.
section 3.1 Technical data. Install spring-loaded valve on the outlet side.
• Broken "FlowControl" cable (see • Check plug connection. Replace cable if Calibrate the pump. See section 5.5 Calibrating
fig. 13) necessary. Faulty calibration
the pump.
Pressure sensor • Sensor defect • Replace sensor if necessary. Deaeration valve open Close the deaeration valve.
(Warning) • Pressure sensor not correctly • Calibrate pressure sensor correctly. See Tighten up valves, replace valves if necessary.
calibrated section 6.8.2 Calibration of pressure Valves leaking or blocked
See section 7.4 Perform service.
sensor. Irregular dosing
Keep backpressure constant.
• Backpressure greater than • Reduce backpressure. Backpressure fluctuations
Activate "AutoFlowAdapt" (only DDA-FCM).
nominal pressure
Motor blocked Immediately separate the pump from the power
• Incorrectly installed diaphragm • Install the diaphragm correctly. Liquid escaping from
(Alarm) supply!
• Damage to gears • Contact your Grundfos service partner. the drain opening on Faulty diaphragm
Observe section 7. Service and especially section
the dosing head
• Hall sensor failure 7.6 Diaphragm leakage.
• Fieldbus communication error • Check cables for correct specification and Dosing head screws not Tighten up screws. See section 4.2 Hydraulic
Bus error damage; replace if necessary. tightened connection.
(Alarm) Liquid escaping
• Check cable routing and shielding; correct Tighten up valves/union nuts. See section
if necessary. Valves not tightened
4.2 Hydraulic connection.
CIU • CIU connection error • Check plug connection. Reduce suction lift; if necessary, provide positive
Suction lift too high
(Alarm) • Faulty CIU • Replace CIU if necessary. inlet pressure.
• Defect in analog cable 4-20 mA • Check cable/plug connections and Pump not sucking in Backpressure too high Open the deaeration valve.
Cable break
(input current < 2 mA) replace, if necessary. Flush system, replace valves if necessary. See
(Alarm) Soiled valves
• Check signal transmitter. section 7.4 Perform service.
• Diaphragm leakage • Read section 7.6 Diaphragm leakage
Diaphragm leak.
(Alarm)
• Change the diaphragm. See section 9. Disposal
7.4 Perform service.
This product or parts of it must be disposed of in an
• Leaky/dirty outlet valve • Replace valve if necessary. See section environmentally sound way. Use appropriate waste
Disch. valve leak
7.4 Perform service. collection services. If this is not possible, contact the
(Alarm)
• Install screen in inlet line. nearest Grundfos company or service workshop.
Overheating • Motor is overheated • Reduce ambient temperature.
(Alarm) • Stop pump until motor cools down.
Subject to alterations.
Service now • Time interval for service expired • Perform service. See section 7.4 Perform
(Warning) service.
* Depending on setting
43 44
Argentina China Germany
Bombas GRUNDFOS de Argentina S.A. Grundfos Alldos GRUNDFOS Water Treatment GmbH
Ruta Panamericana km. 37.500 Centro Dosing & Disinfection Reetzstraße 85
Industrial Garin ALLDOS (Shanghai) Water Technology D-76327 Pfinztal (Söllingen)
1619 - Garin Pcia. de B.A. Co. Ltd. Tel.: +49 7240 61-0
Phone: +54-3327 414 444 West Unit, 1 Floor, No. 2 Building (T 4-2) Telefax: +49 7240 61-177
Telefax: +54-3327 411 111 278 Jinhu Road, Jin Qiao Export E-mail: gwt@grundfos.com
Processing Zone
Australia Pudong New Area
Germany
GRUNDFOS Pumps Pty. Ltd. Shanghai, 201206 GRUNDFOS GMBH
P.O. Box 2040 Phone: +86 21 5055 1012 Schlüterstr. 33
Regency Park Telefax: +86 21 5032 0596 40699 Erkrath
South Australia 5942 E-mail: Tel.: +49-(0) 211 929 69-0
Phone: +61-8-8461-4611 grundfosalldos-CN@grundfos.com Telefax: +49-(0) 211 929 69-3799
Telefax: +61-8-8340 0155 E-mail: infoservice@grundfos.de
China Service in Deutschland:
Austria GRUNDFOS Pumps (Shanghai) Co. Ltd. E-mail: kundendienst@grundfos.de
GRUNDFOS Pumpen Vertrieb 10F The Hub, No. 33 Suhong Road
Ges.m.b.H. Minhang District
Greece
Grundfosstraße 2 Shanghai 201106 GRUNDFOS Hellas A.E.B.E.
A-5082 Grödig/Salzburg PRC 20th km. Athinon-Markopoulou Av.
Tel.: +43-6246-883-0 Phone: +86-21 6122 5222 P.O. Box 71
Telefax: +43-6246-883-30 Telefax: +86-21 6122 5333 GR-19002 Peania
Phone: +0030-210-66 83 400
Belgium COLOMBIA Telefax: +0030-210-66 46 273
N.V. GRUNDFOS Bellux S.A. GRUNDFOS Colombia S.A.S.
Boomsesteenweg 81-83 Km 1.5 vía Siberia-Cota Conj. Potrero
Hong Kong
B-2630 Aartselaar Chico, GRUNDFOS Pumps (Hong Kong) Ltd.
Tél.: +32-3-870 7300 Parque Empresarial Arcos de Cota Bod. Unit 1, Ground floor
Télécopie: +32-3-870 7301 1A. Siu Wai Industrial Centre
29-33 Wing Hong Street &
Belarus Cota, Cundinamarca
68 King Lam Street, Cheung Sha Wan
Представительство ГРУНДФОС в Phone: +57(1)-2913444
Telefax: +57(1)-8764586 Kowloon
Минске Phone: +852-27861706 / 27861741
220125, Минск Croatia Telefax: +852-27858664
ул. Шафарнянская, 11, оф. 56 GRUNDFOS CROATIA d.o.o.
Тел.: +7 (375 17) 286 39 72, 286 39 73 Cebini 37, Buzin
Hungary
Факс: +7 (375 17) 286 39 71 HR-10010 Zagreb GRUNDFOS Hungária Kft.
E-mail: minsk@grundfos.com Phone: +385 1 6595 400 Park u. 8
H-2045 Törökbálint,
Bosnia/Herzegovina Telefax: +385 1 6595 499
Phone: +36-23 511 110
GRUNDFOS Sarajevo www.hr.grundfos.com
Telefax: +36-23 511 111
Trg Heroja 16, GRUNDFOS Sales Czechia and
BiH-71000 Sarajevo India
Phone: +387 33 713 290
Slovakia s.r.o. GRUNDFOS Pumps India Private
Čapkovského 21
Telefax: +387 33 659 079 Limited
e-mail: grundfos@bih.net.ba 779 00 Olomouc 118 Old Mahabalipuram Road
Phone: +420-585-716 111
Thoraipakkam
Brazil
BOMBAS GRUNDFOS DO BRASIL
Denmark Chennai 600 097
GRUNDFOS DK A/S Phone: +91-44 4596 6800
Av. Humberto de Alencar Castelo
Martin Bachs Vej 3 Indonesia
Branco, 630
DK-8850 Bjerringbro
CEP 09850 - 300 PT. GRUNDFOS POMPA
Tlf.: +45-87 50 50 50
São Bernardo do Campo - SP Graha Intirub Lt. 2 & 3
Telefax: +45-87 50 51 51
Phone: +55-11 4393 5533 Jln. Cililitan Besar No.454. Makasar,
Telefax: +55-11 4343 5015 E-mail: info_GDK@grundfos.com Jakarta Timur
www.grundfos.com/DK
ID-Jakarta 13650
Bulgaria
Estonia Phone: +62 21-469-51900
Grundfos Bulgaria EOOD Telefax: +62 21-460 6910 / 460 6901
GRUNDFOS Pumps Eesti OÜ
Slatina District
Peterburi tee 92G Ireland
Iztochna Tangenta street no. 100
BG - 1592 Sofia 11415 Tallinn GRUNDFOS (Ireland) Ltd.
Tel: + 372 606 1690
Tel. +359 2 49 22 200 Unit A, Merrywell Business Park
Fax. +359 2 49 22 201 Fax: + 372 606 1691 Ballymount Road Lower
email: bulgaria@grundfos.bg Finland Dublin 12
OY GRUNDFOS Pumput AB Phone: +353-1-4089 800
Canada Telefax: +353-1-4089 830
Trukkikuja 1
GRUNDFOS Canada Inc.
2941 Brighton Road FI-01360 Vantaa Italy
Phone: +358-(0)207 889 500
Oakville, Ontario GRUNDFOS Pompe Italia S.r.l.
L6H 6C9 France Via Gran Sasso 4
Phone: +1-905 829 9533 Pompes GRUNDFOS Distribution S.A. I-20060 Truccazzano (Milano)
Telefax: +1-905 829 9512 Parc d’Activités de Chesnes Tel.: +39-02-95838112
57, rue de Malacombe Telefax: +39-02-95309290 / 95838461
F-38290 St. Quentin Fallavier (Lyon)
Tél.: +33-4 74 82 15 15
Télécopie: +33-4 74 94 10 51
45
Japan Portugal Switzerland
GRUNDFOS Pumps K.K. Bombas GRUNDFOS Portugal, S.A. GRUNDFOS ALLDOS International AG
1-2-3, Shin-Miyakoda, Kita-ku Rua Calvet de Magalhães, 241 Schönmattstraße 4
Hamamatsu Apartado 1079 CH-4153 Reinach
431-2103 Japan P-2770-153 Paço de Arcos Tel.: +41-61-717 5555
Phone: +81 53 428 4760 Tel.: +351-21-440 76 00 Telefax: +41-61-717 5500
Telefax: +81 53 428 5005 Telefax: +351-21-440 76 90 E-mail:
grundfosalldos-CH@grundfos.com
Korea Romania
GRUNDFOS Pumps Korea Ltd. GRUNDFOS Pompe România SRL Switzerland
6th Floor, Aju Building 679-5 Bd. Biruintei, nr 103 GRUNDFOS Pumpen AG
Yeoksam-dong, Kangnam-ku, 135-916 Pantelimon county Ilfov Bruggacherstrasse 10
Seoul, Korea Phone: +40 21 200 4100 CH-8117 Fällanden/ZH
Phone: +82-2-5317 600 Telefax: +40 21 200 4101 Tel.: +41-44-806 8111
Telefax: +82-2-5633 725 E-mail: romania@grundfos.ro Telefax: +41-44-806 8115
Latvia Russia Taiwan
SIA GRUNDFOS Pumps Latvia ООО Грундфос GRUNDFOS Pumps (Taiwan) Ltd.
Deglava biznesa centrs Россия, 109544 Москва, ул. Школьная 7 Floor, 219 Min-Chuan Road
Augusta Deglava ielā 60, LV-1035, Rīga, 39 Taichung, Taiwan, R.O.C.
Tālr.: + 371 714 9640, 7 149 641 Тел. (+7) 495 737 30 00, 564 88 00 Phone: +886-4-2305 0868
Fakss: + 371 914 9646 Факс (+7) 495 737 75 36, 564 88 11 Telefax: +886-4-2305 0878
E-mail grundfos.moscow@grundfos.com
Lithuania Thailand
GRUNDFOS Pumps UAB Serbia GRUNDFOS (Thailand) Ltd.
Smolensko g. 6 GRUNDFOS Predstavništvo Beograd 92 Chaloem Phrakiat Rama 9 Road,
LT-03201 Vilnius Dr. Milutina Ivkovića 2a/29 Dokmai, Pravej, Bangkok 10250
Tel: + 370 52 395 430 YU-11000 Beograd Phone: +66-2-725 8999
Fax: + 370 52 395 431 Phone: +381 11 26 47 877 / 11 26 47 Telefax: +66-2-725 8998
496
Malaysia Telefax: +381 11 26 48 340
Turkey
GRUNDFOS Pumps Sdn. Bhd. GRUNDFOS POMPA San. ve Tic. Ltd.
7 Jalan Peguam U1/25 Singapore Sti.
Glenmarie Industrial Park GRUNDFOS (Singapore) Pte. Ltd. Gebze Organize Sanayi Bölgesi
40150 Shah Alam 25 Jalan Tukang Ihsan dede Caddesi,
Selangor Singapore 619264 2. yol 200. Sokak No. 204
Phone: +60-3-5569 2922 Phone: +65-6681 9688 41490 Gebze/ Kocaeli
Telefax: +60-3-5569 2866 Telefax: +65-6681 9689 Phone: +90 - 262-679 7979
Telefax: +90 - 262-679 7905
Mexico Slovakia E-mail: satis@grundfos.com
Bombas GRUNDFOS de México S.A. de GRUNDFOS s.r.o.
C.V. Prievozská 4D Ukraine
Boulevard TLC No. 15 821 09 BRATISLAVA Бізнес Центр Європа
Parque Industrial Stiva Aeropuerto Phona: +421 2 5020 1426 Столичне шосе, 103
Apodaca, N.L. 66600 sk.grundfos.com м. Київ, 03131, Україна
Phone: +52-81-8144 4000 Телефон: (+38 044) 237 04 00
Telefax: +52-81-8144 4010
Slovenia Факс.: (+38 044) 237 04 01
GRUNDFOS LJUBLJANA, d.o.o. E-mail: ukraine@grundfos.com
Netherlands Leskoškova 9e, 1122 Ljubljana
GRUNDFOS Netherlands Phone: +386 (0) 1 568 06 10 United Arab Emirates
Veluwezoom 35 Telefax: +386 (0)1 568 0619 GRUNDFOS Gulf Distribution
1326 AE Almere E-mail: tehnika-si@grundfos.com P.O. Box 16768
Postbus 22015 Jebel Ali Free Zone
1302 CA ALMERE
South Africa Dubai
Tel.: +31-88-478 6336 Grundfos (PTY) Ltd. Phone: +971-4- 8815 166
Telefax: +31-88-478 6332 Corner Mountjoy and George Allen Telefax: +971-4-8815 136
E-mail: info_gnl@grundfos.com Roads
Wilbart Ext. 2 United Kingdom
New Zealand Bedfordview 2008 GRUNDFOS Pumps Ltd.
GRUNDFOS Pumps NZ Ltd. Phone: (+27) 11 579 4800 Grovebury Road
17 Beatrice Tinsley Crescent Fax: (+27) 11 455 6066 Leighton Buzzard/Beds. LU7 4TL
North Harbour Industrial Estate E-mail: lsmart@grundfos.com Phone: +44-1525-850000
Albany, Auckland Telefax: +44-1525-850011
Phone: +64-9-415 3240
Spain
Telefax: +64-9-415 3250 Bombas GRUNDFOS España S.A. U.S.A.
Camino de la Fuentecilla, s/n GRUNDFOS Pumps Corporation
Norway E-28110 Algete (Madrid) 17100 West 118th Terrace
GRUNDFOS Pumper A/S Tel.: +34-91-848 8800 Olathe, Kansas 66061
Strømsveien 344 Telefax: +34-91-628 0465 Phone: +1-913-227-3400
Postboks 235, Leirdal Telefax: +1-913-227-3500
98767821 0317
N-1011 Oslo
Sweden
GRUNDFOS AB Uzbekistan ECM: 1205328
Tlf.: +47-22 90 47 00
Telefax: +47-22 32 21 50 (Box 333) Lunnagårdsgatan 6 Grundfos Tashkent, Uzbekistan The
431 24 Mölndal Representative Office of Grundfos
Poland Tel.: +46 31 332 23 000 Kazakhstan in Uzbekistan
GRUNDFOS Pompy Sp. z o.o. Telefax: +46 31-331 94 60 38a, Oybek street, Tashkent
ul. Klonowa 23 Телефон: (+998) 71 150 3290 / 71 150
Baranowo k. Poznania 3291
PL-62-081 Przeźmierowo Факс: (+998) 71 150 3292
Tel: (+48-61) 650 13 00
Fax: (+48-61) 650 13 50 Addresses revised 05.12.2016
www.grundfos.com
22/7/2019 HN 2140
FLOW SWITCH(ES)
22/7/2019 HN 2140
TEMPERATURE SENSOR(S)
n
.
n
n
n n
n n
n n
n n
≤ ≤
≤ ≤
≤ ≤
≤ ≤
≤ ≤
≤ ≤
≤ ≤
≤ ≤
≤ ≤
≤ ≤
≤ ≤
≤ ≤
≤ ≤
≤ ≤
≤ ≤
≤ ≤
≤ ≤
≤ ≤
≤ ≤
≤ ≤
n
≤ ≤
≤ ≤
n
σ
n
n
n ≤ ≤
≤ ≤
n
n
22/7/2019 HN 2140
PRESSURE TRANSMITTERS
Instructions
Pressure transmitters
type MBS 4201, MBS 4251, MBS 4701 MBS 4751
060R9345
060R9345
Content
Page Description/Application
1 Description/application Application: Pressure measurement in
2 Identification potentially explosive areas.
3 Specifications Approval: Ex ia IIC T6...T4 (MBS 42xx series)
4 Safety instructions and Ex ia IIC T4 (MBS 47xx series) in accord-
5 Installation/dimensions ance with ATEX directive 94/9/EC.
6 Electrical connection Function: Pressure transmitters type MBS
6 Maintenance/adjustment 4201, MBS 4251, MBS 4701 and MBS 4751
convert the pressure measured to a
4-20 mA current signal.
© Danfoss A/S (IA-MS/IM),

© 03.2014 IC.PI.P20.C6.02
ERMA FIRST ESK ENGINEERING / 520B6218
SOLUTIONS SA All rights reserved | Confidential | Pages 196 1
Identification
...............................................................................................................................................................................................................................
Code number
Supply voltage
PRESSURE TRANSMITTER
MBS 4701-2011-1AB08
3316
6430 Nordborg Denmark 060G4307
Range Pe : 0...10 bar 0539 II 1G
0...1 Mpa DEMKO 01 ATEX 127938X
02803111
Output signal Ex ia IIC T4 Ga 111=WWY
Made in China
PB/MWP : 2 MPa/20 bar IECEx ULD 12.0005X
Ui : 28V For : Production- week/year (WW/Y)
SUPPLY : 10...28 V d.c.
Ii : 100 mA Ambient
OUTPUT : 4...20 mA
Pi : 0,7 W temperature
+SUPPLY : PIN 1 Li : 8 µH See:
-COMMON : PIN 2 Ci : 50 nF user instruction
Electrical connection 02803=

Serial no.
Type no. (Indicates transmitter specification - see key below)
Type no.
MBS 4201-
MBS 4251-
MBS 4701-
1 –
MBS 4751-
Pressure connection
GB04 ......... DIN 3852-E-G1/4, Gasket: DIN 3869-14-NBR
AB08 ......... G1/2A (EN 837)
AC04 ......... 1/4-18 NPT
AC08 ......... 1/2-14 NPT
FA08 ......... ISO 6149-2, M14x1.5 -6g, O-ring 11.3x2.2, NBR
Measuring range
0-1 bar........................ 10
0-1.6 bar .................... 12
0-2.5 bar .................... 14
Electrical connection
0-4 bar ....................... 16 1 ........... Plug, DIN 43650, Pg9
0-6 bar........................ 18 3 ........... 2 m cable1)
0-10 bar...................... 20 7 ........... Plug, DIN 72585-A1-3.2-Sn
0-16 bar ..................... 22 4 ........... 5 m cable1)
0-25 bar ..................... 24 5 ........... 10 m cable1)
0-40 bar .................... 26
0-60 bar .................... 28 1
) Only MBS 4201 and MBS 4251
0-100 bar ................... 30
0- 160 bar ................. 32
0-250 bar .................. 34
0-400 bar .................. 36
0-600 bar .................. 38 Output signal
Max 600 bar ............. XX 1 .................. 4-20 mA
Pressure reference
1 ............................. Gauge
2 ............................. Absolute
2 SOLUTIONS SA All rights reserved | Confidential | Pages 197

© ERMA FIRST ESK ENGINEERING
Specifications
.........................................................................................................................................................................................................
Output current 4 - 20 mA
Supply voltage 10 - 28 V
Safety specifications
Electrical
Max. supply voltage Ui 28 V
Max. Input current Ii 100 mA
Max. Input power Pi 0.7 W
Internal capacity Ci 50 nF
Internal inductance Li 8 µH
Adjustable Type (MBS47x1-xxxx-1xxxx, MBS47x1-xxxx-7xxxx):
Ambient temperature T4 -40 -> 100 °C
Media temperature T4 -40 -> 125 °C
Plug Type, non-adjustable (MBS42x1-xxxx-1xxxx;; MBS42x1-xxxx-7xxxx):
Ambient temperature T4 -40 -> 100 °C

T5 -40 -> 75 °C
T6 -40 -> 50 °C

T5 -40 -> 95 °C
T6 -40 -> 50 °C
Fixed Cable Types, non-adjustable, MBS 42x1-xxxx-Yxxxx (Y =3, 4, 5 are indicative cable lengths, max. 10 m)
Ambient temperature (fixed installations) T4 -40 -> 80 °C

T5 -40 -> 75 °C
T6 -40 -> 50 °C
Ambient temperature (cables flexed during installation or operation) T4 -5 -> 70 °C

T5 -5 -> 70 °C
T6 -5 -> 50 °C

T5 -40 -> 95 °C
T6 -40 -> 50 °C
Pressure specification
Measuring range bar 0-1 0-1.6 0-2.5 0-4 0-6 0-10 0-16 0-25 0-40 0-60 0-100 0-160 0-250 0-400 0-600
Overload (Static) bar 6 12 24 24 60 60 150 150 300 360 600 1200 1500 1500 1500
Burst pressure bar 100 100 100 100 100 100 150 150 400 800 1200 1200 2000 2000 2000
3
Safety Instructions
DIN 43650, Pg 9 DIN 72585-A1-3.2-Sn
Materialer Glasfyldt polyamid, PA 6.6 Glasfyldt polyester, PBT PVC kabel

Materials of electrical Glass filled polyamid, PA 6.6 Glass filled polyester, PBT PVC cable
connections
Werkstoffe Glasgefülltes Plyamid, PA 6.6 Glassgefülltes Polyester, PBT PVC Kabel
Matériaux Polyamid au verre, PA. 6.6 Polyester au verre, PBT Cäble PVC
Materiales Poliamide reforzado con fibra Poliester reforzado con fibra de Cable de PVC
de vidrio, PA 6.6 vidrio, PBT
Kapsling
Protection
Schutzart IP65 IP67 / IP69K IP67
Etanchéité
Protección
Safety instructions
All national safety regulations must be complied with in connection with installation, start-up and operation of Danfoss pressure transmitters
type MBS 4201, MBS 4251, MBS 4701 and MBS 4751. Furthermore, the requirements of the Declaration of Conformity and national regulations
for installation in explosion areas apply. Disregarding such regulations involves a risk of serious personal injury or extensive material damage.
Work in connection with the pressure transmitters mentioned must be performed only by suitably qualified persons.
Basic safety and health requirements are fulfilled through compliance with:
EN60079-0: 2012, IEC60079-0: 6th edition, EN60079-11: 2012, IEC60079-11: 6th edition, EN60079-26: 2007, IEC60079-26: 2nd edition.
Special Ex protection instructions: In the event of damage to enclosure or diaphragm, the pressure transmitter must be replaced.
The end user must ensure the installation is made in accordance to EN/IEC60079-25 and EN/IEC60079-14.
WARNING –Potential Electrostatic Charging Hazard. The transmitter must only be installed in surroundings with low wind speed, and where
rubbing on the plug is unlikely. Cleaning with a damp cloth is recommended. To avoid build -up of electrostatic discharge it must be ensured
the pressure connection of the pressure transmitter is having a reliable connection to earth with an impedance no exceeding 1 Gohm.
The MBS transmitters do not provide isolation meeting the dielectric strength requirements of IEC/EN60079-11.
MBS transmitters contain 10 nF capacitance from any input terminal to earth.
Special conditions for safe use in accordance to the ATEX/IECEx certificate:

For installations in which both the Ci and Li of the connected apparatus exceeds 1% of Co and Lo parameters (excluding the cable), then 50%
of Co and Lo parameters are applicable and shall not be exceeded.
Special precautions are necessary to reduce the risk due to electro-static discharge. The transmitter must only be installed in surroundings with
low wind speed, and where rubbing the plug is unlikely. Cleaning with a damp cloth is recommended.
The installation shall ensure that the resistance to earth of metallic parts of the equipment enclosure is less than 1 GOhm.
The equipment does not provide 500 V isolation to earth as required by EN60079-11: clause 6.3.12.
Installations of the pressure connection across boundary walls requiring Category 1G equipment and a less hazardous area must
be gas tight as required by EN60079-26. Gaskets and seals used at the pressure connection must be suitable for use with the process medium.
Special instruction when adjusting MBS 47xx series:

If possible only adjust the MBS in non-hazardous area or take precaution to avoid electrostatic discharge and ensure the earthen of the
transmitter housing is maintained. The transmitter must always be supplied from an intrinsic safety barrier.
Demands on the medium:

Parts in contact with the medium are made of stainless steel, EN 1088-1 1.4404 (AISI 316L). The user is responsible for a careful analysis of all
process parameters when materials have to be specified and for ensuring the process medium is neutral to stainless steel as some media can
be corrosive. The end user must ensure that the process connection is gas tight (as required by EN/IEC60079-26) which may require the use of
a suitable gasket/seal in combination with the process connection to obtain a gas-tight connection. Gaskets and seals used at the pressure
connection, including those supplied with the transmitters, must be determined as being suitable for use with the process medium and
process pressure/temperature before use and alternative gasket material chosen if necessary. The end user must ensure the transmitter
pressure connection is tightened with the correct torque as required for the specific thread type.
In case of problems please contact: Danfoss A/S

DK-6430 Nordborg
Denmark
You find the EC-Type Examination Certificate at: www.ia.danfoss.com/ATEXcertificate
© ERMA FIRST ESK ENGINEERING

4 SOLUTIONS SA All rights reserved | Confidential | Pages 199
Installation/dimensions
MBS 4201 MBS 4701

MBS 4251 MBS 4751
DIN3852-E-G 1/4 G 1/2 A 1/4 18 NPT 1/2 - 14 NPT ISO 6149-2

Gasket: DIN 3869-14-NBR (EN 837) M14 x 1.5-6g
incl. O-ring NBR
Dimensioned sketch - Example
5
Electrical connection
DIN 43650
+ -
Pin 1 Pin 2
DIN 72585
+ -
Pin 1 Pin 2
MBS4201
MBS4251
MBS4701
MBS4751
+ -
Load
Black 1 Black 2
Cables must be specified for a minimum test voltage of 500 VAC between conductor/earth, conductor/screen and screen/earth. In addition, the total capacity
and inductivity of the installation (transmitter + cable) must be taken into consideration.
In Zone 0 an intrinsically safe type Ex ia circuit must be used and national regulations for Zone 0 must be complied with. The pressure transmitter must only be
used in Zone 0 at atmospheric pressure between 0.8 and 1.1 bar and at ambient temperatures between –20 and 50°C.
Maintenance/Adjustment
Zero adjustment
0 - 1 to 0 - 10 bar -5 to +20% FS
0 - 16 to 0 - 40 bar -5 to +10% FS
0 - 60 to 0 600 bar -2.5 to +2.5 FS
Span adjustment -5 to +5% FS
See table
Danfoss pressure transmitters type MBS 4201, MBS 4251, MBS 4701 and MBS 4751 are maintenance free.
Zero point and span (measurement area) adjustment is possible on MBS 4701 and MBS 4751.
Adjustment procedure (see drawing):
Loosen screw at top of the DIN 43650 plug. Remove plug.
Unscrew the black milled nut from the pressure transmitter and remove the DIN 43650 insert from the transmitter.
Install the plug on the DIN 43650 insert and connect the current measuring instrument.
Adjust the zero point on the potentiometer below the hole marked ZERO.
Adjust the span (measuring range) on the potentiometer below the hole marked SPAN (precise pressure reference must be used).
Do not remove the silicone during adjustment. Be sure that the potentiometer is covered with silicone after adjustment
6
22/7/2019 HN 2140
SHUTTER VALVES
GENERAL CATALOGUE GENERAL CATALOGUE
5th Edition - 1/2002 5th Edition - 1/2002
Art. “B” - BRONZE GLOBE VALVE Art. “B”

SEAL
MATERIALS
ACTUATOR
SINGLE ACTING DOUBLE ACTING 1 CYLINDER ANODIZED ALUMINIUM
A C T U ATO R A C T U ATO R 2 SPRING HARMONIC STEEL
3 * SELF-LOCKING NUT STAINLESS STEEL
4 * WASHER BRASS
CONNECTIONS 5 PISTON ALUMINIUM 11S
6 O-RING NBR
7 O-RING NBR
8 * CENTRAL BODY BRASS
10 * STEM STAINLESS STEEL
11 O-RING PTFE
ALLOWABLE TEMPERATURES 12 * GASKET-HOLDER PLATE BRASS
14 * WASHER BRASS
15 * BODY GASKET PTFE
16 * VALVE BODY BRONZE
17 FILTER (senc-seno versions) BRASS
19 * GASKET PTFE
ACTUATOR PILOT PRESSURE: S eal NBR
13 * SEAL NBR
VERSIONS AND SIZES 9 * STEM GASKET NBR
18 O-RING NBR
Seal FP M
13 * SEAL FPM
9 * STEM GASKET FPM
18 O-RING FPM
S eal E PDM
13 * SEAL EPDM
DIFFERENTIAL PRESSURE CHART 9 * STEM GASKET EPDM
18 O-RING EPDM
DOUBLE ACTING
*Parts in contact w ith the fluids intercepted
VERSION
PRESS. DeltaP
SINGLE ACTING G PILOTA bar
N.C. VERSION
1/2" 3 12
DeltaP " 4 16
G bar 3/4" 3 8
1/2" 5,5 " 4 10
3/4" 7 1" 3 13
1" 7 " 4 17
1"1/4 3 10
1"1/4 5,5
" 4 13
1"1/2 8
1"1/2 3 9 OVERALL DIMENSIONS
2" 5 " 4 11,5
2" 3 6
" 4 9
DN G A B C d E Ch KV PESO
mm mm mm mm mm mm mm m3/h gr
15 1/2" 105 85 60 17 50 27 3,4 600
MINIMUM PRESSURE REQUIRED TO OPEN
20 3/4" 113 85 75 22 50 36 7,9 700
THE VALVE IN THE S.A.N.C. VERSION
25 1" 125 95 85 28 76 46 11 1300
G 1/2" 3/4" 1" 1"1/4 1"1/2 2" 32 1"1/4 136 103 95 37 76 55 18 1700
40 1"1/2 170 130 110 43 88 60 28 2450
BAR 3 5 3 3 4 4
50 2" 180 135 120 55 88 72 44 2900
not subject
22/7/2019 HN 2140
SALINITY MEASURING DEVICE
22/7/2019 HN 2140
SUCTION PUMP
GARANTIA WARRANTY
CONDICIONES DE LA GARANTIA WARRANTY CONDITIONS
BOMBAS AZCUE, S . A. , garanti za l a BOMBA S A ZC UE, S . A . , w arrant i es t he

cal i dad de sus fabri cados por un perí odo de doce qual i t y of i t s product s for a peri od of t w el v e
meses a partir de la fecha de entrega del material al m ont hs, from t he dat e t he equi pm ent i s del i v e-
cliente. red t o t he cust om er.
La garantía comprende al cambio o reposición The warranty comprehends the exchange or the
sin cargo, de toda pieza o conjunto que sea reconocido replacement of any part or assembly that the technical
por los servicios técnicos de BOMBAS AZCUE, S.A., services of BOMBAS AZCUE, S .A. could find defecti-
como defectuosa por deficiencia de proyecto, fabrica- ve, due to wrong design, manufacturing of material fai-
ción o fallo de material. lure.
El desmontaje y montaje correrán a cargo del The disassembl y and assembl y shall be carried
cliente, así como el transporte en ambos sentidos, los out at the customer´s expense, as well as the transport in
cuales serán facturados al precio de coste. both directions, which will be invoiced at cost price.
La reclamación de la garantía se efectuará The warranty claims will always be done by let-
siempre por escrito, indicando el tipo y número de la ter, indicating the type and number of the pump or
bomba o grupo motobomba, fecha de entrega y agente motor-pump unit, date of delivery and the S ales Agency
de venta donde lo adquirió. La reclamación puede hacer- where it was purchased. The claim may be formulated,
se tanto a través del agente de venta como directamente either through the Agency or directly to BOMBAS
a BOMBAS AZCUE, S.A. AZCUE, S .A.
BOMBAS AZCUE, S.A., declina toda respon- BOMBAS AZCUE, S .A., does not carry any
sabilidad por los accidentes, negligencias y desgastes responsibility over the accidents, negligence or abnormal
anormales en la bomba, provocados por personal incom- wear in the pump, no matter where the origin of these
petente, por haber trabajado sin líquido, o bombeado is, such as unreliable personnel, for having it run dry or
aguas u otros productos con soluciones o materias en pumped water or other products with solutions or mate-
suspensión no detallados en oferta y pedido. ria in suspension, not specified in offer and order.
Asimismo se rechazará toda garantía por repa- All warranty on rectifications or repairs, con-
raciones o transformaciones, efectuadas sin nuestro pre- ducted without our previous consent, shall be refused as
vio consentimiento. well.
En los grupos motobombas eléctricos, nuestras In the motor-pump units, our warranty condi-
condiciones de garantía serán válidas únicamente cuan- tions will only be valid when the electrical installation
do la instalación eléctrica disponga de arrancador guar- is provided with motor protecting thermal relay, calibra-
damotor adecuado con relé térmico de regulación apro- ted fuses and discharge shut-off valve on pump outlet, in
piada, fusibles calibrados y llave de compuerta en la order to regulate the capacity and so, the motor consumed
tubería de impulsión a la salida de la bomba, para regu- amperage to the value marked on the motor plate.
lar el caudal y con ello el consumo del motor al valor en
amperios que señala la placa de características. The repairs or the replacement of the parts under
warranty, cannot in any case, extend the expire of the
La reparación o el cambio de las piezas en warranty. The pumps or motor-pump units already in
garantía no puede en ningún caso prolongar o renovar la use, are not under warranty.
fecha de la misma. No se concede garantía para las bom-
bas o grupos motobombas usados. The illustrations and data shown in this manual
or in publicity catalogues, are not binding.
Las ilustraciones y datos contenidos en este
manual o en folletos de propaganda son sin compromi- BOMBAS AZCUE, S .A., reserves the right to
so. introduce without any previous notice, and at any
moment, the eventual modifications it considers adequa-
BOMBAS AZCUE, S.A., se reserva el derecho te, this being due to market or constructive difficulties
de introducir sin previo aviso y en cualquier momento without being for that obliged to include the above chan-
las eventuales modificaciones que crea oportunas por ges or improvements is all the pumps or motor-pump
exigencias comerciales o constructivas, sin que por ello, units actually in the customer´s hands or out of the fac-
se vea obligada de incluir las modificaciones o mejoras tory.
© ERMA FIRSTenESK
todasENGINEERING
las bombas o grupos motobombas
SOLUTIONS en poderSA
del All rights reserved | Confidential | Pages 347
cliente o fuera de fábrica.
! !
! !
! ! ! !
! !
! !
! !
! !
! !
! !
! !
! !
! !
ALMACENAMIENTO STORAGE
Generalmente la bomba entregada esta disponible para The delivered pump is generally suitable for immediate
la inmediata instalación: installation.
ALMACENAJE PERIODO MENOR A 3 MESES: STORAGE FOR A PERIOD OF LESS THAN 3 MONTHS:
• Almacenar la bomba en lugar seco y protegido. • Store the pump in a dry and sheltered area.
• Temperatura ambiente nuca será menor a 5ºC • Check that ambient temperature never falls below 5ºC
• Es recomendable que el eje de la bomba se gire regu- • It is recommended that the pump shaft is rotated at
larmente (cada 30 días), para prevenir daños en los regular intervals (every 30 days), this prevent damage
rodamientos y agarrotamientos en las partes rotativas. to the bearings and seizure of the rotating parts.
ALMACENAJE PERIODO MAYOR A 3 MESES: STORAGE FOR A PERIOD EXCEEDING 3 MONTHS:
• Elevar la bomba y colocar soportes de madera. • Rise the pump by means of wooden supports.
• Abrir el paquete, si lo hay, quitar las protecciones y • Open the package, if any, remove the protection from
limpiar con aire comprimido, después secar cuidadosa- the pump nozzles and clean by compressed air, then dry
mente si fuese necesario. carefully inside the pump, if necessary.
• Proteger el interior de la bomba con productos anti- • Protect the pump inside with anti-condensation pro-
condensación y tapar las bridas para evitar que entre ducts and close the flanges so that no foreign objects
nada en el interior de la bomba. can enter the pump.
• Cubrir la bomba con plástico y usar productos contra • Cover the pump with a plastic film and put inside
la condensación some products to prevent water condensation.
• Chequear las protecciones periodicamente. • Check protections periodically.
• Es recomendable que el eje de la bomba se gire regu- • It is recommended that the pump shaft is rotated at
larmente (cada 30 días), para prevenir daños en los regular intervals (every 30 days), this prevent damage
rodamientos y agarrotamientos en las partes rotativas. to the bearings and seizure of the rotating parts.
• Si los motores son almacenados más de 2 años, se • If motors are stored more than two years, bearings
debe proceder al cambio de rodamientos o a la sustitu- must be replaced or the lubrication grase must be
ción total de la grasas lubricante después de la limpie- totally removed after cleaning.
za de los mismos.
ALMACENAJE (TRAS PUESTA EN MARCHA) STORAGE (AFTER OPERATION):
• En el caso de largos periodos de almacenaje tras la • In case of long periods after operation, drain the
puesta en marcha, drenar y secar la bomba. pipings and the pump through the drain hole in the
Seguir las instrucciones mencionadas de acuerdo a las lower part of pump casing.
circunstancias. • Follow above instruction according to circumstances.
NOTAS / NOTES NOTAS / NOTES
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
……………………………………………………………………………………………………………………………………………………………………………………………….. ………………………………………………………………………………………………………………………………………………………………………………………………..
NOTAS / NOTES
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
………………………………………………………………………………………………………………………………………………………………………………………………..
22/7/2019 HN 2140
HYDROGEN SENSOR
SMART S SMART S
MANUALE D'INSTALLAZIONE E USO INSTALLATION AND USER MANUAL MANUALE D'INSTALLAZIONE E USO INSTALLATION AND USER MANUAL
Attenzione Warning
QUESTO MANUALE DEVE ESSERE THIS MANUAL MUST BE CAREFULLY
LETTO ATTENTAMENTE DA TUTTI READ BY ALL PERSONS WHO HAVE OR
COLORO CHE HANNO O AVRANNO LA WILL HAVE THE RESPONSIBILITY FOR
RESPONSABILITA' DI INSTALLARE, INSTALLING, USING OR SERVICING
UTILIZZARE O DI PRESTARE UN THIS PRODUCT.
SERVIZIO DI ASSISTENZA SU QUESTO
PRODOTTO.
SMART S (ST/x) Come ogni componente di un sistema,

questo prodotto funzionerà correttamente
Like any equipment, this product will
perform as designed only if installed, used
RIVELATORI PER GAS INFIAMMABILI solo se installato, utilizzato e controllato
come prescritto dal fabbricante.
and serviced in accordance with the
manufacturer’s instructions.
MANUALE D’INSTALLAZIONE ED USO IN CASO CONTRARIO, POTREBBE NON

FUNZIONARE CORRETTAMENTE E LE
OTHERWISE, IT COULD FAIL TO
PERFORM AS DESIGNED AND
PERSONE CHE AFFIDANO LA LORO PERSONS WHO RELY ON THIS
SICUREZZA A QUESTO PRODOTTO PRODUCT FOR THEIR SAFETY COULD
SMART S (ST/x) POTREBBERO SUBIRE DANNI PERSO-
NALI O LETALI.
SUFFER SEVERE PERSONAL INJURY
OR DEATH.
FOR FLAMMABLE GAS DETECTORS La garanzia riconosciuta da Sensitron s.r.l. The warranties made by Sensitron s.r.l.
su questo prodotto potrebbe essere nulla with respect to this product are voided if the
INSTALLATION AND USER MANUAL se il prodotto non venisse installato, product is not installed, used and serviced
utilizzato e controllato secondo le istruzioni in accordance with the instructions in this
fornite con il presente manuale. Per favore, user guide. Please protect yourself and
proteggetevi seguendole attentamente. others by following them.
Invitiamo i nostri clienti a scriverci o a We recommend our customers to write or

chiamarci per ogni informazione riguardo call regarding this equipment prior to use or
questo strumento, il suo uso o una sua for any additional information relative to
eventuale riparazione. use or repair.
SENSITRON S.r.l. Viale della Repubblica, 48

20010 CORNAREDO MI - Italy
Ph: + 39 02 93548155 Fax: + 39 02 93548089
E-MAIL: sales@sensitron.it
MT3567rev1.1 13/10/2017 Page 1 of 18 MT3567rev1.1 13/10/2017 Page 2 of 18
SMART S SMART S
INDICE / INDEX
1 INTRODUZIONE.............................................................................................................................................. 4 1 INTRODUZIONE 1 INTRODUCTION
1 INTRODUCTION ............................................................................................................................................. 4
1.1 Descrizione............................................................................................................................................................... 4
1.1 Descrizione 1.1 Description
1.1 Description ............................................................................................................................................................... 4
1.2 Identificazione rivelatore gas esplosivi...................................................................................................................... 7 Gli SMART S possono essere collegati sia a centrali di The SMART S can be connected to both analog and
tipo analogico sia indirizzate, nonché alle centrali di nuova addressable control panels as well as with the new
1.2 Flammable gas detectors identification..................................................................................................................... 7
concezione MULTISCAN++. MULTISCAN++.
1.3 Caratteristiche tecniche........................................................................................................................................... 7
1.3 Technical specifications.......................................................................................................................................... 7 Progettati per soddisfare i requisiti industriali più esigenti, Designed to meet with the toughest industrial
2 PREDISPOSIZIONE DEL SITO D’INSTALLAZIONE ..................................................................................... 9 gli SMARTS vengono impiegati per rilevare la presenza di requirements, SMARTS gas detectors are used to detect
2 INSTALLATION SITE PREARRANGEMENT ................................................................................................. 9 sostanze combustibili, (%LEL) in una atmosfera costituita the presence combustible gases (%LEL) in environments
principalmente da aria in aree pericolose. where the principal constituent is air in harsh
3 INSTALLAZIONE .......................................................................................................................................... 10 I rivelatori SMART S sono certificati IECEx, ATEX II2G, environments.
3 INSTALLATION............................................................................................................................................. 10 SIL2 Hardware e SIL3 Software SMART S detectors are IECEx, ATEX II2G, SIL2
3.1 Modalità per il corretto montaggio........................................................................................................................ 10 Il sensore catalitico industriale (Pellistor) utilizzato per la Hardware, SIL3 software approved capability.
3.1 Correct positioning mode...................................................................................................................................... 10 rivelazione di miscele infiammabili, conferisce una The industrial line of catalytic sensor (Pellistor) employed
precisione ed una selettività ottimale con la maggior parte for the detection of flammable compounds offers a great
3.2 Schema topografico circuito ................................................................................................................................. 10
dei gas esplosivi, evitando al massimo falsi allarmi. precision and selectivity with most of the explosive gases,
3.2 Detector circuit layout ........................................................................................................................................... 10 thus avoiding false alarms.
3.3 Scheda display per SMART S-SS .......................................................................................................................... 11 Alcuni modelli sono forniti con sensore infrarosso.
3.3 Display board for SMART S-SS ............................................................................................................................. 11 I sensori infrarosso sono immuni dagli avvelenamenti Some models are provided with Infrared sensors. Infrared
3.4 Configurazione del rivelatore ................................................................................................................................ 11 prodotti da alcune sostanze che inibiscono e danneggiano sensors are not affected by those poisoning and inhibiting
3.4 Detector configuration........................................................................................................................................... 11
i Pellistori. substances that damage Pellistor sensors.
Questo permette di aggiungere affidabilità e durata, This grants a higher accuracy and a longer lifetime to the
3.5 Collegamento con uscita 4-20mA ......................................................................................................................... 12
consentendo l’utilizzo dei rivelatori anche nei luoghi in cui i detector and allows the instrument to be used in
3.5 4-20mA output connection .................................................................................................................................... 12 pellistori non possono garantire una funzionalità ottimale. atmospheres where the traditional Pellistor cells could not
3.6 Collegamento uscita seriale RS485 ...................................................................................................................... 13 be used.
3.6 RS485 serial output connection ............................................................................................................................ 13 Il microprocessore presente sulla scheda elettronica del To protect and increase the stability and accuracy of the
3.7 Collegamento con schede opzionali..................................................................................................................... 14 rivelatore, oltre che per il normale funzionamento, è gas detector, the microprocessor present on the internal
provvisto dei seguenti algoritmi software che servono per electric circuit board, is programmed with the following
3.7 Connection to optional boards.............................................................................................................................. 14
aumentare l’accuratezza del rilevatore: software algorithms:
4 COLLAUDO E USO ...................................................................................................................................... 14 Autodiagnosi del sistema, che verifica costantemente il Self diagnostic procedure to check the detector’s main
4 TESTING AND USE ...................................................................................................................................... 14 corretto funzionamento dell’hardware, sensore compreso. operational parts, both hardware and sensing element.
4.1 Accensione............................................................................................................................................................. 14 Inseguitore di Zero per il mantenimento del parametro Zero point tracking to maintain the zero parameter of the
4.1 Power ON................................................................................................................................................................ 14
del sensore prescindendo da possibili derive dovute a sensor apart from possible drifts due to thermal or physical
variazioni termiche o fisiche del sensore stesso. variations of the sensor.
4.2 Collaudo ................................................................................................................................................................. 14
Filtro digitale che consente di correggere fenomeni Digital filter employed in the digital analysis of the
4.2 Testing .................................................................................................................................................................... 14 transitori che potrebbero causare una instabilità del analogue values sampled. It is designed to prevent the
4.3 Uso.......................................................................................................................................................................... 14 sistema o errori di lettura con conseguenti falsi allarmi; effects of transients, which may cause instability or
4.3 Use .......................................................................................................................................................................... 14 Ciclo d’isteresi viene applicato alle uscite digitali incorrect readings with possible false alarms.
5 MANUTENZIONE .......................................................................................................................................... 15 associate alle soglie d’allarme e consente l’eliminazione Hysteresis cycle applied to the digital outputs to eliminate
delle continue commutazioni nell’intorno dei punti di continuous switching close to the preset alarm thresholds.
5 MAINTENANCE ............................................................................................................................................ 15 soglia. Watch-dog for the microprocessor control. In case of
5.1 Manutenzione preventiva ...................................................................................................................................... 15 Watch-dog per il controllo del microprocessore. In caso di intervention, the output current drops down to 0mA while
5.1 Preventive maintenance routines............................................................................................................................... 15 intervento la corrente di uscita viene forzata a 0mA e il the red LED stops blinking and remains on.
5.2 Manutenzione correttiva ........................................................................................................................................ 15 LED rosso di segnalazione resta acceso. If the RS485 interface is connected, the communication
5.2 Corrective maintenance routines.............................................................................................................................. 15
Se sul rilevatore è presente la scheda seriale RS485, la will be interrupted, while if the 3-relay card is plugged in,
trasmissione viene interrotta, mentre se è installata la the Fault relay will activate.
5.3 Istruzioni per la dismissione ................................................................................................................................. 15
scheda 3 relè, il relè di fault si attiva.
5.3 Disassembly instructions ...................................................................................................................................... 15
6 ISTRUZIONI PER L'IMBALLAGGIO............................................................................................................. 15 Lo SMART S è disponibile in due versioni: con display SMART S is available in two versions: with display,
6 PACKING INSTRUCTIONS .......................................................................................................................... 15 SMART S-SS e senza display SMART S-MS. SMART S-SS and without display SMART S-MS.
L’utilizzo del display è riportato nel relativo manuale. The use of the display is shown in the display Manual.
7 ACCESSORI ................................................................................................................................................. 15
7 ACCESSORIES............................................................................................................................................. 15 I rivelatori SMART S-MS possono avere diversi tipi di The SMART S-MS have different types of enclosures:
8 Sensibilità relativa sensori.......................................................................................................................... 17 contenitori: 3A (standard aluminium casing),
3A (Involucro in alluminio standard), 4A (copper free aluminium casing),
8 Sensor Relative Response.......................................................................................................................... 17
4A (Involucro in alluminio senza rame), 6S (stainless steel housing).
9 TAGLIANDO DI GARANZIA PER LA RIPARAZIONE ................................................................................. 18 6S (Involucro in acciaio inox).
9 WARRANTY COUPON FOR REPAIRING .................................................................................................... 18
A seconda dell’elettronica integrata lo SMART S -MS può SMART S-MS can be identified under the following
essere identificato con i seguenti numeri: numbers depending on the integrated electronics:
11 (elettronica con un’uscita RS e un’uscita 4 -20mA), 11 (one 4-20mA output and one RS output),
13 (elettronica con un’uscita RS 485, un’uscita 4 -20mA e 13 (one 4-20mA output, one RS output and one 3 relay
SMART S SMART S
scheda 3 relè), board),
17 (elettronica con un’uscita RS 485, un’uscita 4 -20mA, 17 (one 4-20mA output, one RS output, one 3 relay board CODE INFRARED SENSOR DESCRIPTION
scheda 3 relè e modem Hart). and modem Hart). S4019ME METHANE sensor head, 0-100%LEL
S4004PR PROPANE sensor head, 0-100%LEL
I rivelatori SMART S-SS sono dotati di display a 8 digit, The SMART S-SS detectors offer 5 status LEDs and an 8
S4004BU BUTANE sensor head, 0-100%LEL
con scelta tra display LED e LCD, e 5 LED di stato e digits back-lit display for the gas concentration reading to
permettono una taratura in campo non intrusiva tramite be chosen between LCD or LED display. They feature S4004AT ACETONE sensor head, 0-100% LEL
magneti a effetto Hall che consentono di operare sullo non-intrusive calibration for an accurate and easy S4004BN BUTADIENE sensor head, 4-20 mA, 0-100% LEL
strumento senza aprirlo e quindi senza declassificare adjustment via Hall-effect switches, which allow to access S4004CE CYCLO HEXANE sensor head, 4-20 mA, 0-100% LEL
l’area. the detector without opening the instrument and S4004DT DIMETHYL ETHER sensor head, 4-20 mA, 0-100% LEL
declassifying the area. S4004EN ETHANE sensor head, 4-20 mA, 0-100% LEL
S4004AE ETHYL ACETATE sensor head, 4-20 mA, 0-100% LEL
Essi possono avere diversi tipi di contenitori: They may have different types of enclosures: S4004ET ETHYL ALCOHOL sensor head, 4-20 mA, 0-100% LEL
3A (Involucro in alluminio standard), 3A (standard aluminium casing), S4004EP HEPTANE sensor head, 4-20 mA, 0-100% LEL
4A (Involucro in alluminio senza rame), 4A (copper free aluminium casing), S4004ES HEXANE sensor head, 4-20 mA, 0-100% LEL
2S (Involucro in acciaio inox). 2S (stainless steel housing).
S4004IB ISO BUTANE sensor head, 4-20 mA, 0-100% LEL
S4004IL ISOBUTYLENE sensor head, 4-20 mA, 0-100% LEL
A seconda dell’elettronica inte grata lo SMART S-SS può SMART S-SS can be identified under the following
essere identificato con i seguenti numeri: numbers depending on the integrated electronics: S4004IP ISO PROPYL ALCOHOL sensor head, 4-20 mA, 0-100% LEL
11 (elettronica con un’uscita RS, un’uscita 4 -20mA e 11 (one 4-20mA output, one RS output and LCD display), S4004PE PENTANE sensor head, 4-20 mA, 0-100% LEL
display LCD), 12 (one 4-20mA output, one RS output and LED display), S4004PP PROPYLENE sensor head, 4-20 mA, 0-100% LEL
12 (elettronica con un’uscita RS, un’uscita 4 -20mA e 13 (one 4-20mA output, one RS output, LCD display and 3 S4004DE R152A DIFLUOROETHANE sensor head, 4-20 mA, 0-100% LEL
display LED), relay board), S4004TO TOLUENE sensor head, 0-100% LEL
13 (elettronica con un’uscita RS, un’uscita 4 -20mA, 14 (one 4-20mA output, one RS output, LED display and 3
display LCD e scheda 3 relè), relay board), CODE SF6 & REFRIGERANTS
14 (elettronica con un’uscita RS, un’uscita 4 -20mA, 17 (one 4-20mA output, one RS output, LCD display, 3 S4026R134A R134A sensor head, 0-2000 ppm
display LED e scheda 3 relè), relay board and modem Hart),
S4027SF6 SF6 sensor head, 0-2000 ppm
17 (elettronica con un’uscita RS, un’uscita 4 -20mA, 18 (one 4-20mA output, one RS output, LED display, 3
display LCD, scheda relè e modem Hart) relay board and modem Hart). S4031R125 R125 sensor head, 0-2000 ppm
18 (elettronica con un’uscita RS, un’uscita 4 -20mA, S4032R1234YF S4032R1234YF sensor head, 0-2000 ppm
display LED, scheda 3 relè e modem Hart). S4033R404A S4033R404A sensor head, 0-2000 ppm
S4034R407A S4034R407A sensor head, 0-2000 ppm
Infine, si può selezionare il modello del sensore secondo Finally, you can select the model of the sensor according S4035R507A S4035R507A sensor head, 0-2000 ppm
l’elenco sottostante: to the list below: S4036R410 S4036R410 sensor head, 0-2000 ppm
CODE Fast Response POP-IR Single Point Open Path DESCRIPTION

CODE PELLISTOR SENSOR DESCRIPTION S6002ME METHANE sensor head, 0-100%LEL
S4003ME METHANE sensor head, 0-100%LEL S6002PR PROPANE sensor head, 0-100%LEL
S4003GP LPG sensor head, 0-100%LEL S6002BU BUTANE sensor head, 0-100%LEL
S4003PR PROPANE sensor head, 0-100%LEL S6002AT ACETONE sensor head, 0-100% LEL
S4003BU BUTANE sensor head, 0-100%LEL S6002EN ETHANE sensor head, 0-100% LEL
S4003VB PETROL VAPOURS sensor head, 0-100% LEL S6002ET ETHYL ALCOHOL sensor head, 0-100% LEL
S4003AT ACETONE sensor head, 0-100% LEL S6002EP HEPTANE sensor head, 0-100% LEL
S4003AC ACETYLENE sensor head, 0-100% LEL S6002ES HEXANE sensor head, 0-100% LEL
S4003AM AMMONIA sensor head, 0-100% LEL S6002IB ISO BUTANE sensor head, 0-100% LEL
S4003CP CYCLOPENTANE sensor head, 0-100% LEL S6002PE PENTANE sensor head, 0-100% LEL
S4003EN ETHANE sensor head, 0-100% LEL S6002PP PROPYLENE sensor head, 0-100% LEL
S4003AE ETHYL ACETATE sensor head , 0-100% LEL
S4003ET ETHYL ALCOHOL sensor head, 0-100% LEL CODE COP - Top precision Laser technology DESCRIPTION
S4003EL ETHYLENE sensor head, 0-100% LEL S6003ME METHANE sensor head, 0-100%LEL
S4003EP HEPTANE sensor head, 0-100%LEL
S4003ES HEXANE sensor head, 0-100% LEL CODE POP-LS Top precision Laser technology DESCRIPTION
S4003H2 HYDROGEN sensor head, 0-100% LEL S6XXXME METHANE sensor head, 0-100%LEL
S4003IB ISO BUTANE sensor head, 0-100% LEL S6XXXAM AMMONIA (NH3) sensor head, 0-100%LEL
S4003P8 JP8 sensor head, 0-100% LEL
S4003MT METHYL ALCOHOL sensor head, 0-100% LEL
S4003MK METHYL ETHYL KETONE (MEK) sensor head, 0-100% LEL Se interessati ad altri tipi di gas non esitate a contattare If you are interested in other types of gas, please contact
S4003PE PENTANE sensor head, 0-100% LEL Sensitron Srl. Sensitron Srl.
S4003PP PROPYLENE sensor head, 0-100% LEL
S4003PN PROPYL ALCOHOL sensor head, 0-100% LEL Esempio di codice prodotto: S-SS-3A-11-S4003ME Example of product code: S-SS-3A-11-S4003ME
S4003ST STYRENE sensor head, 0-100% LEL Rivelatore SIL 2 con uscite RS485 & 4-20mA, LCD display SIL 2 gas detector with RS485 & 4-20mA outputs, LCD
e sensore di tipo Pellistore per metano, 0-100%LEL. display and METHANE Pellistor sensor head, 0-100%LEL.
S4003TO TOLUENE sensor head, 0-100% LEL
S4003XI XYLENE sensor head, 0-100% LEL
SMART S SMART S
Filtro digitale medie mobili sui valori Digital filter variable average on the
1.2 Identificazione rivelatore gas esplosivi 1.2 Flammable gas detectors identification acquisiti sampled values
Risoluzione 4096 punti Resolution 4096 dots
Display (SMART S-SS) 8 digit luminosi Display (SMART S-SS) 8 digits
Precisione 0.5% del FS (dipende dal Accuracy 0.5% FS (depending on
tipo di sensore) sensor type)
Tempo preriscaldamento 2 minuti Warm-up time 2 minutes
Tempo stabilizzazione 60 minuti (per test/taratura) Stabilization time 60 minutes (for test/calibr.)
Tempo di risposta T90 Da 9 a 30 secondi (dipende Response time T90 From 9 to 30 secs
dal tipo di sensore) (depending on sensor type)
Ripetibilità da ±2% a ±5% del FS Repeatability from ±2% to ±5% FS
(dipende dal tipo di (depending on sensor type)
sensore)
Temperatura di stock -25 / + 60 °C (o limiti del Storage temperature -25 / + 60 °C (or limits of the
sensore) sensor)
Temperatura operativa Come indicato sull'etichetta Operating temperature As stated on the detector's
dello strumento label
Umidità relativa 20-90 % Rh / 40° C (5-95% Relative humidity 20-90 % Rh / 40° C (5-95%
RH non condensante, a RH non condensing, on
richiesta) request)
Pressione di esercizio 80-110 kPa Operating pressure 80-110 kPa
Velocità dell’aria < 6 m/sec Air velocity < 6 m/sec
Entrata cavi 2 o 3 x ¾” NPT Input cable 2 or 3 x ¾” NPT
Peso g 1500 Weight g 1500
g 2500 (con involucro in g 2500 (with stainless steel
acciaio inox) enclosure)
Watch-dog Interno per il controllo del Watch-dog Internal, for the
microprocessore microprocessor status control
1.3 Caratteristiche tecniche 1.3 Technical specifications Dimensioni L145 x A190 x P130 mm Dimension L145 x H190 x D130 mm
L290 x A190 x P130 mm L290 x H190 x D130 mm with
Elemento sensibile Pellistore (sens catalitico) o Sensing element Pellistor (Catalytic sensor) or con sensore POP IR) POP IR sensor)
Sensore IR, POP IR, COP IR sensor, POP IR sensor, Orientamento Installazione verticale con Positioning To be mounted sensor head
Laser, POP-LS laser COP Laser, POP-LS laser sensore rivolto verso il downward
Campo di misura 0-100%LEL Measurement range 0-100%LEL basso Excluding applications with
Risoluzione Out analog 0,025 mA Resolution Out analog 0,025 mA Escluse le applicazioni con POP IR, POP LS e COP
Display ±1% ±1 digit Display ±1% ±1 digit POP IR, POP LS e COP
Alimentazione 12-24 Vcc -20% +15% Power supply 12- 24 Vdc -20% +15% Marcatura ATEX, Certificati Per spiegazioni sulla ATEX marking, For information on ATEX
Assorbimento a 24Vdc Pellistore Consumption at 24Vdc Pellistor e Norme eventuale marcatura ATEX, Certificates and marking, certificates and
(senza display) 100 mA medio (without display) 100 mA medium certificati e norme, vedere Standards standards, please refer to the
160 mA massimo 160 mA max istruzioni di sicurezza safety instructions supplied
NDIR NDIR fornite con lo strumento. with the instrument
110 mA medio 110 mA medium Norme di riferimento EMC EN50270:2015 EMC Reference norms EN50270:2015
160 mA massimo 160 mA max EN 61000-6-4:2007+ EN 61000-6-4:2007+
Unità di controllo Microprocessor 12 bit Control unit Microprocessor 12 bit A1:2011 A1:2011
Segnalazioni luminose LED ad intermittenza Visual indications Flickering LED Protezione IP IP 65 (IP 67 con: adattatore IP rating IP 65 (IP 67 with: STGD/AD3
(vedi par.4.3) (see paragraph 4.3) STGD/AD3 e pressacavo IP adapter and IP 67 cable
Uscita proporzionale con 4-20 mA (default) Proportional output with 4-20 mA (default) 67) gland)
3mA allarme di under scale 3mA under-scale alarm
2mA guasto 2mA Fault
Uscita proporzionale con 4-20mA Proportional output with 4-20mA
2mA guasto 2mA Fault
22mA allarme over-range 22mA over-range alarm
Resistenza di carico max 300Ω (tipico 200Ω) Max. load resistance 300Ω (typical 200Ω)
Uscita digitale seriale RS485 per MULTISCAN++ Serial Output RS485 for MULTISCAN++
Uscite relè con scheda 3 relè con contatti in Relay outputs, with 3 relays with tension free
STS3REL (opzionale) scambio liberi da tensione STS3REL board (optional) changeover contact 24V-1 A
24V-1 A.
Procedura di auto zero Compensazione delle Auto zeroing routine Zero drift compensation
derive di zero
SMART S SMART S
2 PREDISPOSIZIONE DEL SITO 2 INSTALLATION SITE 3 INSTALLAZIONE 3 INSTALLATION

D’INSTALLAZIONE PREARRANGEMENT
3.1 Modalità per il corretto montaggio 3.1 Correct positioning mode
Durante le operazioni di montaggio e installazione, gli At the mounting and installation phase, be sure all safety
Il rivelatore deve sempre essere installato con l’elemento The gas detector is always to be mounted with the
impianti devono essere messi in sicurezza. Ricordiamo precautions have been considered.
sensibile (testa di rivelazione) rivolta verso il basso ad sensing element placed downward (exluded versions with
anche come in fase di installazione sia opportuno tenere It is important, also during installation, to position the gas
esclusione delle versioni con sensore POP, POP-LS e POP, COP and POP-LS).
in considerazione alcune norme generali in quanto un detectors correctly to get the optimum response. Be
COP. Il contenitore del rivelatore, per nessuna ragione For no reasons at all the enclosure can be drilled.
posizionamento non corretto può pregiudicare il careful never to install gas detectors close to air intakes or
deve essere forato; per il fissaggio utilizzare i fori già Wall mount the detectors by employing the existing holes.
funzionamento ottimale del rivelatore. Si raccomanda di fans causing strong air currents.
esistenti. Detectors come complete with wall fixing brackets.
non installare rivelatori gas nelle vicinanze di prese d’aria Be sure the detectors are attached to a firm base to
I rivelatori sono forniti completi di staffa per fissaggio a
e/o ventilatori che provocano forti correnti d’aria. prevent vibration that can damage them, producing
muro.
I rivelatori non devono essere altresì posti in zone nelle unreliable results.
quali siano presenti vibrazioni e, sebbene immuni da Although the electronics comply with the electromagnetic
disturbi a radiofrequenze è consigliabile non installarle in compatibility rules, it is advised to keep the detectors at a 3.2 Schema topografico circuito 3.2 Detector circuit layout
prossimità di emettitori radio (ponti radio o distance from any radio frequency senders (such as radio
apparecchiature simili). links or similar).
Altra buona norma è quella di installare il rivelatore in Please be also sure that detectors are placed in a
LED Dl3 (red).
zone facilmente accessibili per le operazioni di test e convenient location for future maintenance and calibration Rs4385 TX-Data line monitor
taratura e per l’inserimento dell’adattatore del kit di requirements. Lit when the detector is sending data
calibrazione. STS/3REL to the Rs485 line
I gas più leggeri dell’aria (Metano, Idrogeno, Ammoniaca), All of the gases lighter than air (Methane, Hydrogen, Relay board Sensor Head
disperdendosi nell’ambiente, tenderanno a salire verso Ammonia) tend to spread upwards; the detector should be connection
l'alto; per ottenere un efficace intervento il rivelatore deve placed at 30 cm from the ceiling in order to maximise the
connection
essere posizionato a 30 cm dal soffitto. effectiveness of the detection.
I gas più pesanti dell’aria (GPL, Butano, Vapori Benzina) All of the gases heavier than air (LPG, Butane, Petrol Main terminal block
disperdendosi stazioneranno nella parte bassa Vapours) tend to spread downwards; the detector should
dell’ambiente; il rivelatore deve quindi essere posizionato be placed at 30 cm from the floor. 6
a 30 cm dal pavimento. Rs485 end of line resistor
B
Closed: 120 ohm resistor connected
A Detector
I sensori ad ossidazione catalitica (Pellistori) offrono Catalytic sensor (Pellistors) offer excellent output Open: 120 ohm resistor non-connected - main board
un’eccellente linearità di uscita fino al 100% LEL e hanno linearity up to 100% LEL and have an estimated lifetime + 1
una durata approssimativa di 4 anni. of 4 years.
La loro prestazione può essere alterata dalla presenza di Catalytic sensor performance may be altered by the LED Dl1 (green).
alcune sostanze che possono cambiare presence of some substances that, when present in the indicates the detector's working condition Display board connection
considerevolmente la risposta del sensore e persino atmosphere being analysed, can considerably change the - WARM-UP: Flashing 750mS ON ; 250mS OFF
danneggiarlo irrimediabilmente. La presenza di inibitori o response of the sensor and even damage it irremediably. - FAULT LOW: Fixed lit
veleni è la causa più comune di problemi nella rivelazione The presence of inhibitors or poisons is the most common - ALARM 1: Flashing 250mS ON ; 1750mS OFF.
- ALARM 2: Flashing Led Dl2 (Red)
di gas e per tale ragione è necessario accertarsi che sia cause of problems in the gas detection and, for this 250mS ON ; 250mS OFF External detector WATCH-DOG status
evitata ogni contaminazione. Tra i più comuni veleni o reason, it is necessary to pay attention in order to avoid 250mS ON ; 1250mS OFF -Normal operation mode: LED Off
inibitori si possono elencare siliconi, tetraetile di any contamination. The most common poisons or - ALARM 3: Flashing -Serious failure: LED On
250mS ON ; 250mS OFF
piombo, composti dello zolfo (acido solfidrico), inhibitors are silicones, tetraethyl lead, sulphurous 250mS ON ; 250mS OFF
composti clorurati (tetracloruro di carbonio), trielina, compounds (hydrogen sulphide), chlorinated 250mS ON ; 750mS OFF
e idrocarburi alogenati. compounds (carbon tetrachloride), trichloroethylene - FAULT HIGH: Flashing 250mS ON ; 250 mS OFF.
and halogenated hydrocarbons - NORMAL MODE: Flashing 1 sec ON ; 1 sec OFF.
Questi composti non sono invece nocivi per i sensori ad
assorbimento di infrarosso. These compounds do not affect the Infrared sensor,
I sensori ad assorbimento di infrarosso trovano una which find a suitable application whenever a flammable
applicazione ottimale ogni qual volta un gas infiammabile gas is to be detected in environments where Pellistor
deve essere rivelato in ambienti dove i sensori catalitici cannot work. This new technology has undoubted
non possono essere utilizzati. Questa nuova tecnologia, advantages such as lower dependence from
basandosi su di un sistema ottico, presenta indubbi environmental factors (temperature and humidity and the
vantaggi essendo indipendente dai fattori ambientali. La non “poisoning”. Infrared sensors estimated lifetime is 4
durata stimata dei sensori a raggi infrarossi è di 4 anni. years.
SMART S SMART S
3.5 Collegamento con uscita 4-20mA 3.5 4-20mA output connection

3.3 Scheda display per SMART S-SS 3.3 Display board for SMART S-SS
Il rilevatore viene configurato per avere di default una The default configuration provides a 4-20mA proportional
L’utilizzo del display è riportato nel relativo manuale (solo The use of the display is shown in the related manual uscita proporzionale 4-20mA. output
per versione S-SS) (only for S-SS version) Per il collegamento del rivelatore con la centrale e Wiring between the detector and the control panel should
alimentazione si raccomanda l'uso di cavo schermato. La be carried out with shielded cables. Wires' cross section
sezione del cavo da utilizzare dipende dalla distanza del depends on the distance between the control panel and
Display mounting frame rilevatore dalla centrale: the detector:
Hs8
-per distanze inferiori a m 100 si usino cavi con sezione di -for a distance up to m 100 we advise a 3 core wire with
Display board 0.75 mm2; cross section area of 0.75 mm2;
-per distanze comprese fra m 100 e 200 si usino cavi con -for a distance between m 100 and 200 we recommend a
sezione di 1.0 mm2; 3 core wire with cross section of 1.0 mm2;
LED indication:
-per distanze comprese fra m 200 e 300 si usino cavi con -for a distance between m 200 and 300 we recommend a
1
D2: Power On (Green)
2
D4: Fault (Yellow) sezione di 1.5 mm2. 3 core wire with cross section 1.5 mm2.
D6: Alarm #1 (Red) Nel caso vi siano giunzioni nel cavo di collegamento, If there are junctions on connecting wires, please make
D8: Alarm #2 (Red) assicurarsi che vi sia continuità anche sulla schermatura sure that there is no interruption on the shield.
D10: Alarm #3 (Red) dei cavi.
20
19
D12: Sensor #1 (Green) Ricordarsi che la schermatura deve essere collegata a Please remember that the shield is to be grounded from
Hs2 D14: Sensor #2 (Green) terra unicamente dal lato dalla centrale, mentre non dovrà the control panel side only. Also remember never to
(if used) mai essere collegata sui rilevatori. connect the shield to the detectors.
Assicurarsi che la realizzazione di giunzioni sui cavi di
Hs6 Hs4 alimentazione mediante dispositivi di serraggio o a Ensure the wire connections, either clutching or crimping
Hs2, HS4, HS6 e HS8 : crimpare, sia eseguito a regola d’arte con capicorda e/o type, are properly carried out with terminals that do not
Connection to the detector morsetti che nel tempo non si ossidino o allentino. È oxidise or loosen. We recommend having them soldered.
Hall effect magnets for the detector
Main-Board (by special sempre preferibile eseguire giunzioni saldate.
NON INTRUSIVE calibration.
cable). I rilevatori SMART S possono essere collegati a centrali di The SMART S gas detectors can be connected to control
HS2: Arrow UP
HS4: Arrow DOWN rivelazione gas di altre marche, purché in grado di leggere panels available on the market having 4-20mA input
HS6: ENT un segnale 4-20mA. signals.
HS8: ESC Si raccomanda di accertarsi che le centrali siano Please make sure the panels are certified according to
certificate in conformità alle norme EN60079-29-1. the standards EN60079-29-1.
SCHEMA COLLEGAMENTO per 4-20 mA 4-20 mA CONNECTION SCHEME

3.4 Configurazione del rivelatore 3.4 Detector configuration Nello schema seguente viene riportato il tipico The following drawing shows the connection of a
collegamento di un rilevatore SMART S ad una centrale SMART3G detector to a SENSITRON's control panel like
Il rilevatore dispone di una uscita proporzionale 4-20mA e The detector provides a 4-20mA proportional output and SENSITRON tipo MULTISCAN ++. MULTISCAN++.
RS485. RS485 serial output.
N.B.: Nel caso di centrali con ingresso 4-20 mA, è N.B.: Control panels accepting 4-20mA input signals allow
È possibile integrare nel rivelatore schede opzionali relè It is possible to provide relay and Hart boards. possibile collegare 1 solo rilevatore a ciascun ingresso. the connection of only one detector per input.
ed Hart.
Main terminal block
S1 6
S2
DL3
B
4-20 mA A
Signal 1
S -
+ 1
Power Supply (-)
+ Power Supply (+) DL1
F1 DL2
shield connected to
the earth (just at one
side)
SMART S SMART S
3.6 Collegamento uscita seriale RS485 3.6 RS485 serial output connection 3.7 Collegamento con schede opzionali 3.7 Connection to optional boards
Il collegamento degli SMART S su bus RS485 deve The connection of SMART S to RS485 bus lines should In fase di configurazione della versione display del During the SMART S-SS display configuration, you can
essere eseguito utilizzando un cavo a 4 fili (meglio se 2 be performed by using a 4-wire cable (better is by 2 rilevatore SMART S è possibile associare le soglie di associate the alarm thresholds 1, 2, 3 and fault to
cavi differenti), 1 coppia per il bus RS485 e 1 coppia per different cables), 1 pair for the RS485 bus and 1 pair for allarme 1, 2, 3 ed il guasto alla scheda STRS3REL STRS3REL relay board.
l'alimentazione. the power supply. opzionale. By default, the alarm thresholds are associated as: Fault
Il cablaggio tra i rivelatori e il pannello di controllo deve Wiring between the detectors and the control panel Di default le soglie d’allarme sono così associate: guasto relay 1; alarm1 relay 2; alarm2 relay 3.
essere effettuato utilizzando il cavo di collegamento EIA should be made by using connection cable EIA RS485: 2 relè1; allarme 1 relè 2; allarme 2 relè 3.
RS485: 2 fili di base con la sezione 0,22 / 0,35 mm2 e core wires with section 0.22 / 0.35 mm2 and shield
schermati (twisted pair). capacità nominale tra i fili <50pF (twisted pair). Nominal capacity between the wires
/ m, impedenza nominale 120 ohm. <50pF/m, nominal impedance 120 ohm. 4 COLLAUDO E USO 4 TESTING AND USE
Queste caratteristiche possono essere trovate nel cavo These features can be found in BELDEN cable 9841 or
Belden 9841 o simile (cavo per trasmissione dati in EIA similar (data transmission cable in EIA RS485).
RS485). Using this wiring, the total length of the line should not 4.1 Accensione 4.1 Power ON
Usando questo cablaggio, la lunghezza totale della linea exceed 1000 m.
non deve superare 1000 m. Detectors are to be wired in daisy chain mode. We Al momento in cui il rivelatore viene alimentato, si When the detector is powered on, the red LED on the
I Rivelatori devono essere collegati in modalità daisy recommend avoiding star or tree mode connection as accende, ad intermittenza lenta il LED rosso sulla scheda motherboard starts blinking at slow intermittence. Output
chain. Si consiglia di evitare connessione a stella o ad interference immunity would be reduced. base. L’uscita in corrente è 2 mA circa. current is nearly 2 mA.
albero in quanto l’immunità alle interferenze sarebbe Make sure that each multi-polar wire includes just one Trascorsi 2 minuti circa, il LED rosso lampeggia con una After nearly two minutes, the red LED flash rate is
ridotta. RS485. frequenza pari allo stato in cui si trova il rilevatore (vedere equivalent to the detector working status (see table on
Assicurarsi che ogni cavo multipolare comprende un solo For the detectors' power supply connection, we tabella al punto 4.3) e l’uscita in corrente è a 4,0mA. paragraph 4.3) and the output current is 4.0mA.
RS485. recommend to use a 2-wire cable with suitable section Terminata la fase di preriscaldamento il rivelatore è in Once the warm-up phase is over, the detector can work
Per il collegamento dell’ alimentazione dei rilevatori, si according to the distance and number of detectors. grado di funzionare correttamente, anche se sono correctly, although the optimal performances will be
consiglia di usare un cavo a 2 fili con sezione adeguata a Once the installation has been completed, verify that each comunque necessarie 2 ore circa affinché il rilevatore achieved after two hours.
seconda della distanza e del numero di rivelatori. detector reaches at least 12 Vdc. raggiunga le prestazioni ottimali. Should the detector be provided with display, please refer
Una volta che l'installazione è stata completata, verificare When detectors are RS485 connected, the proportional 4- Se il rivelatore è provvisto di scheda display, consultare il to the additional technical handbook supplied along with
che ogni rivelatore raggiunga almeno 12 Vdc. 20mA output remains active. manuale aggiuntivo fornito con gli SMART S-SS. the SMART S-SS.
Quando i rilevatori sono collegati in RS485, l'uscita 4-20 For each detector connected on the RS485 serial line, an
mA proporzionale rimane attiva. univocal address must be set. 4.2 Collaudo 4.2 Testing
Per ogni sensore collegato sulla linea seriale RS485 deve
essere impostato un indirizzo univoco. Il rilevatore viene tarato in fabbrica per il gas Detectors are factory calibrated for the specific gas
specificamente richiesto dal cliente. Successivamente è required by the customers. Future adjustment of the
Shielded/Twisted cable possibile controllare e eventualmente correggerne la preset calibration can be carried out by employing the
Control Panel shield, connected
to the earth BELDEN 9841 or equivalent taratura utilizzando l’app osita tastiera di calibrazione. calibration keypad.
Rs485 (B)
Rs485 (A) Verificare la risposta del rivelatore utilizzando una miscela Testing should be carried out by using a gas mixture in
Rs485 (B) a composizione nota gas/aria, e l'apposito KIT di taratura. the appropriate range, along with our calibration kit.
Rs485 (A)
max 30 cm
Lo strumento non ha regolazioni (potenziometro etc.), i The instrument has no adjustments (potentiometer etc.),
- Power Supply - Power Supply
controlli dello zero e dello span si eseguono per lo the zero and the span checks are performed for the
+ Power Supply + Power Supply SMART S-MS con la tastiera di calibrazione STS/CKD-PK SMART S-MS with the calibration keypad STS/CKD-PK
Power Supply (-) DL3
e per lo SMART S-SS con il display ed i magneti. and the SMART S-SS with the display and the magnets.
Power Supply (+)
Per entrambe le versioni SMART S-MS e SMART S-SS la For both SMART S-MS and SMART S-SS versions, the
Power Supply (12/24 Vdc) shield, connected JP9 JP9 calibrazione si esegue con un KIT comprendente: calibration is performed with a KIT comprising:
to the earth
• Bombola gas di test • Test gas bottle
JP12 JP12
• Valvola con Flussimetro • Valve with flowmeter
• Adattatore di calibrazione • Calibration adapter
Vedi manuale MT3561 “tastiera di calibrazione” See MT3561 manual "calibration keypad"
Vedi addendum MT3771 “display” See MT3771 addendum "display"
Vedi manuale MT894 “KIT di calibrazione” ed il paragrafo See MT894 manual " calibration KIT " and paragraph 7 of
7 di questo manuale. this manual.
Rs485 (B) Rs485 (B)

Rs485 (A) Rs485 (A)
4.3 Uso 4.3 Use
- Power Supply
Il rivelatore funziona automaticamente e autonomamente, The detector works autonomously and automatically.
+ Power Supply pertanto non è richiesto alcun contributo da parte del suo Once adequately connected, no further operations are
DL 3 utilizzatore. required.
Il LED rosso lampeggiante posto sulla scheda base del The flashing red LED on the motherboard indicates the
JP9 circuito indica lo stato in cui il rilevatore si trova come detector's working condition as detailed in the following
illustrato nella tabella sottostante. table.
JP12
Assicurarsi che la segnalazione dello stato di over-range Make sure the over-range status of the detector is
del rivelatore venga prevista, come indicato dalla norma indicated or signalled, as clearly defined by the standard
EN60079-29-1:2016, paragrafo 4.2.2.3. EN60079-29-1:2016 paragraph 4.2.2.3.
SMART S SMART S
5 MANUTENZIONE 5 MAINTENANCE
STS/CKD-PK, Tastiera di calibrazione ZMCAP/123, adattatore per rivelatori gas
STS/CKD-PK, Handheld calibration keypad Calibration cap adapter ZMCAP/123
5.1 Manutenzione preventiva 5.1 Preventive maintenance routines
Tutti i rivelatori di gas ad uso industriale, sia per gas According to the EN 60079–17, all gas detectors for
infiammabili che per gas tossici, devono essere controllati industrial application, either for flammable or toxic gases,
ogni tre-sei mesi, secondo la guida CEI 31-35 CAP. IV. are to undergo a functional test every three to six months.
I risultati delle prove effettuate dovranno essere registrate Test results are to be recorded into a suitable book to be
su di un apposito quaderno da esibire alle autorità shown to the Authority in case of inspection.
competenti a seguito di un eventuale verifica. In environments where polluting elements might alter the
Nel caso in cui siano presenti inquinanti nell'ambiente in original sensor performance, periodical testing should be
grado di alterare le caratteristiche originali dei sensori, le carried out at shorter time intervals.
operazioni di manutenzione dovranno essere effettuate
con maggior frequenza.
5.2 Manutenzione correttiva 5.2 Corrective maintenance routines

Per anomalie riscontrabili durante il test funzionale, vi For any anomaly found during the functional test, please
invitiamo a controllare la fase di collaudo come descritto check the tests performance as described in paragraph 4.
nel paragrafo 4. If during the preventive maintenance routine, the detector Rivelatori / Detectors
Se durante la manutenzione preventiva il rilevatore non does not react to the gas it has been calibrated for, please
rileva il gas per cui è tarato, inviare il prodotto al fornitore return the instrument to your supplier that on his turn will
che a sua volta provvederà ad inviarlo al costruttore. return it to the manufacturer for repair. Bombola gas di test
È possibile ritarare il rilevatore utilizzando la tastiera di It is possible to adjust the calibration parameters by A Test ga s bottle
calibrazione da richiedere al fornitore. employing the calibration keypad available on request.
Va lvola c on indic atore di flusso
5.3 Istruzioni per la dismissione 5.3 Disassembly instructions B Va lve with flowm eter
p /n PC.VALVOLA
Togliere alimentazione al rilevatore, scablare la Power the unit off, disconnect the wires on the terminals
morsettiera e rimuovere il contenitore dalla tubatura and dismount the housing from any blocking systems. C Tubo / Pipe
metallica e dai relativi sistemi di bloccaggio.
Adattatore di c alibrazione
D Calib ra tion ad apter
p/n ZMCAP/123
6 ISTRUZIONI PER L'IMBALLAGGIO 6 PACKING INSTRUCTIONS B D
Per garantire la protezione agli urti si consiglia di To grant a stout protection against impacts we Nota
Per far fluire il gas al rivelatore: aprire lentamente
imballare lo strumento nell'imballo originale o proteggerlo recommend using the original package, or protect the il rubinetto della valvola in senso antiorario
con fogli di film a bolle (pallinato). device with bubble wrap sheets. fino a quando la pallina interna al flussometro si
C posiziona sulla tacca c entrale. Circ a 0,1 Lt/Min
A Due that the gas flow to the detec tor: slightly turn
the valve plug c ock anti-clockwise until the sm all
7 ACCESSORI 7 ACCESSORIES indicator inside the flow meter stands on the
B central m ark. About 0,1 Lt/Min
Tastierino di taratura da collegare al rivelatore Handheld calibration keypad to be
STS/CKD-PK per regolare i valori zero, span ed uscita in STS/CKD-PK connected to the detector to adjust the Zero,
corrente Span and 4-20mA values.
Accessorio per estendere il modo di protezione da Adapter for sensor heads to upgrade the
STGD/AD3 G a GD
STGD/AD3 protection from G to GD.
Stainless steel calibration adapter for all of

Adattatore universale per rivelatori gas
Sensitron gas detectors. It allows the right
SENSITRON. In acciaio inox, permette di far
ZMCAP/123 fluire la giusta quantità di gas nella testa dei
ZMCAP/123 quantity of gas inlet to flow to the detector. It
comes complete with adapters to fit on the
rivelatori.
detectors' heads.
ZM/TEST/3 Adattatore di test per installazione fissa. ZM/TEST/3 Permanent rain shield/test adapter.
SL517 SL517 Stainless steel collector and weather

Cono raccogli gas in acciaio inox.
protection cone.
SMART S SMART S
8 Sensibilità relativa sensori 8 Sensor Relative Response 9 TAGLIANDO DI GARANZIA PER 9 WARRANTY COUPON FOR
(Sensore Catalitico ed IR per gas infiammabili) (Catalytic and IR sensors for Flammable gases) LA RIPARAZIONE REPAIRING
I rivelatori SMART S per gas infiammabili (con sensori SMART S detectors for Flammable gases (with Catalytic
catalitici ed IR) vengono normalmente tarati con metano. and IR sensors) are most commonly calibrated with La garanzia sui prodotti Sensitron è valida un anno dalla Warranty on Sensitron products is valid 1 one from the
Il costruttore del sensore generalmente fornisce una Methane. The sensor’s manufacturer generally provide s a data di fabbricazione riportata sul prodotto. Si intende manufacturing date placed on the product and it is
tabella con i valori di Sensibilità Relativa che permettono table of correction factors that allow the user to valida comunque per un anno dalla data di installazione, extended of one year from the date of the installation on
al tecnico manutentore di testare e provare il rivelatore measure/adjust the detector to different hydrocarbons by purché la stessa avvenga entro i dodici mesi successivi la condition that the installation is performed within the first
per diversi idrocarburi semplicemente moltiplicando la simply multiplying the reading by the appropriate data di fabbricazione. Fanno fede il timbro e la data posti year of life of the product. As proof will be considered the
lettura per un appropriato coefficiente. correction factor to obtain the reading of a different gas. dall’installatore sul presente modulo, che l’utilizzatore stamp and date of the installer placed on the present
La ragione per usare il metano come primario gas di The reason for using methane as the primary calibration dovrà debitamente conservare e rendere allo stesso in coupon which is to be duly kept by the user and returned
calibrazione è che i sensori sono molto sensibili al metano gas is that methane is well detected by Catalytic and IR caso di verifiche funzionali e riparazioni. to the installer in case of any working tests and repairs
ed altresì che il metano è un gas molto comune e di facile sensors and methane gas is a very common gas, often
reperibilità. In ogni caso, bisogna prestare attenzione ad used in many applications. However, take care to use the Data di installazione *
utilizzare i fattori di conversione in quanto i valori possono correction factors as the correction factors can vary from
cambiare a seconda del modello di sensore, ed altresì sensor to sensor, and they can even change on the same Installation date *
cambiare a parità di sensore a seconda dell’età e qu indi sensor as the sensor ages. Therefore, the best way to
dell’usura del sensore stesso. Il miglior modo per ottenere obtain precise readings for a specific gas is to actually
una lettura precisa dello strumento è quella di eseguire il calibrate the sensor to the gas of interest directly.
test e la taratura con il gas specifico per cui il rivelatore è Modello/i
costruito, quando possibile.
Model(s)
Esempio Example
1) Il rivelatore da testare è per butano. Il gas di 1) Target gas to be detected is butane. The calibration
calibrazione /test disponibile è il metano 30% LIE. gas available is 30%LEL methane.
2) La risposta relativa (sensore NP17) è 1,66. 2) The relative response (sensor NP17) is 1,66. Numero di matricola ______________ ______________ ______________
3) Il rivelatore deve essere tarato per una concentrazione 3) The detector must be adjusted for a concentration of ______________ ______________ ______________
di 30 * 1,66 = 48,9% LIE al fine di ottenere una corretta 30 * 1,66 = 48,9%LEL in order to give an accurate Part Number(s)
lettura per il butano, usando come gas di calibrazione il reading for butane using methane as a calibration gas.
metano.
Richiedete a Sensitron la tabella di risposta relative valida Ask to Sensitron the valid relative response table for the Timbro installatore
per il sensore usato. used sensor
Installer Stamp
Firma installatore
Installer signature
* Utilizzare un singolo modulo per ogni *Use one single coupon for every
data di installazione installation date
Nota Bene: si evidenzia che per i ATTENTION: Please be aware that all
componenti deperibili installati sui prodotti perishables installed in our products
(sensori, batterie tampone in genere), la (sensors, buffer batteries, etc.) benefit only
garanzia è vincolata e limitata ai termini di of the warranty conditions stated by the
garanzia dichiarati dalla casa costruttrice. original manufacturer
Ventis™ MX4 Product Manual
Table of Contents
COPYRIGHT NOTICE ................................................................................................................................................... 3
WARNINGS AND CAUTIONARY STATEMENTS ........................................................................................................ 3
General ................................................................................................................................................................... 3
Multi-gas Monitor Personnel ............................................................................................................................................................... 3
Hazardous Conditions, Poisons, and Contaminants .............................................................................................. 3
General Usage ....................................................................................................................................................... 4
Agency-issued Conditions of Use and Warnings .................................................................................................... 4
Recommended Practices ....................................................................................................................................... 5
Product Manual
VENTIS MX4™ RESOURCES....................................................................................................................................... 6
Set-up
Operation VENTIS MX4 CAPABILITIES ........................................................................................................................................ 6
Service UNPACKING THE MONITOR ....................................................................................................................................... 7
Contents.................................................................................................................................................................. 7
Reporting a Problem .............................................................................................................................................. 7
MONITOR OVERVIEW ................................................................................................................................................. 8
Hardware Features and Functions .......................................................................................................................... 8
Display Screen ........................................................................................................................................................ 9
Alarms ................................................................................................................................................................... 11
MONITOR SET-UP ...................................................................................................................................................... 13
Battery Properties and Monitor Compatibility ....................................................................................................... 13
Charging the Lithium-ion Battery Packs ............................................................................................................... 14
Instruction ...................................................................................................................................................... 14
Power-on and –off ................................................................................................................................................. 15
Configuration......................................................................................................................................................... 16
Introduction .................................................................................................................................................... 16
Instructions .................................................................................................................................................... 16
Configuration Process.................................................................................................................................... 17
MONITOR USE AND SERVICE .................................................................................................................................. 24
Zero, Calibration, and Bump Testing .................................................................................................................... 24
Procedures .................................................................................................................................................... 24
Recommendations ......................................................................................................................................... 25
General Information .............................................................................................................................................. 25
Instructions ................................................................................................................................................... 26
Recommended Practices for In-field Air Sampling ............................................................................................... 32
Cleaning ............................................................................................................................................................... 32
Service .................................................................................................................................................................. 33
Battery Packs ................................................................................................................................................. 33
Monitor Conversion ....................................................................................................................................... 36
Sensor, Sensor Water Barrier, LCD, and Vibrating Motor Replacement ........................................................ 38
Pump Module ................................................................................................................................................. 40
Ventis MX4 Three-Dimensional View Diagrams ............................................................................................ 41
PRODUCTS, SPECIFICATIONS, AND CERTIFICATIONS ........................................................................................ 44
Ventis MX4 Accessories and Parts ....................................................................................................................... 44
Monitor Specifications ........................................................................................................................................... 46
Operating Conditions ............................................................................................................................................ 46
Storage Conditions ............................................................................................................................................... 47
Sensor Specifications ........................................................................................................................................... 47
Toxic Gas Sensor Cross-Sensitivity Table ............................................................................................................ 47
LEL and LEL Correlation Factors for Combustible Gases .................................................................................... 48
Certifications ......................................................................................................................................................... 49
WARRANTY ................................................................................................................................................................ 50
Limitation of Liability .............................................................................................................................................. 50
INDUSTRIAL SCIENTIFIC CORPORATION GLOBAL LOCATIONS ..................................................... BACK COVER
Part Number: 17152357-1

Version 12 1
© 2015 Industrial Scientific Corporation 2
Ventis™ MX4 Product Manual Ventis™ MX4 Product Manual
►Copyright Notice
General Usage
Ventis MX4™ and Ventis™ are trademarks of Industrial Scientific Corporation.
Oxygen-deficient atmospheres may cause combustible gas readings to be lower than actual concentrations.
All trademarks and registered trademarks are the property of their respective owners.
Oxygen-enriched atmospheres may cause combustible gas readings to be higher than actual concentrations.
These help materials or any part thereof may not, without the written consent of Industrial Scientific Corporation, be
copied, reprinted, or reproduced in any material form including but not limited to photocopying, transcribing, Sudden changes in atmospheric pressure may cause temporary fluctuations in the oxygen reading.
transmitting, or storing it in any medium or translating it into any language, in any form or by any means, be it digitally,
electronic, mechanical, xerographic, optical, magnetic, or otherwise. Verify the calibration of the combustible gas sensor after any incident where the combustible gas content has
caused the monitor to display an over-range condition.
The information contained in this document is proprietary and confidential and all copyright, trademarks, trade names, Sensor openings, water barriers, and the pump inlet must be kept clean. Obstruction of the sensor openings or
patents, and other intellectual property rights in the documentation are the exclusive property of Industrial Scientific pump inlet and/or contamination of the water barriers may cause readings to be lower than actual gas
Corporation unless otherwise specified. The information (including but not limited to data, drawings, specification, concentrations.
documentation, software listings, source or object code) shall not at any time be disclosed directly or indirectly to any
third party without prior written consent. To avoid the potential of liquid being pulled into the sample tubing and pump assembly, it is recommended that
Industrial Scientific filter (P/N 17027152) be used on the sample tubing when drawing samples using the
The information contained herein is believed to be accurate and reliable. Industrial Scientific Corporation accepts no aspirated monitor.
responsibility for its use by any means or in any way whatsoever. Industrial Scientific Corporation shall not be liable WARNING: INSERT THE ALKALINE BATTERIES WITH THE CORRECT POSITIVE “+” AND NEGATIVE “-“
for any expenses, costs by damage that may result from the use of the information contained within this document. ORIENTATION. WARNING: The Ventis MX4 is only approved for use with AAA battery types Energizer EN92
Although every effort is made to ensure accuracy, the specifications of this product and the content herein are subject and Duracell MN2400. Do NOT mix battery types.
to change without notice.
WARNING: The use of leather cases can produce inaccurate readings with diffusion (non-aspirated) gas
detection instruments for specific monitoring applications. Leather cases should be used ONLY as carrying
cases, and NOT for continuous monitoring, with diffusion instruments configured to measure gases other than
►Warnings and Cautionary Statements O2, CO, CO2, H 2S, and combustible gases (LEL/CH4).
Agency-issued Conditions of Use and Warnings

General Ensure all part-use restrictions (e.g., battery) meet any agency-mandated conditions of use.
IMPORTANT
Failure to perform certain procedures or note certain conditions may impair the performance of this Ensure all instrument-configurable settings (e.g., always-on setting) meet any agency-mandated conditions of
product. For maximum safety and optimal performance, please read and understand the Ventis MX4 use. When using instrument-compatible Industrial Scientific docking stations, maintain mandated settings
Product Manual available online at the Ventis MX4 Resource Center at through the software (e.g., iNet Control or Accessory Software) or by manually configuring the instrument
www.indsci.com/ VentisMX4resources. settings after docking.
Personnel The Ventis MX4 is CSA certified according to the Canadian Electrical Code for use in Class I, Division 1 and
CAUTION: For safety reasons, this equipment must be operated and serviced by qualified personnel only. Class I, Zone 1 Hazardous Locations within an ambient temperature range of T amb: -20°C to +50°C. CSA has
Read and understand the product manual completely before operating or servicing. assessed only the %LEL combustible gas detection portion of this instrument for performance according to
CSA Standard C22.2 No. 152. This is applicable only when the monitor is used in the diffusion mode and has
been calibrated to 50% LEL CH4, and when the monitor is used in the aspirated mode with an extended range
Hazardous Conditions, Poisons, and Contaminants lithium-ion battery and has been calibrated to 50% LEL CH4.
WARNING: Servicing the unit, replacing or charging battery packs, or using the communications port must only
be done in an area known to be nonhazardous. Not for use in oxygen-enriched atmospheres. CAUTION: CSA C22.2 No. 152 requires before each day’s usage, sensitivity must be tested on a known
concentration of pentane or methane equivalent to 25% or 50% of full scale concentration. Accuracy must be
WARNING: Power-off the monitor before servicing the unit or replacing the battery. within -0% to +20% of actual concentration. Accuracy may be corrected by referring to the zero/calibration
section of the Product Manual.
WARNING: Substitution of components may impair intrinsic safety and may cause an unsafe condition.
The equipment complies with the standards IEC 60079-29-1 and EN 60079-29-1 for methane, propane, and
CAUTION: High off-scale readings may indicate explosive gas concentration(s). hexane with the following exception: as for the methane (mine) detector, the battery run time was verified to be
seven (7) hours rather than the eight (8) hours recommended by the standards, respectively.
CAUTION: Any rapid up-scale reading followed by a declining or erratic reading may indicate gas MED-certified instruments may be used only when configured and maintained to disallow power-off when the
concentration(s) beyond the upper scale limit which may be hazardous. unit is in alarm.
Silicone compound vapors or other known contaminants may affect the combustible gas sensor and cause
The Mine Safety and Health Administration (MSHA) has approved the Ventis MX4 as a Permissible Multi-Gas
readings of combustible gas to be lower than actual gas concentrations. If the monitor has been used in an
Monitor with the following warnings:
area where silicone vapors were present, always calibrate the monitor before next use to ensure accurate
measurements.
· MSHA approved for use with either the P/N 17134453-X2, 3.7 volt, lithium-ion battery or P/N 17148313-2,
3.7 volt, lithium-ion extended battery pack assembly only. The battery pack is not user-replaceable. The
monitor battery and the lithium battery on the main PCB are technician replaceable only. Charge battery
pack with an ISC battery charger designed for use with this monitor in fresh air locations only.
3 © 2015 Industrial Scientific Corporation © 2015 Industrial Scientific Corporation 4
· The monitor is to be calibrated according to the procedures in the instruction manual only. ►Ventis MX4 Resources
· The aspirated version of the Ventis MX4 is only approved for use with the extended battery pack.
· The monitor must display methane in the percent-by-volume mode (0-5%) for compliance determinations The Ventis MX4 Product Manual is the primary resource, within a full suite of learning tools, developed for the monitor
required by 30 CFR Part 75, subpart D. user. Its step-by-step “walk through” format covers everything from unpacking to set-up, operation, and service. All
Ventis MX4 users should read and understand the Product Manual prior to unpacking or using the monitor.
SANS 1515-certified units may be used only as follows:
· Diffusion applications A companion to the manual, the Ventis MX4 Reference Guide ships with the monitor. It serves to announce all
· Configured and maintained to disallow power-off when the unit is in alarm warnings and cautionary statements relevant to general monitor use. The guide also features process charts that
· The Methane alarms are set as follows: low alarm = 1%vol and high alarm =1.4%vol provide an overview of four fundamental tasks: operation/start-up, configuration, calibration, and functional “bump”
· With approved Lithium-ion battery packs (see Ventis MX4 Accessories and Parts in this manual). testing. These charts are tools for the user who is both familiar with the manual and proficient in the performance of
the given task.
Recommended Practices
Ventis MX4 product-specific resources are part of the organization’s broader training line-up, featuring online training
Industrial Scientific Corporation recommends the monitor be fully charged (when equipped with a rechargeable
modules and face-to-face classroom programs for technicians, operators, first responders, trainers, and distributors.
battery pack), configured, and calibrated before first time use. If the lithium-ion battery is deeply discharged, it
Courses combine theory with hands-on learning, and can be tailored to the customer’s unique requirements and gas
can take up to an hour for the instrument display to indicate that the battery is charging. Monitors used
monitoring applications.
infrequently should be fully charged every four months.
No part of the unit should be covered by any garment, part of a garment, or other item that would restrict the The organization’s customer and technical support call centers provide product and order information, how-to product
flow of air to the sensors or impair the operator's access to the audible, visual, or vibration alarms. assistance, and guidance for in-depth technical applications. Its service centers offer comprehensive factory repair
Industrial Scientific Corporation recommends a full monitor calibration be performed monthly (at a minimum), and maintenance services.
using a certified concentration(s) of Industrial Scientific calibration gas(es) to help ensure monitor accuracy.
Industrial Scientific Corporation provides a full suite of resources to aid customers in the competent and safe use of
Industrial Scientific Corporation recommends the monitor be zeroed and bump tested before each use with a its products and services. With 19 manufacturing, support, and service centers and hundreds of distributors
certified concentration(s) of Industrial Scientific calibration gas(es). worldwide, Industrial Scientific serves the globe’s gas detection needs.
Battery contacts are exposed on battery packs when they are removed from the monitor. Do not touch the
battery contacts and do not stack battery packs on top of one another.
When reassembling the instrument or installing a battery pack, maintain ingress protection by tightening each ►Ventis MX4 Capabilities
fastener to its stated torque value (see the “Ventis MX4 Monitor three-Dimensional Diagram” and its key in this
manual). The Ventis MX4 is a portable multi-gas monitor. Offered as a diffusion monitor, it detects and measures gas(es)
present in open space. To enable monitor use within confined space locations, the Ventis MX4 is also offered as an
Contact your service representative immediately if you suspect that the Ventis MX4 is working abnormally. aspirated monitor. A pump module and battery accessories enable the conversion of either monitor for dedicated use
in either confined or open spaces.
Industrial Scientific recommends the “2 & 2 Sampling Rule” when sampling with a motorized pump and tubing,
one should allow for 2 minutes plus 2 seconds per foot of tubing used, prior to noting the monitor readings. Based on the customer’s monitor order, up to four sensors are factory installed enabling the monitor to continuously
This allows time for the gas to reach the instrument and for the sensors to adequately react to any gases and simultaneously detect and measure the presence of up to four specific gases.
present. Industrial Scientific recommends that clear urethane tubing, part number 17065970, be used with the
pumped versions of the Ventis MX4 when sampling for the following gases: Nitrogen Dioxide (NO2) and Sulfur Sensor Number available per Gases Monitored
Dioxide (SO2). Category monitor
Oxygen 1 O2 (Oxygen) only
Combustible 1 Monitor can be configured for sensor to measure ONE of the following:
· LEL (Pentane)
· LEL (Methane)
· CH4 (0%-5%)
Toxic 2 Each sensor detects and measures only ONE of the following:
· CO (Carbon Monoxide)
· CO/H2 Low (Carbon Monoxide with low H2 interference)
· H2S (Hydrogen Sulfide)
· NO2 (Nitrogen Dioxide)
· SO2 (Sulfur Dioxide)
Equipped with a multi-mode (audible, visual, and vibration) and multi-level alarm system, the Ventis MX4 monitor is
capable of notifying its user of potentially hazardous gas concentrations.
The monitor performs continuous datalogging at 10 second intervals. It can store approximately 90 days of data for a
four-sensor configuration. Its date- and time-stamped event log records and stores data for the following: 60 alarm
events, 30 error events, and 250 manually performed calibrations or bump tests. The memory, when full, overwrites
the oldest data as the newest readings and events are logged.
The Ventis MX4 monitor functions as an independent device to monitor the environment for hazardous gas ►Monitor Overview
concentrations. It is compatible with products that charge, calibrate, bump test, read and record instrument data,
protect, and otherwise enable or enhance use of the monitor and its data. For a complete list of these products,
please refer to the manual section, Ventis MX4 Accessories and Parts. HARDWARE FEATURES AND FUNCTIONS
The monitor’s case top (front of monitor) has two main sections. As shown below, the upper section contains the
sensor ports. The lower section houses the user interface features, a LCD display screen and two buttons. Each
►Unpacking the Monitor feature’s general functions are noted below. As shown, the diffusion and aspirated monitors differ with respect to the
location of the air intake mechanism and visual alarm indicators.
CONTENTS
The monitor box contains the following items including, when ordered, those marked optional. Each item ordered The instrument may be used in any orientation when clipped to the user or when used with a compatible carrying
should be accounted for in the unpacking process. case. Normal instrument orientation for measuring gas concentration is hand held with sensors and display facing the
operator.
Quantity Item Notes
1 as ordered Ventis MX4 Portable Multi-gas The monitor type is indicated on the box label.
Monitor Options:
· Ventis MX4 Diffusion
· Ventis MX4 Aspirated
· Ventis MX4 Aspirated with Conversion Kit
1 Ventis MX4 Reference Guide A companion to the Ventis MX4 Product Manual.
1 installed as ordered Battery Pack One of three battery types is factory installed as
indicated on the box label. Options:
· Rechargeable Lithium-ion
· Rechargeable Extended Range Lithium-ion
· Alkaline
1 as ordered Ventis Charger Universal power cord. AC charger products include
interchangeable plugs (US, UK, EU, and AUS).
0 or 1 Calibration Cup Diffusion – 1 included
Aspirated – 0 included
1 Calibration and Bump Test Diffusion – two feet of clear tubing
Tubing
0 or 1 In-field Sampling Tubing Diffusion – 0 included
Aspirated – Ten feet of black tubing
1 Final Inspection & Test Report Contains the following factory set* information:
· Monitor Set-up Date
· Monitor Part Number (P/N)
· Monitor Serial Number (S/N)
· For Each Sensor*:
· P/N
· S/N
· Type Number Feature Functions
· Location 1 Visual alarm indicator Signals an alarm or warning; frequency varies by alarm level. Also used as a
· Alarm level values confidence indicator.
· Span gas values 2 Pump inlet (aspirated) Air intake; calibration and bump test gas intake.
· Span reserve values Sensor ports (diffusion)
*Some factory set sensor values subject to user changes. 3 LCD display User interface; backlight flashes when monitor is in system, high, or low alarm
states.
1 Warranty Card --
4 Audible alarm ports On when monitor is in system, high, or low alarm states; frequency and tone vary
by alarm level. Also used for warnings and as confidence indicator.
5 On/Off/Mode button Used to power-on and power-off. Also used to bypass a process/step or advance
to a next screen in both gas monitoring and configuration modes. Sets values in
REPORTING A PROBLEM configuration mode.
After unpacking, if any item is missing or appears to have been damaged, contact a local distributor of Industrial
6 Enter button Used to begin a process/step in a process. Edits values in configuration mode.
Scientific products or Industrial Scientific Corporation (for contact information, please see the manual’s last page).
7 IrDA interface Indicates infrared light data exchange in-progress.
8 Charging contacts Battery charging.
Lower Explosive Limit. Display variations:

DISPLAY SCREEN “LEL” (English)
The Ventis MX4 Boot-up Screen, as shown below, serves to introduce all icons and the alpha-numeric items (e.g., “LIE” (French)
8.8.8) that can appear on the display when the monitor is in use, docked, or charging. Each display item is stationary, “UEG” (German)
communicates unique information, and appears only when relevant to the task being performed. Oxygen (O 2)
A sample Gas Monitoring Screen is also shown below, next to the boot-up screen. This illustrates how the icons and Nitrogen Dioxide (NO2)
the alpha-numeric characters work together to communicate several points of information to the monitor user.
Hydrogen Sulfide (H2S)
COL CO H2/Low
Percentage Volume: O2 and CH4 measurement unit
Percentage unit for combustible gases; display variations:

“% LEL” (English)
Boot-Up Screen Gas Monitoring Screen “% LIE” (French)
All possible screen images. Sample screen in gas monitoring mode. “% UEG” (German)
Parts Per Million: H2S, CO, SO2 and NO2 measurement unit.
NOTE: Display screens featured throughout this manual include the “pump” icon.
Similar in appearance to a fan, it indicates an aspirated monitor is in use. For a
diffusion monitor, the pump icon does not appear on the display. Over-range: for any sensor in over-range, indicates the measured gas concentration is greater
than the measurement range of the sensor. Display variations:
It is helpful to view the boot-up screen in sections. The top and bottom rows each contain icons. The main function of “Or” (English and German)
the middle section, in gas monitoring mode, is to communicate gas concentration readings. Definitions for all icons, “Sup” (French)
gas name abbreviations, gas measurement units, and other indicators are provided below. Where applicable, display Negative Over-range: for any sensor in negative over-range indicates the measured gas
variations are noted. concentration is less than the negative measurement range of the sensor. Display variations:
“-Or” (English and German)
Top Row Icons Definition “InF” (French)
Status: indicates no monitor or sensor faults. Bottom Row Icons Definition
Battery level indicator; display variations:
Warning: indicates monitor or sensor fault.
0 black bars = low battery warning
1 black bar < 33% charge remaining
Zero: communicates zero status (e.g., zero results, zero in-progress, etc.). 2 black bars = 34% - 66% charge remaining
3 black bars = 67% – 100% charge remaining
Gas Cylinder: communicates calibration related information (calibration due, calibration apply
gas, etc.). Security Code: indicates code is set or to be entered.
Clock: indicates a process is in-progress. Pump: shown anytime an aspirated monitor is in use.
Calendar: communicates overdue warnings for service items (calibration, bump testing, etc.). Indicates IrDA communication is in-progress.
Alarm: indicates an alarm causing condition. Short Term Exposure Limit: communicates STEL values. Display variations:
“STEL” ( English and German)
Low level audio alarm is on. “VLE” (French)
Time Weighted Average: communicates TWA values. Display variations:
High level audio alarm is on. “TWA” (English and German)
“VME” (French)
Peak: displayed when peak detection values are viewed.
Alpha-numeric Definition
display values
Carbon Monoxide (CO)
Methane (CH4)
Sulfur Dioxide (SO2)
ALARMS the up arrow icon displays.

NOTICE A low alarm condition occurs when the
® All monitor alarms and warnings should be taken seriously and responded to as stated in company safety concentration of gas sensed reaches the
standards. monitor’s low alarm value setting for a
® Once initiated, an alarm will remain on while the alarm condition is present. For gas-related alarms, once the sensor(s).
detected gas concentration changes, the alarm indicators will change to reflect any new condition such as
low-alarm gas, high-alarm gas, over-range gas, or no gas alarm.
® When the latch alarm feature is enabled and the monitor goes into alarm, it will remain in alarm until the
alarm condition no longer exists and the monitor user presses the ENTER button for one second. This Low Alarm Screen
applies only to gas-related alarms. A flashing gas concentration value* indicates which sensor(s)
reading(s) is the cause for alarm. The low level alarms turn on and
It is practical for the monitor user to be aware of the possible alarms prior to monitor set-up and use. The Ventis MX4 the down arrow icon displays.
has four alarm and warning levels. A “system level” alarm generates the highest frequency tone and highest level A TWA alarm occurs when the calculated time
visual and vibration signals. It is used to indicate such events as a pump or sensor failure. The “high” or “low” level weighted average reaches the monitor’s
audio alarms, in combination with visual and vibration indicators, turn on when gas concentration readings are over- hazardous value for the set time frame.
range, high, or low. The lowest level indicator is a warning with beep patterns to indicate service needs (e.g., low
battery or calibration due). The beep is also used as a confidence indicator when enabled.
Alarm types and their alarm generating conditions are described below.
TWA Alarm Screen
A flashing gas concentration value* indicates which sensor(s)
Display Description reading(s) is the cause for alarm. The low level alarms turn on and
An over-range condition occurs when the gas the TWA icon flashes.
concentration value sensed is above the The STEL alarm occurs when the short term
sensor’s measuring range. exposure value exceeds the acceptable limit.
After any over-range alarm, the monitor

should be calibrated.
Over-range Alarm Screen NOTES: The O2 and toxic sensor values normally
The “Or” message indicates which sensor(s) is reading an over- reset when the gas sensed reaches an acceptable STEL Alarm Screen
range condition(s). All other sensors show their current gas range. A flashing gas concentration value* indicates which sensor(s)
concentration readings on a numeric display (left) or gas names on reading(s) is the cause for alarm. The low level alarms turn on and
a text display (right). The high level alarms turn on and the alarm If the LEL reads over-range, the alarm latches and the STEL icon flashes.
icon displays. the LEL sensor is automatically turned off. Press
the enter button to turn on the LEL sensor. This will Alarm occurs when the monitor registers no
turn off the alarm indicators. After a warm-up period
sensors installed.
of approximately 30 seconds, an LEL reading will
display. If the new reading is an over-range or other
alarm condition, the alarm indicators will turn on.
A negative over-range condition occurs when
the gas concentration value sensed is less
than the sensor’s measuring range. No Sensor Installed Screen
The system level alarms turn on and the error icon displays.
After any negative over-range alarm, the Alarm occurs when any installed sensor’s
monitor should be calibrated.
data-related operations fail and the sensor is
Negative Over-range Alarm Screen not operational.
The “-Or” message indicates which sensor is reading a negative
over-range condition. All other sensors display their current gas
concentration readings*. The high level alarms turn on and the
alarm icon displays.
Sensor Data Fail Screen
A high alarm condition occurs when the A flashing “F” indicates which sensor is the cause for alarm. The
concentration of gas sensed reaches a level audio alarm turns on and the error icon displays.
greater than the monitor’s high alarm value
Error codes 4XX to 5XX (404 shown here)
setting for a sensor(s).
indicate the monitor has detected a
malfunction. The unit is not operational and
and should be examined by a qualified
High Alarm Screen technician or reported to Industrial Scientific
A flashing gas concentration value* indicates which sensor(s) for service or repair information.
reading(s) is the cause for alarm. The high level alarms turn on and Critical Error Screen
Alarm occurs when, if attached, the pump is Properties and Compatibility Battery Pack
not operating correctly. While in alarm, every Rechargeable Rechargeable Replaceable
ten seconds the monitor attempts to restart Li-ion Extended Range Li-ion Alkaline
the pump. If unsuccessful, the monitor
remains in alarm. Ventis MX4 aspirated monitor compatible No Yes Yes
Ventis MX4 diffusion monitor compatible Yes Yes Yes
Note: The nominal flow rate is >200 cc/m (.2
Pump Fault Alarm LPM). A pump fault alarm will occur when Battery lifetime 300 charge cycles 300 charge cycles --
The system level alarms turn on and the error icon displays. the flow is less than 200 cc/m +0, -25%. Battery re-charge time 3-5 hours 3-7.5 hours N/A
Alarm occurs when the monitor’s battery Nominal run time (when fully charged and operating at room temperature)
reaches a low level of charge or is nearing its
For the aspirated monitor -- 12 hours 4 hours
end of life.
For the diffusion monitor 12 hours 20 hours 8 hours
NOTE: When a lithium-ion battery becomes deeply discharged and the instrument is docked, it can take up to an hour for the
instrument display to indicate that the battery is charging. Battery charging is suspended in temperatures below 0 °C (32 °F) and
Low Battery Warning Screen above 50 °C (122 °F).
A beep sounds every 30 seconds and the empty battery icon
flashes.
Alarm occurs when one or more sensors are
due for a bump test. If the monitor settings CHARGING THE LITHIUM-ION BATTERY PACKS
permit, an in-field bump test may be The lithium-ion battery packs are charged at the factory. As some or all of the charge may deplete before the monitor
performed in an area known to be arrives or is unpacked, it is recommended that the monitor be fully charged before first time use. The lithium-ion
nonhazardous. equipped Ventis MX4 can be charged with any of the products listed below.
Bump Overdue Screen · DS2 Docking Station™ for Ventis

A “b” indicates which sensor(s) is overdue for bump testing. Two · V-Cal™ Calibration Station
beeps sound every 30 seconds and the calendar and alarm icons · V-Cal™ 6-Unit Calibration Station
display. · Ventis Single Unit Charger
· Ventis Single Unit Charger/Datalink
Alarm occurs when one or more sensors are · Ventis 6-Unit Charger
due for calibration. If the monitor settings
· Ventis Single Unit Automotive Charger, 12 VDC
permit, an in-field calibration can be performed
· Ventis Single Unit Truck-Mount Charger, 12 VDC, with Cigarette Adapter
in an area known to be nonhazardous.
· Ventis Single Unit Truck-Mount Charger, 12 VDC, Hard Wired
NOTE: The above products are all equipped with a yellow LED “presence” indicator. This LED confirms that the monitor is properly seated
Calibration Due Alarm Screen in the cradle such that the monitor can charge; however, it is NOT intended to be used as a charging indicator.
The gas value flashes for each sensor overdue for calibration.
This LED indicator may go out intermittently during normal charging functions and will not light if the unit is fully charged when placed in the
Three beeps sound every 30 seconds and the calendar and alarm cradle. Always refer to the monitor display’s battery level indicator to confirm the battery charge level.
icons display. The gas cylinder icon flashes.
* The numeric mode display shows gas concentration values; the text mode display shows gas type names in place of gas values. The Ventis Single Unit Charger is generally shipped with the monitor. Equipped with a movable partition, which fits in
each of two dedicated slots, it charges the diffusion and aspirated monitors with their compatible lithium-ion battery
packs. Place the partition in the back slot for a diffusion or aspirated monitor with an Extended Range Li-ion battery
pack. Place the partition in the front slot to charge a diffusion monitor with a Li-ion battery pack.
►Monitor Set-up Instructions

NOTICES
Preparing the monitor for first time use is a “3-C” process: charge (if equipped with a lithium-ion battery pack), ® Charge the monitor in an area known to be nonhazardous.
configure, and calibrate. This manual section covers charging and configuration for set-up purposes and can be ® When using the charger and adjusting its partition, take care NOT to touch the battery contacts located at
consulted for ongoing instruction thereafter. Immediately following this section, calibration is covered in the manual the front of the cradle bottom.
section, Use and Service.
· The single unit charger has a universal power cord; change the plug insert, if needed, and plug into the
BATTERY PROPERTIES AND MONITOR COMPATIBILITY appropriate outlet.
Based on the customer order, the Ventis MX4 comes equipped with one of three factory installed batteries: · To properly adjust the partition, if needed, complete and observe the following.
rechargeable Lithium-ion (Li-ion), rechargeable Extended Range Lithium-ion (extended range Li-ion), or replaceable o Lift up to remove from slot.
alkaline. The factory installed battery pack type is stated on the label affixed to the monitor box. Basic battery o Push down to place in the desired slot.
properties and acceptable monitor/battery combinations are shown below. o When partition is inserted correctly, a click sounds.
Recommended Practice: To prevent the loss of the partition, it should always reside in the cradle in one of its two
dedicated slots. Choose the most used slot. Do not place the partition in the forward most compartment of the charger
where the battery contacts are located.
· To properly place the monitor in the charger, complete or observe the following.
o The monitor’s display side faces the user. To enter gas monitoring mode:
o The charging contacts on the monitor bottom meet the contact pins inside the charger’s cradle. allow the countdown to complete and advance
o Refer to the monitor’s battery icon to confirm the battery charge level. to the Gas Monitoring Screen. Proceed to the
- If the battery is less than fully charged, the monitor displays the battery icon (flashing empty manual section, Monitor Use and Service.
to full, repeatedly).
- If the battery is fully charged, the monitor displays a full battery icon. To enter configuration mode:
Countdown Screen simultaneously press ON/OFF/MODE and
Displays the 20 second countdown, one second at a time, from 20 ENTER, hold for three seconds, and release.
POWER-ON AND -OFF to one. Options :
To power-on the Ventis MX4, press ON/OFF/MODE and hold for three to five seconds. During the first ten to15 Enter gas monitoring mode
seconds the monitor is on, its firmware completes internal tests and the user sees or hears what is described and Enter configuration mode
shown below. Following this initialization phase, a countdown screen displays. During this 20-second countdown, the Press ON/OFF/MODE, hold for the full five
monitor user can enter configuration mode to manually adjust monitor settings. second countdown to zero, and release to
power-off the monitor.
Display and Options Instructions
No user action required.
Power-Off Screen
The screen displays a five-second countdown accompanied by five
beeps and LED flashes.
Visual Test Screen CONFIGURATION

Displays for up to five seconds as the monitor completes a sensor Introduction
and alarm check. Visual, vibration, and audio alarms turn on Before first time use of the monitor, its settings should be reviewed and, if needed, be adjusted. Qualified safety
briefly, then off. personnel should complete the following tasks.
Be sure the pump inlet is not blocked. · Review the monitor settings for compliance with company policy and any applicable regulations, laws, and
observed guidelines as issued by regulatory agencies and government or industry groups.
· Determine which settings, if any, require adjustment.
· Make the adjustments or supervise other qualified personnel in the process.
· When using instrument-compatible Industrial Scientific docking station software (e.g., iNet, Docking Station
Server Administrative Console [DSSAC], or Accessory Software), maintain the mandated settings through
Pump Set-up Screen the software or by manually configuring the instrument settings after docking.
Displays for five to seven seconds for an aspirated monitor. The
monitor checks for the presence of a pump. If present, the pump is Monitor settings should be reviewed regularly and adjusted as needed. The following settings are adjustable or
started and, if needed, adjusted for optimum flow. “configurable" for the Ventis MX4.
No user action required. LEL Type Display Mode Setting Calibration In-field
Calibration Mode Setting Confidence Indicator (on/off) Calibration Due Alarm
Low Alarm Settings Confidence Indicator (type) Calibration Due Set-point
High Alarm Settings Bump Test In-field Security Code
TWA Alarm Settings Bump Test Due Warning Language Selection
TWA Interval Settings Bump Test Time Set-point Always-on Setting
Software Version Screen STEL Alarm Setting Bump Test Percentage Shutdown In Alarm Setting
The Software Version Screen message displays for five seconds. Calibration Gas Settings Bump Test Response Time Alarm on Dock Setting
Clock Settings Alarm Latch Set
No user action required. Date Settings Zero In-field
The Ventis MX4 can be configured manually as instructed below. Any changes made take effect immediately upon
exiting the configuration mode.
Calibration Days Screen Instructions

When the up arrow (▲) is featured, the number of days displayed NOTICES
for each sensor indicates when the next calibration is due. When ® The configuration mode should be accessed only by safety personnel authorized to change monitor settings
the down arrow (▼) is featured, the number of days displayed based on company policy.
indicates when the last calibration occurred. ® Read ALL requirements and instructions outlined below, including the screen-by-screen process description,
before beginning the configuration process.
The configuration mode can be entered during the 20-second countdown of the power-on process. During the Press ON/OFF/MODE to bypass the zero and calibration processes and
countdown, simultaneously press ON/OFF/MODE and ENTER, hold for three seconds, and release to enter advance to one of two screens.
configuration mode. (While in the configuration mode, the same button presses cause the monitor to exit
configuration). Each configuration screen times out after 30 seconds and the monitor enters gas monitoring mode. To If the installed sensor set includes H2S and NO2, OR, SO2 and NO2,
re-enter the configuration mode, power-off the monitor, then power-on and repeat the entry process. the monitor is pre-set for standard calibration mode and the Low
Alarm Set-point Screen displays.
Throughout the configuration process, the main functions of the two buttons are as follows. Zero Initiate Screen
· The ENTER button is used to edit values. It is also used, where noted, to begin a process or a step in a Options For all others installed sensor combinations, the Calibration Mode
process. Bypass zero and calibration process. Selection Screen displays.
· The ON/OFF/MODE button is used to set the value. Where noted, it is also used to bypass a process or Begin zero and calibration process.
step in a process, or to advance to the next configuration screen. Press ENTER to begin the zero and calibration process. Proceed to the
manual section, Zero, Calibration, and Bump Testing
The first screen to display in configuration mode depends on three things:
The quick calibration option sets the monitor to calibrate all four sensors
· security code setting,
simultaneously. The standard calibration option sets the monitor to
· the presence or absence of the China MA feature,
calibrate each sensor independently.
· and the presence or absence of an LEL sensor.
Press ENTER to edit the value, if needed.
If the security code setting is 000, the security feature is disabled and the Enter Security Code Screen does NOT Press ON/OFF/MODE to set the value and advance to the Low Alarm
appear. If the security code is NOT 000, the security feature is enabled and the monitor displays the Enter Set Screen.
Security Code Screen. Calibration Mode Selection
Options
The monitor next checks for the presence of a China MA mining feature. If this feature is operational, the monitor 0 = Standard Calibration
displays the Zero Initiate Screen. 1 = Quick Calibration
NOTE: The user can edit the values for four alarm types in configuration mode. The monitor presents these options
If the China MA mining feature is NOT operational, the monitor then checks for an installed LEL sensor. If
in the order shown below.
installed, the monitor displays the LEL Type Screen. If no LEL sensor is installed, the monitor displays the Zero
1. Low alarm
Initiate Screen.
2. High alarm
3. TWA (if toxic sensors installed)
Configuration Process 4. STEL (if toxic sensors installed)
Display and Options Instructions For each alarm type (e.g., low alarm), the user can edit the alarm settings for each installed sensor, one sensor
at a time. The order in which the sensors are subject to change is as follows.
Press ENTER to edit the value, if needed; press repeatedly or hold down 1. Toxic sensor 1
to speed the increment pace to reach the valid security code. 2. LEL sensor
Press ON/OFF/MODE to enter configuration mode and arrive at the 3. Toxic sensor 2
next applicable screen. 4. O2 sensor
Press ON/OFF/MODE to bypass the low alarm value set process and
advance to the High Alarm Set-point Screen.
Enter Security Code Screen Press ENTER to begin the low alarm value set process.
The presence of this screen indicates an On the display, the first sensor subject to change flashes.
enabled security feature. Press ENTER to edit the value, if needed; press repeatedly or
Press ENTER to edit the value, if needed. hold down to speed the increment pace.
Press ON/OFF/MODE to set the value and advance to the Zero Initiate Press ON/OFF/MODE to set the value.
Low Alarm Set-point Screen
Screen. Displays the existing low alarm value for The next sensor subject to change flashes. Continue to use the
each installed sensor. If any one of the ENTER and ON/OFF/MODE buttons, respectively, to edit and
NOTE: If the LEL type is changed, the sensor goes into calibration fail mode. A full calibration
is required before the monitor can be used and is accessible from the next screen in the sensors is NOT installed, its position on set each sensor’s low alarm value.
configuration process, the Zero Initiate Screen. For complete calibration instructions, proceed the display is blank.
to the manual section, Zero, Calibration, and Bump Testing.
LEL Type Set Screen After the alarm value is set for each installed sensor,
Options press ON/OFF/MODE to advance to the High Alarm Set-
LEL point Screen.
CH4
Press ON/OFF/MODE to bypass high alarm value set process and Press ON/OFF/MODE to bypass the calibration gas set process and
advance to one of two screens as noted below. advance to the Clock Set Screen.
Press ENTER to begin the high alarm value set process. Press ENTER to begin the calibration gas value set process.
On the display, the first sensor subject to change flashes. On the display, the first sensor subject to change flashes.
Press ENTER to edit the value, if needed; press repeatedly or Press ENTER to edit the value, if needed; press repeatedly or
hold down to speed the increment pace. hold down to speed the increment pace.
Press ON/OFF/MODE to set the value. Press ON/OFF/MODE to set the value.
High Alarm Set-point Screen Calibration Gas Set Screen
Displays the existing high alarm value The next sensor subject to change flashes. Continue to use the Displays the existing calibration gas The next sensor subject to change flashes. Continue to use the
for each installed sensor. If any one of ENTER and ON/OFF/MODE buttons, respectively, to edit and value for each installed sensor. ENTER and ON/OFF/MODE buttons, respectively, to edit and
the sensors is not installed, its position set each sensor’s high alarm value. set each sensor’s calibration gas value.
on the display is blank. If any one of the sensors is not installed,
After the alarm value is set for each installed sensor, its position on the display is blank. After calibration gas value is set for each installed sensor,
press ON/OFF/MODE and advance to one of two screens. press ON/OFF/MODE to advance to the Clock Set Screen.
If at least one toxic sensor is installed, the TWA Alarm
Press ON/OFF/MODE to bypass the clock set process and advance to
Set Screen displays.
the Date Set Screen.
Press ENTER to begin the clock set process.
If NO toxic sensors are installed, the Calibration Gas
On the display, the first time value subject to change flashes.
Set Screen displays.
Press ENTER to edit the value, if needed; press repeatedly or
Press ON/OFF/MODE to bypass the TWA alarm value set process and hold down to speed the increment pace.
advance to the TWA Interval Set-point Screen. Press ON/OFF/MODE to set the value.
Press ENTER to begin the TWA alarm value set process. Clock Set Screen
On the display, the first sensor subject to change flashes. Displays the existing time values using a The next value subject to change flashes. Use the ENTER
Press ENTER to edit the value, if needed; press repeatedly or 24-hour time format. and ON/OFF/MODE buttons, respectively, to edit the value.
hold down to speed the increment pace.
Press ON/OFF/MODE to set the value. After all values are set, press ON/OFF/MODE and
TWA Alarm Set-point Screen advance to the Date Set Screen.
Displays the existing TWA values for the The next sensor subject to change flashes. Continue to use
toxic sensors installed. No other sensor the ENTER and ON/OFF/MODE buttons, respectively, to
readings appear. Press ON/OFF/MODE to bypass the date set process and advance to
edit and set each alarm value.
the Display Mode Set Screen.
Press ENTER to begin the date set process
After the alarm value is set for each installed sensor,
On the display, the first date value subject to change flashes.
press ON/OFF/MODE to advance to the TWA Interval
Set Screen.
hold down to speed the increment pace. Press ON/OFF/MODE
Press ENTER to edit the value, if needed. to set the value.
Date Set Screen
Press ON/OFF/MODE to set the value and advance to the STEL Alarm Displays the existing date. The value
Set-point Screen. The next date value subject to change flashes. Continue to use
displayed on the far left is the month the ENTER and ON/OFF/MODE buttons, respectively, to edit
and to its right the day. The year is and set each value.
displayed beneath the day.
After all values are set, press ON/OFF/MODE and
TWA Interval Set-point Screen advance to the Display Mode Set Screen.
Displays the existing TWA interval.
The display mode selected determines whether the monitor user will see
The value can be set from one to 40
a numeric or text display (including alarm displays) when the monitor is in
hours, in increments of one.
the gas monitoring mode.
Press ON/OFF/MODE to bypass the STEL alarm value set process and
advance to the Calibration Gas Set Screen. Press ENTER to edit the value, if needed.
Press ENTER to begin the STEL alarm value set process. Press ON/OFF/MODE to set the value and advance to the Confidence
On the display, the first sensor subject to change flashes. Indicator Set Screen.
Press ENTER to edit the value, if needed; press repeatedly or Display Mode Set Screen
hold down to speed the increment pace. Options
Press ON/OFF/MODE to set the value. 0 = Numeric Mode
STEL Alarm Set-point Screen 1 = Text Mode
Displays the existing STEL values for The next sensor subject to change flashes. Continue to use the
the toxic sensors installed. No other ENTER and ON/OFF/MODE buttons, respectively, to edit and
sensor readings appear. set each sensor’s STEL alarm value.
After the alarm value is set for each installed sensor,

press ON/OFF/MODE to advance to the Calibration Gas
Set Screen.
With an enabled confidence indicator, the monitor will emit a Sets the percentage of calibration gas the monitor expects to be
signal, every 90 seconds in gas monitoring mode, to inform the exposed to.
user it is operational.
Press ENTER to edit the value, if needed. hold down to speed the increment pace.
Press ON/OFF/MODE to set the value and advance to one of two Press ON/OFF/MODE to set the value and advance to the Bump
screens. Test Response Time Screen.
Confidence Indicator On-Off Screen If the confidence indicator is enabled, the Confidence Bump Test Percentage Requirement Screen
Options Indicator Type Set Screen displays. Value range: 50% to 99%
0 = Disable/off Value increment: one percent
1 = Enable/on If the confidence indicator is disabled, the Bump Test In- Sets the bump test response time period.
field Option Screen displays.
Sets the type of signal that will be emitted by an enabled Press ENTER to edit the value, if needed; press repeatedly or
confidence indicator. hold down to speed the increment pace.
Press ON/OFF/MODE to set the value and advance to the Latch
Press ENTER to edit the value, if needed. Alarm Set Screen.
Press ON/OFF/MODE to set the value and advance to the Bump Bump Test Response Time Screen
Test In-field Option Screen. Value range: 30 to 300 seconds
Value increment: five seconds
Confidence Indicator Type Set Screen
Options When enabled, if the monitor goes into any gas-related alarm, it
will remain in alarm until after the gas concentration is less than (or
1 = audible chirp
more than for oxygen) the alarm set point, and the monitor user
2 = LED flash presses the ENTER button for one second.
3 = combination audible chirp and LED flash
When enabled, permits all monitor users to bump test the monitor Press ENTER to edit the value, if needed.
from the gas monitoring mode. Latch Alarm Set Screen Press ON/OFF/MODE to set the value and advance to the Zero
Options In-field Screen.
Press ENTER to edit the value, if needed. 0 = Normal mode
Press ON/OFF/MODE to set the value and advance to one of two 1 = Latching mode
screens. When enabled, all monitor users are permitted to zero the monitor
If Bump Test In-field is enabled, the Bump Due Warning from the gas monitoring mode.
Bump Test In-field Option Screen Option Screen displays.
Options
0 = Disable/off Press ENTER to edit the value, if needed.
If the Bump Test In-field is disabled, the Alarm Latch Set Press ON/OFF/MODE to set the value and advance to one of two
1 = Enable/on Screen displays. screens.
When enabled, the monitor will sound two beeps every 30 Zero In-field Screen If Zero In-field is enabled, the Calibration In-field Option
seconds and its display icons will indicate a bump test is due. Options screen displays.
0 = Disable/off If Zero In-field is disabled, the Calibration Due Alarm screen
Press ENTER to edit the value, if needed. 1 = Enable/on displays.
Press ON/OFF/MODE to set the value and advance to the Bump
Test Time Set-point Screen. When enabled, all monitor users are permitted to calibrate the
monitor from the gas monitoring mode.
Bump Due Warning Option Screen
Options Press ENTER to edit the value, if needed.
0 = Disable/off Press ON/OFF/MODE to set the value and advance to the
1 = Enable/on Calibration Due Alarm Option.
Sets the elapsed time allowed between bump tests. Calibration In-field Option Screen
Options
Press ENTER to edit the value, if needed; press repeatedly or 0 = Disable/off
hold down to speed the increment pace. 1 = Enable/on
Press ON/OFF/MODE to set the value and advance to the Bump When enabled, the monitor will activate the calibration due alarm,
Test Percentage Requirement Screen. in gas monitoring mode, when any sensor is due for calibration. A
flashing gas cylinder and gas type will appear on the display and
Bump Test Time Set-point Screen
three beeps will sound every 30 seconds.
Value range: .5 days to 7.0 days
Value increment: .5 days
Calibration Due Alarm Option Screen Press ON/OFF/MODE to set the value and advance to the
Options Calibration Due Set-point screen.
0 = Disable/off
1 = Enable/on
Sets the elapsed time allowed between calibrations. Disallow or allow operator-activated shutdown when the unit is in
alarm.
Press ON/OFF/MODE to set the value and advance to the Press ENTER to edit the value, if needed.
Calibration Days Set Screen. Press ON/OFF/MODE to set the value and advance to the next
configuration mode screen.
Shutdown In Alarm Screen
Calibration Due Set-point Screen
Options
Value range: one to 365 days
0 = Disallows shutdown
Value increment: one day
1 = Allows shutdown
Sets how the Calibration Days Screen will display in operation
Disable or enable alarm indicators when the unit is docked.
mode.
NOTE: The up arrow ( ▲) will be featured on-screen when the Press ENTER to edit the value, if needed.
unit is set to display the number of days before a sensor’s Press ON/OFF/MODE to set the value and advance to the next
next calibration is due. The down arrow (▼) will be featured configuration mode screen.
Calibration Days Set Screen when the unit is set to display the number of days since the
Options last calibration was performed. A value will be displayed for Alarm on Dock Screen
0 = display days since last calibration each installed sensor. Options
1 = display days until next calibration 0 = Disable/off
Press ENTER to edit the value, if needed. 1 = Enable/on
Press ON/OFF/MODE to set the value and advance to the
Security Code Set Screen
A security code value of 000 permits all monitor users to enter ►Monitor Use and Service
configuration mode and gain access to change the monitor’s
settings. A value other than 000 will restrict access to the
Proper monitor use and service includes everything from bump testing and calibration to keeping the monitor clean,
configuration mode; it will also restrict access to the shutdown
proper air sampling, and the replacement of parts and components. Beginning with calibration and bump testing, the
process for an instrument that is configured for “always on”.
following sections provide information and instruction on all use and service tasks.
Security Code Set Screen hold down to speed the increment pace.
Valid values: 000 to 999.
ZERO, CALIBRATION, AND BUMP TESTING
Press ON/OFF/MODE to set the value and advance to the
Increment value: one Language Selection Screen. Gas detection instruments are potentially life-saving devices. When completed regularly, the procedures defined
Allows the choice of display languages as applied to select below help to maintain proper instrument functionality and enhance operator safety.
screens.
Procedures
Press ON/OFF/MODE to set the value and return to the LEL Type Configuration. The configuration process allows qualified personnel to review and adjust a unit's settings.
Set Screen.
Bump Test (or "functional test"). Bump testing checks for sensor and alarm functionality. The installed sensors are
Language Selection Screen briefly exposed to expected concentrations of calibration gases that are greater than the sensors’ low alarm set
Options points. When one or more sensors “pass” the test, they are “functional” and the unit will alarm. Each sensor’s “pass”
E = English
F = French or “fail” result is indicated on the unit’s display.
d = German Note: a bump test does not measure for sensor accuracy (see “Calibration”).
When enabled, the shutdown process is security-code protected Zero. Zeroing sets each installed sensor to recognize the ambient air as clean air. If the ambient air is not truly clean
only if the security code is not equal to 000. If the code is set to air, any gasses that are present and relevant to the installed sensor types will be measured and displayed as zero.
anything other than 000, the user will be prompted to enter the
unit's security code to complete the shutdown process.
Readings will be inaccurate until the unit is correctly zeroed in truly fresh air or with a zero air cylinder.
Calibration. All sensors gradually degrade over time. This diminishes a sensor's ability to measure gas
Press ENTER to edit the value, if needed. concentrations accurately; however, regular calibrations adjust the instrument to compensate for this decline in
Always-on Set Screen
Press ON/OFF/MODE to set the value and advance to the next
Options sensitivity. During calibration, the installed sensors are exposed to expected concentrations of calibration gases and,
configuration mode screen.
0 = Disable/off when needed, the instrument will self-adjust to ensure the accurate measurement and display of gas concentration
1 = Enable/on
values.
Note: when a sensor has degraded beyond an acceptable level, no further adjustment is possible and the sensor will no longer pass
calibration.
Peak Readings. The instrument stores the highest detected gas readings, the "peak readings" or "peaks". Bump
testing and calibration will often register new peak readings. Therefore, the clearing of the peak readings should
follow each calibration. The instrument operator may also wish to clear the peak readings after a bump test, before a
change in location, or after an alarm is addressed and cleared.
Note: The peak readings and the data log readings are stored independently of one another; therefore, clearing the peak reading does not Instructions
affect the data log. Powering the instrument off or changing its battery does not affect the peak reading. These checks and balances help Calibration and Bump Testing with Calibration Cup and/or Tubing
promote operator safety, and serve to contain the peak readings in a "black-box" manner. In the event of a gas-related incident, this black-box Read all instructions before beginning: notices, supply check-list, gas cylinder preparation, and the complete screen-
record can be useful to the safety team or a prospective investigator. by-screen walk-through of the zero, calibrate, and bump test processes. Each process is presented in the order in
which it is accessible from gas monitoring mode.
Recommendations NOTICES
Industrial Scientific Corporation (ISC) minimum frequency recommendations for each procedure are summarized in ® Industrial Scientific recommends that full monitor calibration be performed, using a known certified
the table below. These recommendations are based on field data, safe work procedures, industry best practices, and concentration(s) of Industrial Scientific calibration gas(es), to prepare the monitor for first time use, and
regulatory standards to help ensure worker safety. Industrial Scientific is not responsible for setting safety practices monthly (at a minimum) thereafter, to help ensure monitor accuracy.
® Industrial Scientific also recommends that each monitor be zeroed and bump tested before each use with a
and policies. These policies may be affected by the directives and recommendations of regulatory groups,
known certified concentration(s) of Industrial Scientific calibration gas(es).
environmental conditions, operating conditions, instrument use patterns and exposure to gas, and other factors.
® Read ALL requirements and instructions outlined below, including the screen-by-screen process description,
before beginning the zero, calibration, or bump testing processes.
Procedure ISC Recommended minimum frequency ® Only qualified personnel should zero, calibrate, or bump test a monitor.
® Zero, calibration, and bump testing functions should be performed in a fresh air environment known to be
Configuration Before first use and as needed thereafter.
nonhazardous.
Calibrationa Before first use and monthly thereafter. ® After calibration or bump testing, or after terminating either process, stop the flow of gas.
Bump testb Prior to each day’s use.
aBetween regular calibrations, ISC also recommends a calibration be performed immediately following each of these incidences: the unit falls, Supplies
is dropped, or experiences another significant impact; is exposed to water; fails a bump test; or has been repeatedly exposed to an over-range Item Monitor/Regulator**
(positive or negative) gas concentration. A calibration is also recommended after the installation of a new (or replacement) sensor.
bIf conditions do not permit daily testing, bump tests may be done less frequently based on company safety policy. Aspirated monitor Aspirated monitor Diffusion monitor
with Demand Flow with Positive Flow with Positive Flow
Note: The use of calibration gases not provided by ISC may void product warranties and limit potential liability claims. Regulator** Regulator** Regulator**
Calibration cup* No No Yes
General information Calibration tubing 2 feet in length* Yes No Yes
The zero, calibration, and bump testing tasks are in-field enabled or in-field disabled in the configuration process.
This permits or denies access to these functions from the gas monitoring mode. When any of these options is Calibration tubing 2 feet in length with No Yes No
enabled, it is accessible to all monitor users. In gas monitoring mode, a series of presses on the ON/OFF/MODE integrated “t” fitting
button gives the user access to the following screens and processes in the order shown. Calibration gas cylinder Yes Yes Yes
· Gas Monitoring Screen *Shipped with monitor.

· Days Since Calibration **Industrial Scientific recommends 1) the use of positive flow regulators with a flow rate of .5 LPM, and 2) the diffusion monitor be calibrated or bump
tested using a positive flow regulator, NOT a demand flow regulator.
· Zero Initiate (if in-field enabled)
o Calibration Apply Gas Screen (if in-field enabled)
· Bump Test Initiate (if in-field enabled)
· Peak Readings
· TWA Readings
· STEL Readings
The monitor is capable of performing two types of calibration, and this option is set in configuration mode. The
calibration type selected also determines the monitor’s bump test type. With a “quick” calibration, the monitor is set to
calibrate and bump test all installed sensors simultaneously. With a “standard” calibration setting, these tasks are
completed independently for each installed sensor in the order shown below.
1. Oxygen sensor*
2. Toxic sensor 1
3. LEL sensor
4. Toxic sensor 2
*If set to the default value of 20.9% or 21%, the Oxygen sensor calibrates during the zero process and toxic 1 is the first to calibrate in the
calibration process.
The Ventis MX4 monitor can be calibrated with any of the accessories listed.
· Calibration cup and/or tubing shipped with the monitor (see instructions below)
· V-Cal Calibration Station (consult the calibration station manual for instruction)
· DS2 Docking Station for Ventis MX4 (consult the docking station manual for instruction)
Diffusion monitor with positive flow regulator. Aspirated monitor with demand flow regulator.
Prepare the gas cylinder for use Press ENTER to begin the zero process and advance to
· According to the supply chart above, attach the correct regulator to the gas cylinder and turn clockwise to tighten. the Zero In-process Screen.
· Next, choose instruction A., B., or C. based on the monitor/regulator combination in use. Press ON/OFF/MODE to bypass zero and calibration
and advance to one of two screens.
A. Aspirated with demand flow regulator
Attach either end of the tubing to the cylinder’s nipple. If bump test in-field is enabled, the user advances to
the Bump Test Initiate Screen.
Zero Initiate Screen
DO NOT ATTACH THE OTHER END OF THE TUBING TO THE MONITOR BEFORE REACHING THE Options:
“APPLY GAS SCREEN”. Completing the connection of the tubing will cause gas to flow. If gas is If bump test in-field is disabled, the user advances to
Enter Zero the Peak Readings Screen.
applied before reaching the appropriate screen, the monitor will go into alarm and a failure will be Bypass Zero
logged.
Allow the zero process to complete and advance to the
B. Aspirated with positive flow regulator Zero Results (Pass or Fail) Screen.
The calibration tubing with the t-fitting (not included) has two different sized openings, a narrow opening
at one end and a wider opening at the other end. After the zero process, press ON/OFF/MODE to
Attach the wider opening to the nipple on the cylinder’s regulator. bypass calibration of the installed toxic and combustible
Attach the smaller opening to the pump inlet. sensors. The user returns to the mode from which the
calibration process was entered (configuration or gas
Zero In-process Screen monitoring).
DO NOT APPLY THE GAS BEFORE REACHING THE “APPLY GAS SCREEN”. If gas is applied before Each sensor’s numerical value becomes zero except
that point, the monitor will go into alarm and a failure will be logged. O2. An updated O2 span value displays. The clock icon NOTE: during the zero process, the O2 sensor is calibrated (when set to
flashes and the zero icon displays. default gas volume of 20.9%)
C. Diffusion with positive flow regulator
Attach either end of the tubing to the cylinder’s nipple. NOTE: The “span reserve” of a sensor measures its sensitivity. The
Attach the other end of the tubing to the calibration cup’s nipple. displayed span value divided by the calibration gas value equals the
span reserve percentage. A span reserve percentage of greater than
70% indicates a “good” sensor; 50%-70% indicates “marginal”
DO NOT ATTACH THE CALIBRATION CUP TO THE MONITOR OR APPLY THE GAS BEFORE sensitivity. When the span reserve percentage is less than 50%, the
REACHING THE “APPLY GAS SCREEN”. If gas is applied before that point, the monitor will go into sensor will not pass calibration.
alarm and a failure will be logged.
Within Ten Seconds
Press ENTER to repeat the zero process.
Zero and Quick Calibration Process Press ON/OFF/MODE to advance to one of two screens.
Display and Options Instructions
If zero was entered from…
Press ON/OFF/MODE to advance to the Days since
Calibration Screen. …configuration mode, the user advances to the
Zero Results (Pass) Screen Calibration Apply Gas Screen.
The check mark displays to indicate a successful zero
and a short beep sounds. Each sensor’s numerical … gas monitoring mode and the calibration in-field
values display at zero except O2. option is enabled, the user advances to the
Gas Monitoring Screen Calibration Apply Gas Screen.
Numeric mode display (left) Options:
Text mode display (right) Repeat zero …gas monitoring mode and the calibration in-field
Displays the gas concentration readings (or gas names Begin calibration option is disabled, the user advances to the Gas
in text mode) for all installed sensors. If a sensor is NOT Enter gas monitoring mode Monitoring Screen in the gas monitoring mode.
installed, its position on the LCD is blank.
Press ON/OFF/MODE to advance to one of three If neither ENTER nor ON/OFF/MODE is pressed, within
screens. ten seconds, the user advances to the Gas Monitoring
Screen in the gas monitoring mode.
If zero in-field is enabled, the user advances to the Press ON/OFF/MODE (or wait ten seconds) to return to
Zero Initiate Screen. the Zero Initiate Screen and repeat the zero process.
If zero in-field is disabled and bump test in-field is
Days Since Calibration Screen enabled, the user advances to the Bump Test Initiate
Displays the number of days since the last successful Screen.
calibration for each installed sensor. Each value can be If zero in-field and bump test in-field are both
different. disabled, the user advances to the Peak Readings Zero Results (Fail) Screen
Screen. Displays an “F” or “P”, respectively, for each failed or
NOTE: When zero, calibration, and bump test are ALL in-field enabled, and the user has entered zero from the gas passed sensor. For O 2, if the sensor passed its
monitoring mode, the monitor expects to be calibrated following a successful zero. calibration, the sensor reading displays.
If the desired task, after zero, is bump testing (or clearing the peaks) and NOT calibration, follow the instructions at
the Calibration Apply Gas Screen to terminate calibration.
To Terminate Any failed sensor stays in alarm until it passes a

Press ON/OFF/MODE while the gas cylinder icon flashes calibration or is replaced.
to terminate the quick calibration process (or to skip a
sensor’s calibration in standard calibration) and return to Press ON/OFF/MODE to repeat calibration.
the gas monitoring mode.
To Calibrate
Calibration Apply Gas Screen* From the already prepared gas cylinder, start the flow of Calibration Failed Screen*
The gas cylinder icon flashes. Each sensor’s display gas as noted below for the monitor/regulator combination Gas readings display for all successfully calibrated
shows the calibration gas concentration to be applied. in use. sensors and an “F” displays for any failed sensors. A
(The O2 display is blank as the sensor was calibrated system level alarm turns on. The warning icon and gas
during zeroing.) The monitor waits up to five minutes to For an aspirated monitor with a demand flow cylinder display to indicate a sensor calibration failure.
successfully sense the gas. regulator, complete the tubing connection from the * During the standard calibration or standard bump test process, a series of apply gas, in-progress, and results screens show for EACH sensor as it
regulator to the pump inlet. is calibrated or tested.
Calibration In-progress Screen*
If gas is sensed, the gas values for the LEL and For an aspirated monitor with a positive flow Bump Test Process
toxic sensors increase and the O2 value decreases. regulator, turn (counterclockwise) the regulator’s
knob.
If gas is NOT sensed, a failed calibration registers Display and Options Instructions
and the Calibration Failed Screen displays. For a diffusion monitor with a positive flow Press ON/OFF/MODE to bypass the bump test process
regulator: and advance to the Peak Readings Screen.
· Place the calibration cup over the upper portion Press ENTER to begin the bump test process.
of the monitor’s case top (front of monitor). To
attach properly, complete or observe the
following.
o The cup fully covers the sensor ports.
o The monitor’s display and buttons are NOT Bump Test Initiate Screen
covered. Options
o The cup’s side arms fit securely in the Begin process
grooves on the sides of the monitor. Bypass process
o The Ventis name on the calibration cup is To Terminate
upright and readable. Press ON/OFF/MODE while the gas cylinder icon flashes
o The cup’s nipple points up and away from to terminate the quick bump test process (or to skip a
the monitor. sensor’s testing in standard bump testing). The user
· Turn (counterclockwise) the regulator’s returns to the Gas Monitoring Screen.
knob.
STOP THE FLOW OF GAS. To Bump Test
Bump Test Apply Gas Screen From the already prepared gas cylinder, start the flow of
After calibration, or if calibration is terminated at anytime Displays the bump test gas concentrations the monitor
during the process, stop the flow of gas as follows. gas as noted below for the monitor/regulator combination
is expecting to receive. The monitor waits up to five in use.
minutes to successfully sense the gas.
For an aspirated monitor with a demand flow
regulator, disconnect the tubing from the pump inlet. For an aspirated monitor with a demand flow
If gas is sensed, the user advances to the Bump regulator, complete the tubing connection from the
Test In-progress Screen. regulator to the pump inlet.
For an aspirated or diffusion monitor with a
positive flow regulator, turn (clockwise) the If gas is NOT sensed, a failed bump test occurs
regulator’s knob. For an aspirated monitor with a positive flow
and the user advances to the Bump Test Results regulator, turn (counterclockwise) the regulator’s
Screen displays. knob.
All Sensors Pass
The user returns to the mode from which the calibration For a diffusion monitor with a positive flow
Sensor Results Screen*
process was entered (configuration or gas monitoring). regulator:
Pass (top) or Fail (bottom) Screen
· Place the calibration cup over the upper portion
The display alternately shows a “P” for pass (or “F” for
Sensor Fail of the monitor’s case top (front of monitor). To
fail) and the final span value reading for each sensor. A
If one or more sensors fail calibration, the Calibration Fail attach properly, complete or observe the
check mark displays and a single beep sounds.
Screen displays and a system level alarm turns on. following.
NOTE: The “span reserve” of a sensor measures its sensitivity. The o The cup fully covers the sensor ports.
displayed span value divided by the calibration gas value equals the o The monitor’s display and buttons are not
span reserve percentage. A span reserve percentage of greater than covered.
70% indicates a “good” sensor; 50%-70% indicates “marginal”
sensitivity. When the span reserve percentage is less than 50%, the
o The cup’s side arms fit securely in the
sensor will not pass calibration. grooves on the sides of the monitor.
o The Ventis name on the calibration cup is
upright and readable. Press and release ENTER to clear the displayed TWA
o The cup’s nipple points up and away from reading(s), if desired.
the monitor. Press ON/OFF/MODE to advance to the STEL Readings
· Turn (counterclockwise) the regulator’s knob. Screen.
As the bump test progresses, observe the display

activity (left). TWA Readings Screen
Displays the TWA (time weighted average) icon and
After the bump test, the Bump Test Results Screen calculated readings for each toxic sensor installed; all
displays. other sensor values are blank.
Press and release ENTER to clear the reading(s), if
STOP THE FLOW OF GAS.
Bump Test In-progress Screen desired.
After bump testing, or if bump testing is terminated at
Displays when gas is sensed within five minutes. The Press ON/OFF/MODE to advance to the Gas Monitoring
anytime during the process, stop the flow of gas
clock icon flashes to indicate the test is in-progress. The Screen.
from the cylinder as follows.
sensor reading(s) display. The LEL and toxic sensor
readings increase and the O2 reading decreases. For an aspirated monitor with a demand flow
regulator, disconnect the tubing from the pump inlet. STEL Readings Screen
Displays the STEL (short term exposure limit) icon and
For an aspirated or diffusion monitor with a STEL values for each toxic sensor installed; all other
positive flow regulator, turn (clockwise) the sensor values are blank. The STEL value is the running
regulator’s knob. average over the last 15 minutes.
* During the standard calibration process, a series of apply gas, in-progress, and results screens show for EACH sensor as it is calibrated or tested.
No User Action Required

After a passed bump test, the monitor goes into gas
monitoring mode. RECOMMENDED PRACTICES FOR IN-FIELD AIR SAMPLING
Diffusion monitor
When worn, the diffusion monitor should be fastened securely and attached to ensure the sensor portals are exposed
to the air. The monitor should be in full view. No part of the monitor should be covered by any garment or part of a
garment.
Bump Test Results (Pass) Screen
The above displays an all sensor pass result. If one or Aspirated monitor
more sensors fail, the “F” shows in place of the “P”. The Before using an aspirated monitor, force a pump fault to ensure the pump and air-sample accessories (sample
pass/fail screen (left) and the final sensor reading tubing, probe, or sample tubing and probe) are working as intended:
screen (right) display alternately three times. A single 1 Power on the monitor.
beep sounds to indicate the bump test is completed. 2 Attach the air-sample accessory(ies) to the pump inlet.
3 Using a finger, cover the opening at the other end of the air-sample tubing (or probe) to block the flow of air.
After a failed bump test, the Bump Test Fail Screen This should result in a pump fault alarm.
4 After a pump fault occurs, remove the finger from the tubing (or probe). If the unit resumes normal
displays and a low level audio alarm turns on.
operation, the pump and air-sampling accessories are working as intended.
The monitor should be fully calibrated after a failed bump
test. Note: If no pump fault occurs or if the unit stays in pump fault, check for debris at these locations: the pump nipple,
inside the inlet barrel, at the water barrier, and inside the pump cradle; attempt to clear any blockage. Check the air-
NOTE: After a full calibration, the O2 sensor must pass a bump test to sample accessories, too, for debris and for possible crack or leaks.
Bump Test Results (Fail) Screen clear the bump test fail status.
The “bF” displays under each gas type to indicate a The Ventis MX4 aspirated monitor is rated to sustain a continuous sample draw for up to 100 feet (30.48 m) with
bump test failure. The system level alarm turns on and 0.125 inch (0.3175 cm) inside diameter sample tubing. In confined space, an air sample should be taken in four foot
the gas cylinder icon flashes. (1.2192 m) intervals. With each sample, the minimum time required to successfully draw air and read the gas
concentrations should include two minutes plus two seconds for every 12 inches (30.48 cm) of tubing.
Press and release ENTER to clear the peak values, if
desired.
Press ON/OFF/MODE to advance to one of two screens. CLEANING
· NEVER use solvents or cleaning solutions of any type.
If toxic sensors are installed, the user advances to · When necessary, wipe the outside of the Ventis MX4 with a soft, clean cloth.
the TWA Readings Screen. · Make sure the sensor diffusion membrane, inside and out, is free of debris; wipe gently with a cloth or brush that
is soft, clean, and dry.
Peak Readings Screen If no toxic sensors are installed, the user advances · Make sure the aspirated monitor’s inlet is free of debris.
Displays the peak icon and peak gas concentrations for to the Gas Monitoring Screen.
each installed sensor since the last time the peak
readings were cleared. (For O2, the lowest reading is
shown.)
SERVICE Reassembling the Aspirated Monitor.

Instructions are provided for battery service; monitor conversion (diffusion to aspirated and vice versa); sensor,
1 Re-place the monitor inside the pump module. The monitor is display side up and its logo readable.
sensor barrier and LCD service; and pump assembly service. Refer to the three-dimensional view diagrams to
Its lower exposed bottom portion covers the battery.
identify the parts referenced in the instruction sets, and for screw torque values.
2 Tighten the four screws on the pump module bottom to secure the module to the monitor.
Read all instructions before beginning any monitor service. 3 Lower and close the pump door; slide up to click in place.
NOTICES 4 Tighten the pump door screw to secure the door in place.
® Before beginning any service tasks, power-off the monitor. 5 Dispose of any spent batteries according to company policy.
® Only qualified staff should perform monitor service and should take the following precautions.
® Take care not to touch battery contacts on the monitor or the battery itself. Diffusion Monitor Battery Replacement or Changeover
® Perform work in a clean air environment that is known to be nonhazardous. The diffusion monitor can be used with all three Ventis battery packs.
® Perform work on a nonconductive work surface. · The Li-ion battery kit is a single part consisting of the monitor’s lower case bottom and the battery. It is
® Wear grounding straps. removed from and attached to the diffusion monitor as a single item.
· The Extended Range Li-ion battery pack and its cover are two distinct items.
· The Alkaline battery pack consists of three items: the batteries, the battery pack, and a battery pack cover
BATTERY PACKS (the same cover that holds the Extended Range Li-ion battery).
NOTICES NOTE: When an Extended Range Li-ion (or Alkaline) battery pack is attached to a diffusion monitor, the monitor’s lower portion becomes
® WARNING: INSERT THE ALKALINE BATTERIES WITH THE CORRECT POSITIVE “ + ” AND NEGATIVE deeper than its upper portion. The Conversion Kit’s suspender clip components are used to make the upper and lower portions depth-
“-“ ORIENTATION. FAILURE TO FOLLOW PROPER BATTERY ORIENTATION WILL RESULT IN compatible. The Conversion Kit provides a battery cover (battery not included), a suspender clip and spacer, and a screw and washer.
DAMAGE TO THE MONITOR.
® WARNING: The Ventis MX4 is only approved for use with AAA battery types Energizer EN92 and Duracell
MN2400. Do NOT mix battery types. ATTACHING THE LI-ION BATTERY TO A DIFFUSION MONITOR.
Battery Replacement.
Battery service instruction sets are provided below for each allowable monitor/battery pack combination. Please
choose, read, and then follow the appropriate instruction set. 1 Power-off the monitor.
2 Loosen the four captive screws on the lower portion of the case bottom (or the battery cover if the
Aspirated Monitor Battery Replacement Extended Range Li-ion or Alkaline battery pack is attached).
For an aspirated monitor, two of the three Ventis battery packs can be used. The Extended Range Li-ion battery
is replaced as a single part. The Alkaline battery unit consists of batteries and a pack for the batteries. 3 Lift and remove the Li-ion kit (or Extended Range Li-ion battery Alkaline battery pack and cover); set
aside.
ASPIRATED MONITOR BATTERY REPLACEMENT. 4 To properly attach the new Li-ion battery kit to the monitor, align its exterior charging contacts with
the monitor’s bottom.
Removing the Battery Pack.
5 Tighten the four captive screws to secure the battery pack to the monitor.
1 Power-off the monitor.
6 Dispose of any spent batteries according to company policy, or properly store any battery packs that
2 Loosen the four captive screws on the lower portion of the pump module bottom (back of the have a remaining life.
module).
To changeover from an Extended Range Li-ion (or Alkaline) battery pack to a Li-ion battery continue with
3 Loosen the single captive screw on the pump door. the following suspender clip instruction sets.
4 Slide the pump door down; lift to reveal and access the monitor.
5 Lift and remove the monitor from the pump module; set aside the monitor. Removal of the Suspender Clip and Spacer.
6 Lift and remove the battery pack from inside the lower portion of the pump module. 1 On the monitor’s case bottom, open the suspender clip.
Replacing the Battery Pack. 2 Using a Phillips head screwdriver, remove the screw and washer that attach the suspender clip and
If inserting the Alkaline battery pack, follow steps 1-5. spacer to the monitor.
If inserting the Extended Range Li-ion battery pack, follow step 5 ONLY.
3 Set aside and store the removed items for future use with the Extended Range Li-ion (or Alkaline)
1 To prepare the alkaline battery pack, unlatch and lift the hinged portion of the battery pack. battery pack on a diffusion monitor.
2 If needed, remove and set aside the spent batteries from within the pack. Attachment of the Suspender Clip.
3 Insert new batteries so that their negative contacts are in contact with the springs inside the pack. 1 Open the suspender clip.
DO NOT MIX BATTERY TYPES.
2 Place the washer on the screw (P/N 17139262).
4 Close the latch. A click sounds.
3 Insert the screw with washer through the clip’s center hole and into the screw hole on the monitor.
5 To properly place the Extended Range Li-ion (or Alkaline) battery pack inside the pump module,
4 Tighten the screw to secure the suspender clip to the monitor.
complete or observe the following:
· the battery circuitry is exposed and faces the user;
· a small groove at the back of the battery bottom fits over the small rib at the back of the pump
module bottom.
ATTACHING THE EXTENDED RANGE LI-ION (OR ALKALINE) BATTERY PACK TO A DIFFUSION MONITOR CONVERSION
MONITOR. To convert a diffusion monitor to an aspirated monitor, only the Extended Range Li-ion or Alkaline battery packs are
approved for use.
Battery Removal.
1 Power-off the monitor. To convert an aspirated monitor to a diffusion monitor, a suspender clip, washer, and screw are recommended for
use with the Li-ion battery pack. If attaching the Extended Range Li-ion or Alkaline battery packs, the conversion kit is
2 Loosen the four captive screws on the lower portion of the Case Bottom (back of the monitor. required.
3 Lift the battery unit to remove; set it aside.
NOTE: When an Extended Range Li-ion (or Alkaline) battery pack is attached to a diffusion monitor, the monitor’s lower portion becomes
deeper than its upper portion. The Conversion Kit’s suspender clip components are used to make the upper and lower portions depth-
compatible. The Conversion Kit provides a battery cover (battery not included), a suspender clip and spacer, and a screw and washer.
Battery Attachment.
If inserting the Alkaline battery, follow steps 1-7.
If inserting the Extended Range Li-ion battery, follow steps 5-7 ONLY. CONVERTING A DIFFUSION MONITOR TO AN ASPIRATED MONITOR.
Removing the Suspender Clip and Battery Pack.
1 To prepare the Alkaline battery pack, unlatch and lift the hinged lid of the battery housing.
2 If needed, remove and set aside the spent batteries from within the housing.
2 On the monitor’s case bottom (back of the monitor), open the suspender clip.
3 Insert new batteries so that their negative contacts are in contact with the springs inside the housing.
DO NOT MIX BATTERY TYPES. 3 Using a Phillips head screwdriver, remove the screw and washer that attach the suspender clip (and
spacer, if applicable) to the monitor. Set aside and store any removed, unused items for future use with
4 Close and latch the lid. A click sounds.
a diffusion monitor.
5 To properly place the Extended Range (or Alkaline) battery pack inside the battery cover ensure:
4 Loosen the four captive screws on the lower portion of the case bottom. Lift and remove the battery
pack (and cover, if applicable). Set aside and store any removed, unused items for future use with a
· a small groove at the back of the battery bottom fits over the small rib at the back of the pump diffusion monitor.
module bottom.
Assembling the Aspirated Monitor (including battery insertion).
6 To properly attach the cover (and its enclosed battery) to the monitor, ensure the battery contacts are
If inserting the Alkaline battery pack, follow steps 1-10.
showing at the bottom of the monitor. If inserting the Extended Range Li-ion battery pack, follow steps 5-10 ONLY.
NOTE: each of the above battery packs easily fits within the battery cover. If the battery does not easily insert, stop to ensure 1 To prepare the Alkaline battery pack, unlatch and lift the hinged portion of the battery pack.
proper placement as noted above.
2 If needed, remove and set aside any spent batteries from within the pack.
7 Tighten the four captive screws to secure the battery cover to the monitor.
3 Insert new batteries so that their negative contacts are in contact with the springs inside the pack. DO
To changeover from a Li-ion battery kit to an Extended Range Li-ion (or Alkaline) battery pack, continue with
NOT MIX BATTERY TYPES.
the following suspender clip instruction sets.
4 Close the latch. A click sounds.
Removal of the Suspender Clip.
5 To properly place the Extended Range Li-ion (or Alkaline) battery pack inside the pump module,
1 Open the suspender clip.
complete or observe the following:
2 Using a Phillips head screwdriver, remove the screw and washer that attach the clip to the monitor · the battery circuitry is exposed and faces the user;
3 Set aside and store the removed clip, washer, and screw for future use with a diffusion monitor and · a small groove at the back of the battery bottom fits over the small rib at the back of the pump
Li-ion battery pack. module bottom.
Attachment of the Suspender Clip and Spacer (from the Conversion Kit). 6 Loosen the captive screw on the front of the pump module. Slide the module’s door down and lift to
open.
1 Place the monitor face down.
7 Place the monitor inside the pump module. The monitor is display side up and its logo readable. Its
2 The spacer has one flat end. Place the spacer on the monitor’s case back so its flat end meets top lower exposed bottom portion covers the battery.
edge of the battery cover; the hole in the spacer aligns with the screw hole on the monitor.
3 Place the washer on the screw.
9 Close the pump door; slide up to click in place.
4 Insert the screw with washer through the clip’s hole and through the center hole on the clip back.
10 Tighten the pump door screw.
5 Place the clip on top of the spacer, inserting its screw into the spacer’s hole. Be sure the clip’s ring is
at the top of the monitor.
6 Grasp the clip and spacer with one hand. With the other hand, tighten the screw with the Phillips
screwdriver. CONVERTING AN ASPIRATED MONITOR TO A DIFFUSION MONITOR.
Removing the Pump Module.
2 Loosen the four captive screws on the lower portion of the pump module bottom (back of the module).
3 Loosen the single captive screw on the pump module door.
4 Slide the pump door down; lift to reveal and access the monitor.
5 Lift and remove the monitor from the pump module; set aside and store for future use.
Choose OPTION 1 or OPTION 2 below depending on the battery pack to be attached. SENSOR, SENSOR BARRIER, LCD, AND VIBRATING MOTOR REPLACEMENT
Service instruction sets are provided below for each monitor type. Please choose, read, and then follow the
OPTION 1: Attaching the Li-ion Battery Kit and its Compatible Suspender Clip Components. appropriate instruction set . Within each set of instructions, follow those relevant to the desired task(s) and note the
1 To properly place the Li-ion battery kit, align its contacts with the monitor’s contacts, at the monitor following.
bottom. · The monitor has a two-part circuit board assembly, the main board and a smaller sensor board. They are
attached to one another with a connecter at the center of the sensor board.
2 To secure the battery kit to the monitor, tighten the four captive screws on the kit bottom. · The sensor barrier can be replaced as an assembly that fits in the monitor’s case top, or the full case top can be
3 Open the suspender clip. replaced. NOTE: When a sensor is replaced, it is recommended that the sensor barrier/case top also be replaced. After reassembling the
monitor, a full calibration should be completed.
4 Place the washer on the screw. · The LCD is removed and attached as a single component.
5 Insert the screw with washer through the clip’s center hole and into the screw hole on the monitor. Be
sure the clip’s ring is at the top of the monitor. ASPIRATED
6 Tighten the screw. Disassembling the Monitor.
OPTION 2: Attaching the Extended Range Li-ion (or Alkaline) Battery Pack and its Compatible 1 Power-off the monitor.
Suspender Clip Components. 2 Loosen the four captive screws on the lower portion of the pump case module bottom (back of the
If inserting the Alkaline battery pack, follow steps 1-14. module).
If inserting the Extended Range Li-ion battery pack, follow steps 5-14 ONLY.
3 Loosen the single captive screw on the pump case module top.
1 To prepare the Alkaline battery pack, unlatch and lift the hinged portion of the battery pack.
4 Slide the case door down; lift the hinged door to reveal and access the monitor.
2 If needed, remove and set aside any spent batteries from within the pack.
5 Lift and remove the monitor from the pump module; set aside the module.
3 Insert new batteries so that their negative contacts are in contact with the springs inside the pack. DO
NOT MIX BATTERY TYPES. 6 Place the monitor display side down.
4 Close the latch. A click sounds. 7 Loosen the two captive screws on the upper portion of the case bottom.
5 To properly place the Extended Range Li-ion (or Alkaline) battery pack inside the battery cover, ensure: 8 Lift to separate the monitor case top from the monitor case bottom to reveal the circuit board
assembly.
· a small groove at the back of the battery bottom fits over the small rib at the back of the pump 9 Remove the circuit board assembly and set aside the monitor case top and bottom.
module bottom. 10 Separate the main circuit board from the sensor board.
NOTE: each of these two battery packs easily fits within the battery case. If the battery does not easily insert, stop to
ensure proper placement as noted above. Replacing the LCD (if needed).
6 To properly attach the cover containing the Extended Range Li-ion or Alkaline battery pack, ensure the 1 Grasp the sides of the LCD and lift straight up to remove from the main circuit board.
battery contacts are showing at the bottom of the monitor.
2 To properly place the new LCD, align the pins on the LCD with their receptacles on the main circuit
7 To secure the battery cover (and its enclosed battery pack) to the monitor, tighten the four captive board.
screws on the battery cover.
3 Gently press straight down and into place.
8 Place the monitor face down.
Replacing the Sensor(s) (if needed).
9 The spacer for the suspender clip has one flat end. Place the spacer on the monitor’s case back so its
flat end meets top edge of the battery cover; the hole in the spacer aligns with the screw hole on the 1 Identify the sensor to be removed.
monitor. 2 Gently lift and remove the sensor.
10 Open the suspender clip. 3 To add the new sensor, align its pins or connector(s), with the respective receptacles on the sensor
11 Place the washer on the screw. board.
12 Insert the screw with washer through the clip’s hole and through the center hole on the clip back. 4 Press down. A slight click indicates the sensor is securely in place.
13 Place the clip on top of the spacer, inserting its screw into the spacer’s hole and ensuring the clip’s ring Reassembling the Circuit Board Assembly.
is at the top of the case back. 1 Re-attach the main circuit board to the sensor board, aligning their connectors.
14 Grasp the clip and spacer with one hand. With the other hand, tighten the screw with the Phillips 2 Press. A slight click indicates the boards are securely attached.
screwdriver.
Replacing the Sensor Barrier or Case Top (if needed).
To replace the sensor barrier on the inside of the case top, follow steps 1-5 below.
To replace the entire case top, skip to the instruction set, “Reassembling the Monitor”.
1 Observe the placement of the existing sensor barrier. Note that each cut-out is shaped to match the
sensor it protects.
2 Lift and remove the sensor barrier and gasket from inside the monitor case top. Ensure the entire
case top is free of adhesive; gently scrape, if needed. Wipe with a clean, dry, soft cloth or brush.
3 Lift the backing from the new sensor barrier assembly to reveal the adhesive.
4 Carefully position the new barrier. Each shaped opening matches the shape of the sensor it
protects. Press to attach to the inside of the case top.
Replacing the Vibrating Motor (if needed). 2 Lift and remove the sensor barrier and gasket from the inside the monitor case top. Ensure the
entire case top is free of adhesive; gently scrape, if needed. Wipe with a clean, dry, soft cloth or
1 Place the monitor’s case top face down.
brush.
2 Lift the vibrating motor from its partition. The partition has two sections divided by a ridge. Discard
3 Lift the backing from the new sensor barrier to reveal the adhesive.
the used motor.
4 Carefully position the new barrier. Each shaped opening matches the shape of the sensor it
3 To properly place the new vibrating motor, its contact pins face the user and align with the left edge
protects. Press to attach to the inside of the case top.
of the partition. (The motor’s movable component fits within the small section of the partition.)
Replacing the Vibrating Motor (if needed).
4 Press into place.
1 Place the monitor’s case top face down.
Reassembling the Monitor.
2 Lift the vibrating motor from its partition. The partition has two sections divided by a ridge. Discard
1 Re-place the board assembly into the monitor’s case bottom. The LCD faces the user.
the used motor.
2 Re-place the monitor’s case top (or place its new case top).
3 To properly place the new vibrating motor, its contact pins face the user and align with the left edge
3 Tighten the two captive screws on the upper portion of the monitor case bottom. of the partition. (The motor’s movable component fits within the small section of the partition.)
4 Re-place the monitor inside the pump module. The monitor is display side up and its logo readable. 4 Press into place.
Its lower exposed bottom portion covers the battery.
Reassembling the Circuit Board Assembly and Monitor.
1 Re-attach the main board to the sensor board, aligning their connectors.
6 Close the pump module door; slide up to click in place.
2 Press. A slight click indicates the boards are securely attached.
7 Tighten the pump door screw to secure.
3 Re-place the circuit board assembly into the monitor’s case bottom.
8 Dispose of the used sensor(s) according to company policy.
4 Re-place the monitor’s case top (or its new case top).
9 Perform a full calibration following the addition or replacement of any sensor, or the replacement of
5 Tighten the two captive screws on the upper portion of the case bottom.
the sensor water barrier or monitor case top.
6 Re-place the battery pack and tighten the four captive screws on the case bottom.
7 Dispose of the used sensor(s) according to company policy.
8 Perform a full calibration following the addition or replacement of any sensor, or the replacement of
DIFFUSION the sensor water barrier or the monitor case top.
Disassembling the Monitor.
2 Loosen the four captive screws on the lower portion of the case bottom (back of the monitor) to PUMP MODULE
remove the battery pack. Set aside the battery kit (or pack and cover if applicable). There are two field replaceable parts on the aspirated case: the water barrier and case top door. As needed, choose,
read, and follow the appropriate instruction set(s).
3 Loosen the two captive screws on the upper portion of the case bottom.
pump module
4 Lift to separate the case top from the case bottom.
Pump Inlet Filter Cap and/or Water Barrier Replacement (if needed).
5 Remove the circuit board assembly.
1 Power off the monitor.
6 Separate the main circuit board from the sensor board.
2 To remove the pump inlet filter cap, turn counter clockwise; set aside.
Replacing the LCD (if needed).
3 Remove the water barrier from inside the inlet.
1 Grasp the sides of the LCD and lift straight up to remove.
4 To properly place the new water barrier, its bottom will come into contact with the pump inlet surface on
2 To properly position the new LCD, align the pins on the LCD with their receptacles on the main which the barrier sits. The barrier’s bottom side has the smaller diameter opening in the black ring.
circuit board.
5 Re-place the pump inlet filter cap (or new cap); turn clockwise to tighten.
3 Gently press straight down and into place.
Pump Door Removal and Replacement (if needed).
Replacing the Sensor(s) (if needed).
1 Power off the monitor.
1 Identify the sensor to be removed.
2 Loosen the single captive screw on the pump module door.
2 Gently lift and remove the sensor.
3 Slide the door down and lift.
3 To add the new sensor, align its pins or connector(s), with the respective receptacles on the board.
4 The upper portion of the door has pegs on either side. The pegs fit into grooves where the door meets
4 Press down. A slight click indicates the sensor is securely in place. the module; they flex slightly for easy door removal. Angle the door so that one peg moves to the bottom
Replacing the Sensor Barrier (if needed). of its groove and the other moves the top of its groove. Lift to unhinge the pegs and remove the door.
To replace the sensor barrier assembly, follow instruction 1-5 below. 5 To properly place the new door, secure one of the pegs into its groove on the pump module.
To replace the entire case top, including its sensor barrier, skip to the next instruction set, “Reassembling
6 Angle the door and press the other peg into its groove.
the circuit board assembly and monitor.”
7 Close the door and slide up into place.
1 Observe the placement of the existing water barrier. Note that each cut-out is shaped to match the
sensor it protects. 8 Tighten the single captive screw on the pump door.
KEY FOR VENTIS MX4 MONITOR THREE-DIMENSIONAL DIAGRAM

VENTIS MX4 MONITOR THREE-DIMENSIONAL DIAGRAM
Number Part Number (P/N) Description
1 17152380-X Ventis MX4 Diffusion Case Top Assembly (includes items 2 and 3)
X = Case Color, where: 0 = Black, 1 = Orange
2 17152429 Sensor Barrier Assembly

3 17145285 Vibrating Motor
4 17150772 Ventis MX4 LCD Assembly
5 17134495 Ventis MX4 Sensor, Combustible Gas (LEL/CH4)
6 17134461 Ventis MX4 Sensor, Oxygen (O2)
7 17134487 Ventis MX4 Sensor, Carbon Monoxide (CO)
7 17155564 Ventis MX4 Sensor, Carbon Monoxide/Low Hydrogen Interference (CO/H2 Low)
8 17134479 Ventis MX4 Sensor, Hydrogen Sulfide (H2S)
9 17134503 Ventis MX4 Sensor, Nitrogen Dioxide (NO2)
10 17143595 Ventis MX4 Sensor, Sulfur Dioxide (SO2)
11 17147281 Captive Case Screw, Torx (torque value: 55 oz-in or .39 N.m +/- 10%)
11 17147273 Captive Case Screw, Phillips (torque value: 55 oz-in or .39 N.m +/- 10%)
12 17152506 Suspender Clip Spacer

13 17120528 Suspender Clip
14 17153137 Locking Washer
15 17152507 Screw, Phillips (for use with items 12, 13 and 14)
(torque value: 115 oz-in or .81 N.m +/- 10%)
16 17139262 Screw, Phillips (torque value: 115 oz-in or .81 N.m +/- 10%)
17 17134453-XY Lithium-ion Battery Kit

X = Battery Cover Color, where: 0 = Black, 1 = Orange
(captive screw torque value: 55 oz-in or .39 N.m +/- 10%)
Y=1: UL, CSA, ATEX, IECEx, GOST-R, GOST-K, KOSHA, MED, and SANS approvals
Y=2: MSHA
Y=3: China Ex
Y=4: ANZEx
Y=5: INMETRO
XY=0D: TIIS
18 17148313-Y Extended Range Lithium-ion Battery Pack

Y=1: UL, CSA, ATEX, IECEx, INMETRO, GOST-R, GOST-K, KOSHA, MED, SANS, and TIIS approvals
Y=2: MSHA
Y=3: China Ex
Y=4: ANZEx
19 17150608 Alkaline Battery Pack

UL, CSA, ATEX, IECEx, ANZEx, China MA, China KA, and INMETRO approvals (CSA, China MA, and
China KA approved for diffusion monitor only.)
20 17151184-XY Cover, Extended Range Lithium-ion or Alkaline

X = Cover Color, where: 0 = Black, 1 = Orange
(captive screw torque value: 55 oz-in or .39 n.m . +/- 10%)
Y=1: UL, CSA, ATEX, IECEx, GOST-R, GOST-K, and KOSHA approvals
Y=2: MSHA (Extended Range Lithium-ion only)
Y=3: China Ex
Y=4: ANZEx
Y=5: INMETRO
Y=C: China KA
* Item is not user replaceable. The Ventis MX4 monitor must be sent to an authorized ISC Service Center for this item to be replaced.
VENTIS MX4 PUMP MODULE THREE-DIMENSIONAL DIAGRAM 8 17151002 Captive Case Screw, Phillips (torque value: 55 oz-in or .39 N.m +/- 10%)
9 17151010 Captive Case Screw, Phillips (torque value: 55 oz-in or .39 N.m +/- 10%)
* Item is not user replaceable. The Ventis MX4 Pump Module must be sent to an authorized ISC Service Center for this item to be replaced.
►Products, Specifications, and Certifications

VENTIS MX4 ACCESSORIES AND PARTS
Docking and Calibration Stations
18108630-0BC DS2 Docking Station™ for Ventis MX4
B = Quantity of iGas® Readers
C = Power Cord, where 0 = US, 1 = UK, 2 = EU, 3 = AUS, 4 = ITA, 5 = DEN, 6 = SWZ
18108631-AB V•Cal ™ Calibration Station

A = Instrument Type, where 0 = Diffusion, 1 = Aspirated
B = Power Cord, where 0 = US, 1 = UK, 2 = EU, 3 = AUS, 4 = ITA, 5 = DEN, 6 = SWZ
Printer
18107763 Serial data dot matrix printer for V•Cal™ – 120 VAC powered
Chargers
18108191 Ventis Single-Unit Charger
18108209 Ventis Single-Unit Charger/Datalink
18108651 Ventis Single-Unit Automotive Charger, 12VDC
18108652 Ventis Single-Unit Truck-Mount Charger, 12VDC, with Cigarette Adapter
18108653 Ventis Single-Unit Truck-Mount Charger, 12VDC, Hard Wired
18108650-A Ventis 6-Unit Charger
Pumps
18108830 Ventis MX4 Hand Pump (manual bulb)
VTSP-ABCD Ventis MX4 Pump Module*
A = Battery Type, where 0 = No Battery, 2 = Li-ion Extended Range Battery Pack, 3 = Alkaline Battery Pack
B = Color, where: 0 = Black, 1 = Orange
C = Approvals, where 1 = UL and CSA; 2 = ATEX, and IECEx,; 3=MSHA; 4= ANZEx; 5 = China EX; 7 = GOST-R and
GOST-K; 8 = KOSHA; 9 = INMETRO; A = MED; and D = TIIS
KEY FOR VENTIS MX4 PUMP MODULE THREE-DIMENSIONAL DIAGRAM D = Assembly Guide language, where: 1 = English, 2 = French, 3 = Spanish, 4 = German, 5 = Italian, 6 = Dutch, 7 =
Portuguese, 9 = Russian, A = Polish, B = Czech, C = Chinese, D = Danish, E = Norwegian, F = Finnish, G = Swedish,
Number Part Number (P/N) Description J = Japanese
1 17151150-X0 Ventis MX4 Pump Door Assembly *Ventis MX4 Pump Module replacement parts
X = Pump Door Assembly Color, where: 0 = Black, 1 = Orange
(captive screw torque value: 55 oz. in. or .39 n.m . +/- 10%) 17151150-X0 Ventis MX4 Pump Door Assembly
X = Pump Door Assembly Color, where: 0 = Black, 1 = Orange
2 17129909 Pump Inlet Filter Cap
17129909 Pump Inlet Filter Cap
2 17141581 Pump Inlet-Filter Cap for use 6’ extendable probe
17152395 Water Barrier
2 17141599 Filter Cap, 1/8 NPT Female
17151275 Screw, Torx
3 17152395 Water Barrier
17052558 Screw
4 17151275 Screw, Torx (torque value: 55 oz-in or .39 N.m +/- 10%)
17148313-Y Extended Range Lithium-ion Battery Pack,
5 17052558 Screw (torque value: 25 oz-in or .17 N.m +/- 10%) Y = Approvals where:
1 = UL, CSA, ATEX, IECEx, INMETRO, GOST-R, GOST-K, KOSHA, and TIIS
6 17148313-Y Extended Range Lithium-ion Battery Pack 2 = MSHA
Y = Approval where: 3 = China Ex
1 = UL, CSA, ATEX, IECEx, INMETRO, GOST-R, GOST-K, KOSHA, and TIIS 4 = ANZEx
2 = MSHA
3 = China Ex 17151002 Captive Case Screw, Phillips
4 = ANZEx
17151028 Captive Case Screw, Torx
7 17150608 Alkaline Battery Pack: UL, ATEX, IECEx, ANZEx, and INMETRO approvals
(CSA, China KA and China MA approved for diffusion monitor only.) 17151010 Captive Case Screw, Phillips
17151036 Captive Case Screw, Torx 17148313-Y Extended Range Lithium-ion Battery Pack
Y = Approvals where:
17116096 Calibration Tubing Assembly with Integrated “T” Fitting (For use when calibrating a monitor 1 = UL, CSA, ATEX, IECEx, INMETRO, GOST-R, GOST-K, KOSHA, MED, SANS, and TIIS
with pump using a positive flow regulator) 2 = MSHA
3 = China Ex
Carrying Cases 4 = ANZEx
18108175 Ventis Diffusion Soft Carrying Case, Lithium-ion Battery (black) 17150608 Alkaline Battery Pack: UL, ATEX, IECEx, ANZEx, and INMETRO approvals (CSA, China KA
and China MA approved for diffusion monitor only.)
18109150 Ventis Diffusion Soft Carrying Case, Lithium-ion Battery (orange)
Conversion Kit** for the diffusion monitor.
18108183 Ventis Diffusion Soft Carrying Case, Extended Range Lithium-ion Battery or Alkaline (black) NOTE: For use in converting an aspirated monitor with a rechargeable Extended Range Lithium-ion battery pack to a diffusion monitor with a
rechargeable Extended Range Lithium-ion (or Alkaline) Battery Pack. (Batteries sold separately.) Kit parts listed below can be ordered separately as
18109151 Ventis Diffusion Soft Carrying Case, Extended Range Lithium-ion Battery or Alkaline replacement parts.
(orange)
**17151184-XY Cover, Extended Range Lithium-ion or Alkaline
18108813 Ventis Diffusion Hard Carrying Case with Display, Lithium-ion Battery X = Cover Color, where: 0 = Black, 1 = Orange
(captive screw torque value: 55 oz-in or .39 n.m . +/- 10%)
18108814 Ventis Diffusion Hard Carrying Case with Display, Extended Range Lithium-ion Battery or Y = Approvals where:
Alkaline 1 = UL, CSA, ATEX, IECEx, GOST-R, GOST-K, and KOSHA; MED (Lithium-ion only)
2 = MSHA (Extended Range Lithium-ion only)
18108815 Ventis Diffusion Hard Carrying Case without Display, Lithium-ion Battery 3 = China Ex
4 = ANZEx
18108816 Ventis Diffusion Hard Carrying Case without Display, Extended Range Lithium-ion Battery or 5 = INMETRO
Alkaline C = China KA
18108810 Ventis Aspirated Soft Carrying Case (black) **17152506 Suspender Clip Spacer
18109152 Ventis Aspirated Soft Carrying Case (orange) **17120528 Suspender Clip
18108811 Ventis Aspirated Hard Carrying Case with Display **17153137 Locking Washer
18108812 Ventis Aspirated Hard Carrying Case without Display ** 17152507 Screw, Phillips
Clip Assembly
17120528 Suspender Clip (for diffusion monitor with Lithium-ion Battery Pack)
MONITOR SPECIFICATIONS
17139262 Clip screw and washer (for diffusion monitor with Lithium-ion Battery Pack)
Item Description
Sensors, Sensor Barrier, Vibrating Motor, LCD, and Calibration Cup
Display Backlit Liquid Crystal Display (LCD)
17134495 Ventis MX4 Sensor, Combustible Gas (LEL/CH4)
Buttons Two (ON/OFF/MODE and ENTER)
17134461 Ventis MX4 Sensor, Oxygen (O 2)
Monitor case Polycarbonate with ESD protective rubber overmold
17134487 Ventis MX4 Sensor, Carbon Monoxide (CO)
Alarms Ultra-bright LEDs, loud audible alarm (95dB at 30 cm), and vibrating alarm
17155564 Ventis MX4 Sensor, Carbon Monoxide/Low Hydrogen Interference (CO/H2 Low)
Size and Weight Diffusion with Lithium-ion (typical) Aspirated with Extended Range
17134479 Ventis MX4 Sensor, Hydrogen Sulfide (H2S) Lithium-ion (typical)
17134503 Ventis MX4 Sensor, Nitrogen Dioxide (NO2) Size 103 mm x 58 mm x 30 mm 172 mm x 67 mm x 66 mm
17143595 Ventis MX4 Sensor, Sulfur Dioxide (SO2) (4.1” x 2.3” x 1.2”) (6.8” x 2.6” x 2.6”)
17152380-X Diffusion Case Top Assembly (includes Sensor Barrier Assembly) Weight 182 g (6.4 oz) 380 g (13.4 oz)
X = Case Top Color, where: 0 = Black, 1 = Orange
17152429 Sensor Barrier Assembly

17145285 Vibrating Motor OPERATING CONDITIONS
Warm-up time 40 seconds (includes stabilization time)
17150772 Ventis MX4 LCD Assembly
Temperature range -20 °C to +50 °C (-4 °F to +122 °F)
17156189 Ventis Calibration Cup Assembly, calibration cup with tubing
Humidity range 15–95% relative humidity (RH) noncondensing (during continuous operation)
17152455 Ventis Calibration Cup
Battery Packs and Components Pressure range 1 atm ±20%
17134453-XY Lithium-ion Battery Kit
X = Battery Cover Color, where: 0 = Black, 1 = Orange
(captive screw torque value: 55 oz-in or .39 N.m +/- 10%)
Y = Approvals where:
1 = UL, CSA, ATEX, IECEx, GOST-R, GOST-K, KOSHA, MED, and SANS
2 = MSHA
3 = China Ex
4 = ANZEx
5 = INMETRO
XY=0D; TIIS
STORAGE CONDITIONS
Temperature range 0−25 ºC (32−77 ºF) The numbers were measured under these environmental conditions: 20 °C (68 °F) , 50% RH and 1 atm.
Humidity range 40–70% relative humidity (RH) noncondensing The specified cross-interference numbers apply to new sensors only, and may vary with time as well as from sensor
to sensor.
Pressure range 0.9–1.1 atm
“—” means no data available.
Maximum time Up to 6 months
Note: Industrial Scientific recommends that infrequently used lithium-ion batteries be This table is given as a reference only and is subject to change.
fully charged every four months.
LEL AND LEL CORRELATION FACTORS FOR COMBUSTIBLE GASES
SENSOR SPECIFICATIONS Sample gas* LEL LEL correlation factors
Gas Name Abbr. Measuring Resolution Accuracy at Time and Response Response (% vol)
Calibration gas
Range Temperature of Time Time
Calibration* (typical) (typical) Butane Hexane Hydrogen Methane Pentane Propane
T50 T90
Acetone 2.5% 1.00 0.70 1.70 1.70 0.90 1.10
Oxygen O2 0–30% vol 0.1% vol ± 0.5% 15 30
Acetylene 2.5% 0.70 0.60 1.30 1.30 0.70 0.80
Carbon Monoxide CO/H2 0–1000 ppm 1 ppm ± 5% (0-300 ppm) 8 17 Benzene 1.2% 1.10 0.80 1.90 1.90 1.00 1.20
with low H2 Low ± 15% (301-1000 ppm)
Butane 1.9% 1.00 0.58 1.78 1.67 0.83 1.03
interference
Ethane 3.0% 0.80 0.60 1.30 1.30 0.70 0.80
Carbon Monoxide CO 0–1000 ppm 1 ppm ± 5% 15 50
Ethanol 3.3% 0.89 0.52 1.59 1.49 0.74 0.92
Hydrogen Sulfide H 2S 0–500 ppm 0.1 ppm ± 5% 15 30 Ethylene 2.7% 0.80 0.60 1.40 1.30 0.70 0.90
Hexane 1.1% 1.71 1.00 3.04 2.86 1.42 1.77
Nitrogen Dioxide NO2 0–150 ppm 0.1 ppm ± 10% 10 30
Hydrogen 4.0% 0.56 0.33 1.00 0.94 0.47 0.58
Sulfur Dioxide SO2 0–150 ppm 0.1 ppm ± 10% 20 80 Isopropanol 2.0% 1.10 0.90 2.00 1.90 1.00 1.20
Methane 5.0% 0.60 0.35 1.06 1.00 0.50 0.62
Combustible LEL 0–100% LEL 1% LEL ± 5% 15 35
Methanol 6.0% 0.60 0.50 1.10 1.10 0.60 0.70
Methane CH4 0–5% vol 0.01% vol ± 5% 15 35 Nonane 0.8% 2.22 1.30 3.95 3.71 1.84 2.29
*The accuracy specification for each sensor is ± the stated percentage or 1 unit of resolution, whichever is greater. Pentane 1.4% 1.21 0.71 2.15 2.02 1.00 1.25
Propane 2.1% 0.97 0.57 1.72 1.62 0.80 1.00
Styrene 0.9% 1.30 1.00 2.20 2.20 1.10 1.40
TOXIC GAS SENSOR CROSS-SENSITIVITY TABLE
Toluene 1.1% 1.53 0.89 2.71 2.55 1.26 1.57
Xylene 1.1% 1.50 1.10 2.60 2.50 1.30 1.60
Target Gas Sensor
JP-4 — — — — — 1.20 —
CO JP-5 — — — — — 0.90 —
(H2
CO Low) H2S SO2 NO2 Cl2 ClO2 HCN HCl PH3 NO H2 NH3 JP-8 — — — — — 1.50 —
CO 100 100 1 1 0 0 0 0 0 0 0 20 0
NOTE: The table above provides the LEL for select combustible gases*. It also provides correlation factors that help the safety
H2S 5 5 100 1 -40 -3 -25 10 300 25 10 20 25 technician and instrument operator determine the actual percentage LEL when the sample gas differs from the gas that was used to
calibrate the unit.
SO2 0 5 5 100 0 0 0 — 40 — 0 0 -40 For example, if the unit reads 10% LEL in a pentane atmosphere, and was calibrated to methane, the actual percentage LEL is
NO2 -5 5 -25 -165 100 45 — -70 — — 30 0 -10 determined as follows:
1. Locate the table cell where the sample gas (pentane) intersects with the calibration gas (methane).
Cl2 -10 0 -20 -25 10 100 60 -20 6 -20 0 0 -50 2. Multiply the cell's value (2.02) by the unit's LEL reading (10%) to calculate the actual concentration of 20.2% LEL.
ClO2 — — — — — 20 100 — — — — — — * The combustible gas list is not a comprehensive list of all combustible gases that can be detected by the Ventis MX4. For
HCN 15 — 10 50 1 0 0 100 35 1 0 30 5 additional information about combustible gas detection and the Ventis MX4, contact the ISC Technical Service department.
HCl 3 — 0 5 0 2 0 0 100 0 15 0 0
PH3 — — — — — — -100 425 300 100 — — —
NO 25 40 1 1 5 — — -5 — — 100 30 0
H2 22 3 0.3 0.5 0 0 0 0 0 0 0 100 0
NH3 0 0 0 0 0 0 0 0 0 0 0 0 100
The Sensor Cross Sensitivity Table (above) reflects the percentage response provided by the sensor (top row) when
exposed to a known concentration of the target gas (column 1).
CERTIFICATIONS ►Warranty
Directive/Code Certification Marking
Industrial Scientific Corporation's Ventis MX4 portable gas monitors are warranted to be free from defects in material and workmanship for
ATEX Ex ia IIC T4 Ga and Ex ia I Ma; a period of two years after purchase. This warranty includes the sensors, the pump, and the lithium-ion battery pack as shipped with the
Equipment Group and Category II 1G and I M1; Ventis MX4.
IP66; IP67
Filters are warranted to be free from defects in material and workmanship for 18 months from date of shipment, or one year from
ANZEx Ex ia s Zone 0 I/IIC T4; IP66; IP67 date of first use, whichever occurs first, except where otherwise stated in writing in Industrial Scientific literature.
China Ex Ex ia IIC T4 Ga
China CMC Metrology Approval LIMITATION OF LIABILITY
INDUSTRIAL SCIENTIFIC MAKES NO OTHER WARRANTIES, EITHER EXPRESSED OR IMPLIED, INCLUDING BUT NOT
China KA Ex ia d I Mb; Metalliferous and nonmetallic l Mine LIMITED TO THE WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE.
China MA Approved for Underground Mines; diffusion (without pump) alkaline version SHOULD THE PRODUCT FAIL TO CONFORM TO THE ABOVE WARRANTY, BUYER’S ONLY REMEDY AND INDUSTRIAL
only SCIENTIFIC’S ONLY OBLIGATION SHALL BE, AT INDUSTRIAL SCIENTIFIC’S SOLE OPTION, REPLACEMENT OR REPAIR OF
SUCH NON-CONFORMING GOODS OR REFUND OF THE ORIGINAL PURCHASE PRICE OF THE NON-CONFORMING
CSA Class I, Division 1, Groups A B C D, T4; Ex d ia IIC T4 GOODS.
C22.2 No. 152 for %LEL reading only
IN NO EVENT WILL INDUSTRIAL SCIENTIFIC BE LIABLE FOR ANY OTHER SPECIAL, INCIDENTAL, OR CONSEQUENTIAL
GOST – R and GOST - K PBExdiaI X and 1ExdiaIICT4 X DAMAGES, INCLUDING LOSS OF PROFIT OR LOSS OF USE, ARISING OUT OF THE SALE, MANUFACTURE, OR USE OF
ANY PRODUCTS SOLD HEREUNDER WHETHER SUCH CLAIM IS PLEADED IN CONTRACT OR IN TORT, INCLUDING
IECEx Ex ia IIC T4 Ga; IP66; IP67 STRICT LIABILITY IN TORT.
It shall be an express condition to Industrial Scientific’s warranty that all products be carefully inspected for damage by Buyer upon
INMETRO Ex ia IIC T4 Ga; IP66; IP67
receipt, be properly calibrated for Buyer’s particular use, and be used, repaired, and maintained in strict accordance with the
-20°C ≤ Ta ≤ +50 °C instructions set forth in Industrial Scientific’s product literature. Repair or maintenance by non-qualified personnel will invalidate the
KOSHA Ex d ia IIC T4 warranty, as will the use of non-approved consumables or spare parts. As with any other sophisticated product, it is essential and a
condition of Industrial Scientific’s warranty that all personnel using the products be fully acquainted with their use, capabilities, and
MED Portable Multigas Detector; Category 2 (MED 2012/32/EU); Li-Ion only limitations as set forth in the applicable product literature.
Charger/Docking Station accessories; category 1
Buyer acknowledges that it alone has determined the intended purpose and suitability of the goods purchased. It is expressly
MSHA Permissible for Underground Mines; li-ion versions only agreed by the parties that any technical or other advice given by Industrial Scientific with respect to the use of the goods or services
SANS-1515 SANS 1515-1 is given without charge and at Buyer’s risk; therefore, Industrial Scientific assumes no obligations or liability for the advice given or
results obtained.
Type A; Ex ia I/IIC T4 IP66/67; Li-Ion only
TIIS Ex ia IIC T4 X
UL Class I, Division 1, Groups A B C D, T4; Zone 0, AEx ia IIC T4

Class II, Groups F G (Carbonaceous and Grain Dust);
Class I, Zone 0, AEx ia IIC T4
IP66 ; IP67
Marking Requirements
ATEX Markings IECEx Markings
Industrial Scientific Corp. Industrial Scientific Corp.
15071 USA 15071 USA
VENTIS MX4 VENTIS MX4
DEMKO 10 ATEX 1006410 IECEx UL10.0034
Ex ia IIC T4 Ga / Ex ia I Ma IP 66/67 Ex ia IIC T4 Ga IP 66/67
o o o o
-20 C ≤ Ta ≤ +50 C -20 C ≤ Ta ≤ +50 C
[Serial Number] [Month/Year of Production] [Serial Number] [Month/Year of Production]
Charging contact parameters: Um = 6.2V; Ii = 1.3A Charging contact parameters: Um = 6.2V; Ii = 1.3A
EN 60079-29-1; EN 50104
Diffusion Version: Aspirated Version:
Warning: Do not recharge or replace battery in hazardous Warning: Do not recharge or replace battery in hazardous
locations. Replace only with P/N 17148313-1, P/N locations. Replace only with P/N 17148313-1 or P/N 17050608
17134453-X1, or P/N 17050608
Li-Ion Battery Packs, P/N 17148313-1 or P/N 17134453-X1 Alkaline Battery Pack, P/N 17150608
Warning: Only charge instrument in non-hazardous Warning: Only replace batteries in non-hazardous locations;
locations. Charging contact parameters: Um = 6.2V; Ii = Only approved for use with three (3) AAA battery types Duracell
1.3A; Do Not Connect in Hazardous Locations MN2400 and Energizer EN92. Replace all batteries at the same
time.
Warning: Read and understand manual before use.
Warning: Read and understand manual before use.
Ventis™ MX4 Product Manual
►Ventis MX4 Resource Center

Product documentation.
Online training.
And more!
www.indsci.com/ventis
Contact Information
Industrial Scientific Corporation
1 Life Way
Pittsburgh, PA 15205-7500
USA
Web: www.indsci.com
Phone: +1 412-788-4353 or 1-800-DETECTS (338-3287)
E-mail: info@indsci.com To locate a nearby distributor of our products or an
Fax: +1 412-788-8353 Industrial Scientific service center or business
office, visit us at www.indsci.com.
Industrial Scientific France S.A.S.
5 Rue Frédéric Degeorge, CS 80097 Rendez-vous sur notre site Web www.indsci.com, si
vous voulez trouver un distributeur de nos produits
62002 Arras Cedex,
près de chez vous, ou, si vous recherchez un
France centre de service ou un bureau Industrial Scientific.
Web: www.indsci.com
Phone: +33 (0)1 57 32 92 61 Besuchen Sie uns unter www.indsci.com, um einen
E-mail: info@eu.indsci.com Vertriebshändler unserer Produkte oder ein
Fax: +33 (0)1 57 32 92 67 Servicecenter bzw. eine Niederlassung von
Industrial Scientific zu finden.
英思科传
Para buscar un distribuidor local de nuestros
地址：中国上海市浦区 290号 productos o un centro de servicio u oficina
编 201206 comercial de Industrial Scientific, visite
话 +86 21 5899 3279 www.indsci.com.
+86 21 5899 3280
如需查找就近的产品经销商或 Industrial
传
E-mail： info@ap.indsci.com Scientific
网址： www.indsci.com 服务中心或业务办事处，请访问我们的网
服热线 +86 400 820 2515 站 www.indsci.com。
51 © 2015 Industrial Scientific Corporation
22/7/2019 HN 2140
DIAPHRAGM AIR PUMP
22/7/2019 HN 2140
BUTTERFLY VALVES
The art of power and perfection
PNEUMATIC ACTUATORS
RACK AND PINION
RACK AND PINION
Aluminium housing
TORQUES UP TO
6.500 Nm
ACTUATORS IN

14 different sizes

We are a manufacturer of rack and pinion aluminium housing actuators with torque gures up to
6,500 Nm and scotch yoke actuators for heavy duty service up to 700.000 Nm. Our products offer
reliable and dependable automation for ¼ turn valves.
Engineered and built to withstand most of the applications and environmental conditions, the
precision in design and quality provides a long and safe operational performance in valve control.
ACTREG has invested in quality assurance, state-of-the-art machining and testing facilities in order
ACTREG, established in 1992, is a multinational
to assist customers in safely controlling their processes.
company specializing in the manufacture and
ACTREG engineers are happy to help you with your automation requirements.
sales of high quality actuators for valves requiring
a rotary quarter turn movement for either On/Off
or modulating duty. The expertise and know how
ESTABLISHED IN
has made ACTREG leader in actuation technology.
1992
INTERNATIONAL
Distribution
DESIGN &
Quality
PERSONALIZED
ACTREG provides world coverage thanks to the
strategic locations of its factories and of ces. The
Service
international distribution ensures quick availability
and more important, personalized service for valve
manufacturers, valve stocking distributors and
contractors.
www.actreg.com |1| |2| www.actreg.com
MAIN FEATURES
& CHARACTERISTICS
1 BODY POSITION INDICATOR

5
The body is hard anodized aluminum with low surface Multi-function indicator suitable for mechanical or
roughness making it extremely abrasion resistant. Every inductive switches is a standard feature. There are many
single actuator is tested and provided with a unique different combinations so no need for external indicators.
serial number for traceability. This heat number is
stamped on the body. 6 SPRINGS
This system allows an easy t for the necessary torque
Certificates 2 PINION to open or close the valve which offers safe replacement
SCOTCH YOKE
The carbon steel shaft is electroless nickel plated that and manipulation.
Heavy duty service protects against external and internal corrosion and is an
anti-blowout design. 7 END CAPS
ACTREG, S.A. has a Quality Management System certi ed The are different end caps for double acting and spring
TORQUES UP TO
in accordance with the requirements of ISO 9001:2008 for 3 ADJUSTMENT STROKE return for quick and safe identi cation without need to
700.000 Nm External stroke adjustment for 5 degree is placed on read label. End caps are epoxy coated as a standard
the design, development, manufacturing and distribution of
opposite side of Namur connection for better manipulation protecting them against environmental corrosion.
pneumatic actuators and accessories for valves. Certi ed by when the solenoid valve is assembled.
ACTUATORS IN
BVQI No. ESPMDD005463. 8 CONNECTION VDI/VDE 3845
29 different sizes 4 PISTONS The assembly of switch boxes, proximity switches
ADA/ASR 10 up to ADA/ASR 300 are classi ed as category Pistons are coated with a special treatment for corrosion or positioners take place by means of the Namur
SEP in accordance with the requirements of Pressure resistance. Backlash is avoided by a special tooth connection VDI/VDE 3845, which is a standard feature
machining. The pistons have a 3-way guide for low in all of our models. The height of the axis for all our
Equipment Directive 97/23/EC. ADA/ASR 500 up to ADA/
friction between body and pistons. The pistons are also products is 30mm, which means with a single model box
ASR 4000 are classi ed as Category I, Procedure module A. provided with an integral guide machined between or positioner all manufacturing ranges can be covered.
pistons and pinion.
All ACTREG pneumatic actuators are classi ed for use in
potentially explosive atmospheres as Group II Category 2,
suitable for zones 1, 2, 21 and 22 in accordance with Annex
VIII of Directive 94/9/CE (ATEX). Technical le is deposited to
LCIE, No. LCIE 05 AR 022. 3 1 8 2
ACTREG pneumatic actuators have SIL 3 (Safety Integrity level
3) certi cate. The ACTREG actuators meets manufacturer
design process requirements of Safety Integrity Level (SIL)
5 4 6 7
3. This is intended to achieve suf cient integrity against
systematic errors of design by the manufacturer.
Multi-function
Types of Actuators position indicator
Double Acting & Spring Return
PARTS & MATERIALS
1 Body
ADA ASR Aluminium Hard Anodized
DOUBLE SPRING
ACTING RETURN 2 Piston
ACTUATOR ACTUATOR Aluminium
Inductive switch indicating
open or closed position 3 Pinion
Nickel Plated Carbon Steel
4 End Caps
Rack and pinion design | Linear torque | Rotation angle 90º ± 5º | Antifriction sliding bearings |
Aluminium Epoxy Coated
Long life without maintenance | Total safety for springs replacement | Mounting of solenoid valves
acc. NAMUR Std. | Mounting of devices acc. NAMUR VDI/VDE 3845 Std. | Coupling according 25
5 Soft Pinion Washer *
to ISO 5211 and DIN 3337 (Octogonal drive) | Multi-function position indicator suitable for Polyamide PA 6,6
mechanical and inductive direct switches.
6 Slide Piston * 113
Working temperature: Polyamide PA 6,6 + 30% G.F.
-30 ºC to 100 ºC in Standard Construction. Mechanical switches indicating 4
-15 ºC to 150 ºC with FKM O-rings (high temperature execution). open and close 7 Lug **
-40 ºC to 80 ºC with Silicone O-rings (low temperature execution). Nickel Plated Carbon Steel
-60º C to 80º C with Silicone O-rings and 316 pinion (extreme low temperature).
8 Pinion Washer
Maximum working pressure: Stainless Steel
8 bar (116 psig). (Except ADA10 at 10 barg)
10 Upper Pinion Bearing
Polyamide PA 6,6 (bronze
Bi-Directional Coatings for special for sizes 500 and 2100)
Travel Stops applications 12
Stop
Inductive switches indicating ASTM A 105
ACTREG pneumatic actuators are provided Actreg Pneumatic actuators are protected open and closed position
with bi-directional pinion travel stops. against external corrosion by proper material 14 Spring’s Long Support
selection or surface treatment. Polyamide PA 6,6
Side located stops allow a full ± 5º travel
adjustment between 85º and 95º. These travel Standard execution 15 Spring’s Short Support
stops are designed to absorb the maximum Anticorrosive C3 according to EN-ISO 12944-2 Polyamide PA 6,6
rated torque of the actuator and the maximum PARTS DESCRIPTION COATING
impact loads associated with recommended BODY Hard anodized 25-30 µm 16 Leveling Screw
travel speed. END CAPS Epoxy painted 80-90 µm Stainless Steel
STEM Carbon Steel + ENP 25-30 µm
Adjustment of the travel limits are accom- SCREWS A2 18 Bolt
plished by unscrewing the locking nuts, Namur connection for direct Stainless Steel
turning the respective left and right stop studs Execution A mounting switch box
to reduce or increase the travel angle and Anticorrosive C5-I/C5-M according to EN-ISO 12944-2 19 Spring 109
screwing the locking nuts. PARTS DESCRIPTION COATING DIN 2076 · D-5.6
BODY Epoxy painted 200-300 µm
END CAPS Epoxy painted 140-180 µm 20 Position Indicator
STEM SS 316 Polypropylene
SCREWS A4 POSITION INDICATOR
21 Cam 113 Bolt
95º
Polypropylene Stainless Steel FROM SIZE 20 TO 850 FROM SIZE 1200 TO 4000
90º
85º
Execution B
Anticorrosive C4 according EN-ISO 12944-2 Centering Ring O-Ring *
23 118
PARTS DESCRIPTION COATING Nickel Plated Carbon Steel NBR
Inductive switches indicating
BODY Epoxy painted 80-90 µm
open and closed position
END CAPS Epoxy painted 80-90 µm Slide Guide * 119 O-Ring *
(45º detecting switches…) 25
STEMS Carbon Steel + ENP Polyamide PA 6,6 + 30% G.F. NBR
SCREWS A2
26 Lower Pinion Bearing * 125 Washer

Polyamide PA 6,6 Stainless Steel
Options On Request
109 O-Ring * 471 Slip Washer *
· Locking device with padlock. NBR Stainless Steel
· Fast acting actuators.
110 O-Ring * 934 Nut Inserts
· 100% travel adjustment stroke. NBR Stainless Steel Stainless Steel
· Fire proof systems (K-mass, blanket). Inductive switches indicating
open and closed position 111 O-Ring * 985 Nut Position indicator & Cams
(up/down detecting switches…)© ERMA FIRST ESKNBR
ENGINEERING SOLUTIONSStainless
SA All Steel
rights reserved | Confidential | Pages 404
Polypropylene

GENERAL DIMENSIONS
20 985 118
18 15 SIZES 10 | 20 | 40 | 80 | 130 | 200 | 300 | 500 | 850

19
21 14
10
111
471
3 5
SIZES 1200 | 1750
119
125
934
2
6
1
16
SIZE 2100
26
110
12
4
23
DOUBLE ACTING & SPRING RETURN ACTUATORS GENERAL DIMENSIONS (mm)
SIZE A A’ B C D E F I R øS ISO 5211 øL MxV ISO 5211 øL1 M1xV1 øT X U

10 - 100 76 56 33 23 9 6 9 12,5 F03 36 M5x8 - - - 11 2 12
20 163 145 96 76 48 34 9 12,5 9 12,5 F03 36 M5x8 F05 50 M6x10 25 2 10
20 163 145 96 76 48 34 9 12,5 14 18,1 F05 50 M6x10 - - - 35 3 12
20 163 145 96 76 48 34 9 12,5 14 18,1 F04 42 M5x10 - - - 35 3 12
40 195 158 115 91 56 45 9 12,5 14 18,1 F04 42 M5x10 - - - 35 3 12
40 195 158 115 91 56 45 9 12,5 14 18,1 F05 50 M6x10 - - - 35 3 12
* Recommended spare parts. 80 217 177 137 111 66 55 12 12,5 17 22,5 F05 50 M6x10 F07 70 M8x16 55 3 19
** Only for sizes 2500 & 4000.
130 258 196 147 122 71 60 12 12,5 17 22,5 F05 50 M6x10 F07 70 M8x16 55 3 22
200 299 225 165 135.5 78 70 12 12,5 17 22,5 F07 70 M8x16 F10 102 M10x16 55 3 23

DOUBLE ACTING ACTUATOR TORQUE OUTPUT (Nm)
3 bar 3,5 bar 4 bar 4,5 bar 5 bar 5,5 bar 6 bar 6,5 bar 7 bar 8 bar 10 bar
Size Weight
0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º (kg)
10 3 4 4,5 5,1 6 6,5 7 7,5 8,2 9,1 11 0,64
SIZE 2500 20 9,7 11,4 13 14,6 16,2 17,8 19,5 21,1 23 26 - 1,4
40 20,3 23,7 27,1 30,5 33,9 37,3 41 44 47 54 - 2,1
80 38,5 44,9 51,3 57,7 64,1 70,5 77 83 90 103 - 3
130 59,1 68,9 78,7 88,6 98,4 108,3 118 128 138 157 - 3,8
200 88 102 117 131 146 161 175 190 205 234 - 5,6
300 145 170 194 218 242 267 291 315 339 388 - 8,5
500 217 253 289 325 361 397 433 469 505 577 - 11,2
850 359 419 479 538 598 658 718 778 837 957 - 16,9
1200 519 606 692 779 865 952 1038 1125 1211 1384 - 25,8
1750 707 824 942 1060 1178 1295 1413 1531 1649 1884 - 32,5
2100 1086 1267 1448 1629 1810 1991 2172 2353 2534 2896 - 49,7
2500 1730 2019 2307 2596 2884 3172 3461 3749 4038 4614 - 69,6
4000 2408 2809 3210 3612 4013 4414 4816 5217 5618 6421 - 129,4
SPRING RETURN ACTUATOR TORQUE OUTPUT (Nm)

Spring
Type 3 bar 3,5 bar 4 bar 4,5 bar 5 bar 5,5 bar 6 bar 6,5 bar 7 bar 8 bar Stroke
Size END START Weight
Pressure (kg)
0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º
S04 8 5 9 7 11 8 13 10 14 12 16 13 17 15 19 17 22 20 4 7 1,51
20 S06 A 11 7 12 9 14 10 15 12 17 13 20 17 7 11 1,54
S08 10 5 12 7 14 9 15 10 18 14 9 15 1,56
SIZE 4000 S04 16 14 20 17 23 20 26 24 30 27 33 30 37 34 40 37 43 41 50 47 5 8 2,17
S06 14 10 18 14 21 17 24 20 28 24 31 27 34 30 38 34 41 37 48 44 7 12 2,20
S08 15 10 19 14 22 17 26 20 29 24 32 27 36 30 39 34 46 41 10 16 2,23
40
S10 20 14 24 17 27 20 30 24 34 27 37 30 44 37 12 20 2,26
S12 21 13 25 17 28 20 32 24 35 27 42 34 15 24 2,29
S14 A 23 13 26 17 30 20 33 24 40 30 17 28 2,32
S04 31 27 38 34 44 40 50 46 57 53 63 59 70 66 76 72 82 78 95 91 9 13 3,28
S06 27 21 34 28 40 34 47 41 53 47 59 53 66 60 72 66 79 73 92 86 13 20 3,36
S08 37 29 43 35 49 41 56 48 62 54 69 61 75 67 88 80 17 27 3,43
80
S10 39 29 46 36 52 42 59 49 65 55 71 61 84 74 22 33 3,51
S12 42 30 48 36 55 43 61 49 68 56 81 69 26 40 3,58
S14 A 45 31 51 37 58 44 64 50 77 63 30 47 3,65
S06 43 36 52 46 62 56 72 65 82 75 92 85 102 95 111 105 121 115 141 134 19 27 4,40
S08 47 38 57 48 67 58 76 68 86 77 96 87 106 97 116 107 135 127 26 36 4,50
130 S10 51 40 61 50 71 60 81 70 91 80 100 89 110 99 130 119 32 45 4,60
S12 56 42 65 52 75 62 85 72 95 82 105 92 124 111 39 54 4,70
S14 A 70 54 80 64 89 74 99 84 119 103 45 64 4,80
S06 61 49 76 63 90 78 105 92 119 107 134 122 149 136 163 151 178 166 207 195 31 46 6,50
S08 67 50 81 65 96 79 111 94 125 109 140 123 154 138 169 152 198 182 42 61 6,70
200 S10 72 52 87 66 102 81 116 96 131 110 146 125 160 139 189 169 52 77 6,90
S12 78 53 93 68 107 83 122 97 137 112 151 126 180 156 63 92 7,00
S14 A 99 70 113 84 128 99 142 113 172 143 73 107 7,30
S06 102 75 126 99 151 123 175 148 199 172 223 196 247 220 272 245 296 269 344 317 51 83 9,65
S08 112 76 136 100 160 124 185 148 209 173 233 197 257 221 281 245 330 294 68 111 9,92
300 S10 122 76 146 101 170 125 194 149 219 173 243 198 267 222 315 270 85 138 10,20
ISO 5211 DETAIL S12 131 77 156 101 180 126 204 150 228 174 253 198 301 247 102 166 10,50
S14 A 165 102 190 126 214 151 238 175 287 223 119 193 10,80
S06 152 119 188 155 224 191 260 227 296 263 333 299 369 335 405 371 441 407 513 480 76 115 13,33
SIZES SIZES SIZE S08 131 86 167 122 203 158 239 194 275 231 311 267 347 303 383 339 419 375 492 447 101 153 13,84
10 | 20 | 40 | 500 | 1750 | 2100 | 2500 20 | 80 | 130 | 200 | 300 | 850 | 1200 4000 500 S10 181 126 217 162 254 198 290 234 326 270 362 306 398 342 470 414 126 192 14,35
S12 196 129 232 165 268 201 304 238 340 274 376 310 449 382 152 230 14,85
S14 A 247 169 283 205 319 241 355 277 427 349 177 268 15,36
S06 260 209 320 269 380 328 440 388 500 448 559 508 619 568 679 627 739 687 858 807 116 177 19,7
S08 227 159 287 218 347 278 407 338 467 398 526 458 586 518 646 577 706 637 826 757 155 236 20,3
850 S10 254 168 314 228 374 288 434 348 494 408 553 467 613 527 673 587 793 707 193 295 20,9
S12 341 238 401 298 461 358 521 417 580 477 640 537 760 657 232 353 21,6
S14 A 428 307 488 367 547 427 607 487 727 607 271 412 22,2
S06 373 289 460 376 546 462 633 549 720 635 806 722 893 808 979 895 1066 981 1239 1154 171 271 30,1
S08 325 213 411 299 498 386 584 472 671 559 758 645 844 732 931 818 1017 905 1190 1078 229 361 31,1
1200 S10 276 136 363 222 449 309 536 395 622 482 709 569 795 655 882 742 969 828 1142 1001 286 451 32,2
S12 401 232 487 319 574 405 660 492 747 578 833 665 920 751 1093 924 343 541 33,2
S14 A 525 329 612 415 698 502 785 588 871 675 1044 848 400 631 34,3
S06 477 349 595 466 712 584 830 702 948 820 1066 937 1183 1055 1301 1173 1419 1291 1654 1526 270 421 39,3
S08 400 229 518 347 636 465 754 582 871 700 989 818 1107 936 1225 1053 1342 1171 1578 1407 360 562 41,0
1750 S10 441 228 559 345 677 463 795 581 912 699 1030 816 1148 934 1266 1052 1501 1287 451 702 42,7
S12 600 344 718 461 836 579 954 697 1071 815 1189 933 1425 1168 541 843 44,4
S14 A 642 342 759 460 877 578 995 695 1113 813 1348 1049 631 983 46,0
S06 702 509 883 690 1064 871 1245 1052 1426 1233 1607 1414 1788 1595 1969 1776 2150 1957 2512 2319 384 577 60,3
S08 574 316 755 497 936 678 1117 859 1298 1040 1479 1221 1660 1402 1841 1583 2022 1764 2384 2126 512 770 62,5
2100 S10 627 305 808 486 989 667 1170 848 1351 1029 1532 1210 1713 1391 1894 1572 2256 1934 640 962 64,2
DOUBLE ACTING & SPRING RETURN ACTUATORS GENERAL DIMENSIONS (mm) S12 861 474 1042 655 1223 836 1404 1017 1585 1198 1766 1379 2128 1741 768 1154 66,3
S14 A 914 463 1095 644 1276 825 1457 1006 1638 1187 2000 1549 896 1347 68,0
SIZE A A’ B C D E F I R øS ISO 5211 øL MxV ISO 5211 øL1 M1xV1 øT X U S06 1299 1045 1587 1333 1876 1622 2164 1910 2453 2199 2741 2487 3029 2775 3318 3064 3606 3352 4183 3929 508 806 85,9
S08 1155 816 1444 1105 1732 1393 2020 1682 2309 1970 2597 2258 2886 2547 3174 2835 3462 3124 4039 3700 677 1075 89,4
300 348,5 273 182 152,5 86 80 12 12,5 22 28,5 F07 70 M8x16 F10 102 M10x16 70 3 24 2500 S10 1300 876 1588 1165 1877 1453 2165 1742 2453 2030 2742 2318 3030 2607 3319 2895 3895 3472 846 1344 92,9
500 397 304 199 173 96 85 12 12,5 22 28,5 F10 102 M10x16 - - - 70 3 32 S12 1444 936 1733 1225 2021 1513 2310 1802 2598 2090 2886 2378 3175 2667 3752 3243 1015 1613 96,4
850 473 372 221 191,5 106 98 12 12,5 27 36,5 F10 102 M10x17 F12 125 M12x20 85 3 39 S14 A 1589 996 1877 1285 2166 1573 2454 1861 2742 2150 3031 2438 3608 3015 1184 1882 99,9
1200 560 439 249 212,5 116 114 16 18,6 36 48,5 F10 102 M10x17 F14 140 M16x26 100 4 48 S06 1763 1262 2165 1663 2566 2065 2967 2466 3369 2867 3770 3269 758 1348 158,7
1750 601 461 280 242,5 131 130 16 18,6 36 48,5 F14 140 M16x26 - - - 100 4 50 S08 1549 880 1950 1282 2351 1683 2752 2084 3154 2485 3555 2887 3956 3288 4358 3689 4759 4091 5068 4399 1011 1797 164,7
2100 702 510 313 276,5 148 147 16 18,6 46 60,1 F16 165 M20x29 - - - 130 4 50 4000 S10 2136 1301 2538 1702 2939 2104 3340 2505 3742 2906 4143 3307 4544 3709 4853 4017 1264 2246 170,8
2500 738 518 383 356 177,5 176,5 16 18,6 46 60,2 F16 165 M20x29 - - - 130 4 58 S12 2323 1320 2724 1722 3125 2123 3527 2524 3928 2926 4329 3327 4638 3636 1516 2696 176,9
4000 940 630 434 415 213 201 16 18,6 55 72,5 F16 165 M20x30 F25 254 M16x30 200 4 60 S14 A 2911 1741 3312 2142 3713 2544 4115 2945 4423 3254 1769 3145 182,9
Note: A=Standard
www.actreg.com |9| | 10 | www.actreg.com
DOUBLE ACTING ACTUATOR TORQUE OUTPUT (inch lb)
Size
43.5 psi 50 psi 60 psi 70 psi 80 psi 90 psi 100 psi 110 psi 116 psi 145 psi
Weight
OTHER PRODUCTS
0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º (lb)
10 27 35 41 50 58 64 71 77 81 97 1.4
20 86 99 119 139 158 179 200 219 230 - 3.1
40 180 207 248 290 331 374 411 453 478 - 4.6 SY SERIES
80 341 392 470 548 626 704 784 864 912 - 6.6
130 523 601 721 841 962 1082 1204 1321 1390 - 8.4
200 779 890 1070 1247 1430 1605 1788 1966 2071 - 12.3
· Heavy duty applications.
300 1283 1482 1777 2070 2372 2665 2958 3256 3434 - 18.7 · Hydraulic or pneumatic actuators.
500 1921 2207 2647 3087 3526 3966 4406 4846 5107 - 24.7
· Scotch yoke design.
850 3177 3655 4386 5112 5845 6578 7304 8035 8470 - 37.3
1200 4594 5287 6340 7397 8456 9510 10566 11622 12249 - 56.9 · Up to 258616 Nm in double acting and 111245 Nm in Spring return.
1750 6257 7189 8630 10071 11503 12945 14386 15822 16675 - 71.7 · Modular design.
2100 9612 11054 13264 15475 17686 19897 22107 24318 25632 - 109.6
2500 15312 17614 21135 24659 28177 31703 35228 38747 40837 - 153.4 · ATEX.
4000 21313 24507 29407 34311 39210 44116 49014 53917 56831 - 285.3 · CE.
· VDI/VDE 3845.
SPRING RETURN ACTUATOR TORQUE OUTPUT (inch lb) · ISO 5211.
Spring
Type 43.5 psi 50 psi 60 psi 70 psi 80 psi 90 psi 100 psi 110 psi 116 psi Stroke
Size END START Weight DECLUTCHABLE GEAR BOXES
Pressure (lb)
0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º 0º 90º
S04 64 40 85 64 109 82 125 107 145 122 165 147 184 166 195 177 35 62 3.3 · Aluminium Housing.
20 S06 A 64 41 107 80 128 96 147 113 166 136 177 150 62 97 3.4 · Rugged construction.
S08 89 45 114 69 131 87 148 109 159 124 80 133 3.4
S04 142 124 173 148 211 187 253 230 293 267 339 312 375 356 417 394 443 416 44 71 4.8 · Sealed to IP-65.
S06 124 89 156 120 193 158 236 200 275 240 316 280 358 322 399 364 425 389 62 106 4.9 · ACTREG’s Actuators direct mounting.
S08 119 80 176 131 218 168 258 213 298 250 340 294 382 337 407 363 89 142 4.9
40 · Compact design-low weight.
S10 200 141 240 178 280 224 322 260 364 302 389 327 106 177 5.0
S12 123 76 222 152 263 192 304 234 346 276 372 301 133 212 5.0 · Integral top ange.
S14 A 205 116 245 162 287 205 329 244 354 266 150 248 5.1
· User friendly.
S04 274 239 330 295 404 369 483 448 560 525 642 606 715 680 794 758 841 805 80 115 7.2
S06 239 186 295 242 371 318 451 398 525 472 606 553 687 634 767 714 814 761 115 177 7.4 · Double adjustment stroke.
S08 342 272 416 345 498 427 575 504 653 582 732 661 779 708 150 239 7.6
80
S10 386 298 463 374 544 456 618 529 696 608 743 655 195 292 7.7
S12 245 175 427 321 509 403 589 483 670 564 717 611 230 354 7.9 BRACKETS AND COUPLINGS
S14 A 400 276 477 353 556 432 634 510 682 558 266 416 8.0
S06 381 319 452 398 574 518 696 634 818 756 936 878 1053 1000 1175 1117 1248 1186 168 239 9.7
S08 374 303 529 450 646 572 765 685 887 807 1009 929 1126 1051 1195 1124 230 319 9.9 · Stainless steel, carbon steel or other materials upon request.
130 S10 476 379 598 501 720 623 839 742 956 859 1078 981 1151 1053 283 398 10.1
S12 548 430 667 552 789 674 912 797 1029 913 1097 982 345 478 10.4
· Machined for every kind of valve.
S14 A 623 481 742 604 859 726 981 843 1053 912 398 566 10.6
S06 540 434 659 545 834 725 1011 902 1191 1085 1371 1259 1549 1443 1727 1621 1832 1726 274 407 14.3
S08 534 398 754 610 937 787 1112 970 1291 1144 1469 1321 1647 1502 1752 1611 372 540 14.8
200 S10 674 495 858 672 1032 855 1215 1029 1391 1205 1568 1387 1673 1496 460 682 15.2
S12 778 557 952 740 1136 914 1312 1090 1488 1272 1593 1381 558 814 15.4
S14 A 881 625 1056 799 1232 975 1413 1157 1522 1266 646 947 16.1
S06 903 664 1094 855 1396 1151 1689 1450 1982 1743 2279 2040 2577 2338 2870 2632 3045 2806 451 735 21.3
S08 892 605 1263 945 1562 1238 1858 1540 2151 1833 2445 2126 2743 2424 2921 2602 602 982 21.9 SWITCH BOXES
300 S10 1139 735 1432 1034 1726 1327 2028 1624 2321 1922 2614 2216 2788 2390 752 1221 22.5
S12 1305 822 1602 1124 1895 1417 2195 1710 2490 2008 2664 2186 903 1469 23.1
S14 A 1469 911 1771 1208 2064 1506 2362 1800 2540 1974 1053 1708 23.8 · Micromechanical switches or inductive switches.
S06 1345 1053 1632 1340 2072 1780 2511 2219 2960 2659 3400 3099 3839 3539 4279 3983 4540 4248 673 1018 29.4
S08 1159 761 1446 1048 1886 1488 2326 1933 2765 2376 3205 2816 3645 3255 4090 3695 4355 3956 894 1354 30.5 · Inductive switches for direct mounting.
500 S10 1691 1204 2137 1644 2579 2084 3019 2524 3459 2963 3899 3403 4160 3664 1115 1699 31.6 · ATEX execution.
S12 1945 1352 2385 1792 2824 2240 3264 2680 3709 3120 3974 3381 1345 2036 32.7
S14 A 2199 1509 2639 1948 3078 2388 3518 2828 3779 3089 1567 2372 33.9 · Feedback and positioner.
S06 2301 1850 2779 2328 3512 3052 4245 3785 4969 4517 5702 5247 6434 5974 7162 6707 7594 7143 1027 1567 43.4
S08 2009 1407 2487 1877 3220 2609 3953 3342 4677 4075 5410 4804 6142 5532 6875 6265 7311 6700 1372 2089 44.8
850 S10 2023 1338 2928 2167 3661 2900 4393 3632 5118 4356 5850 5089 6583 5822 7019 6257 1708 2611 46.1
S12 3369 2457 4101 3189 4831 3914 5558 4647 6291 5379 6727 5815 2053 3124 47.6
S14 A 3809 2738 4538 3471 5266 4204 5999 4937 6434 5372 2399 3647 48.9
S06 3301 2558 3994 3251 5048 4305 6111 5361 7165 6421 8223 7475 9281 8530 10338 9586 10966 10214 1513 2399 66.4
PNEUMATIC CONTROL DESIGNS
S08 2876 1885 3562 2570 4621 3630 5677 4686 6739 5740 7793 6798 8849 7856 9905 8913 10532 9541 2027 3195 68.6
1200 S10 2443 1204 3136 1889 4190 2948 5246 4004 6306 5067 7360 6121 8422 7176 9480 8232 10108 8860 2531 3992 71.0
· Solenoid valves, lters, quick exhaust valves, tubing, regulators…
S12 3762 2269 4819 3326 5872 4385 6931 5439 7989 6495 9046 7550 9674 8178 3036 4788 73.2
S14 A 3067 1922 5447 3704 6501 4763 7557 5820 8612 6878 9240 7505 3540 5585 75.6 · Line Break systems.
S06 4222 3089 5162 4021 6594 5461 8035 6903 9476 8335 10909 9776 12350 11217 13786 12653 14639 13506 2390 3726 86.6 · Emergency shut down systems.
S08 3540 2027 4480 2967 5922 4406 7357 5840 8795 7282 10236 8719 11671 10155 13110 11597 13966 12453 3186 4974 90.4
1750 S10 3513 1816 5240 3346 6681 4787 8114 6228 9555 7661 10996 9102 12432 10538 13285 11391 3992 6213 94.1 · Design and manufacturing control cabinets.
S12 6000 3728 7441 5166 8879 6608 10315 8049 11756 9485 12612 10338 4788 7461 97.9 · Remote control cabinets.
S14 A 3750 1998 6759 4113 8201 5551 9642 6987 11078 8428 11931 9284 5585 8700 101.4
S06 6213 4505 7655 5947 9866 8158 12076 10368 14287 12579 16498 14790 18709 17001 20919 19211 22233 20525 3399 5107 132.9
S08 5080 2797 6522 4239 8733 6449 10944 8660 13154 10871 15365 13082 17576 15292 19787 17503 21100 18817 4532 6815 137.8
2100 S10 4994 2430 7600 4750 9811 6961 12021 9171 14232 11382 16443 13593 18654 15804 19967 17117 5664 8514 141.5
S12 8678 5253 10889 7463 13099 9674 15310 11885 17521 14096 18834 15409 6797 10214 146.2 SPECIAL ACTUATORS
S14 A 5339 2705 9756 5764 11966 7975 14177 10185 16388 12396 17701 13710 7930 11922 149.9
S06 11497 9249 13791 11543 17318 15070 20841 18593 24362 22114 27883 25635 31406 29158 34929 32681 37023 34775 4496 7134 189.4
S08 10223 7222 12525 9524 16043 13045 19567 16569 23088 20087 26614 23613 30131 27138 33654 30658 35748 32748 5992 9515 197.1 · FIRE-proof.
2500 S10 10355 6978 14771 11025 18295 14548 21813 18069 25339 21590 28864 25113 32383 28636 34474 30730 7488 11895 204.8 · Fast acting actuators.
S12 13497 9001 17021 12525 20547 16051 24065 19569 27590 23093 31114 26613 33208 28703 8984 14276 212.5
S14 A 15746 10504 19273 14024 22790 17546 26315 21068 29840 24591 31933 26685 10479 16657 220.2
· 100% adjustment stroke actuators.
S06 15604 11170 18806 14364 23705 19271 28608 24168 32033 27776 6709 11931 349.9 · Special coatings.
S08 13710 7789 16904 10991 21802 15890 26706 20787 31606 25694 36508 30592 41411 35497 43734 37817 44856 38934 8948 15905 363.1 · Special actuators for critical applications.
4000 S10 19901 12509 24806 17412 29704 22313 34610 27211 39508 32116 41831 34436 42953 35553 11187 19879 376.5
S12 22903 14031 27801 18932 32707 23834 37605 28737 39928 31060 41050 32181 13418 23862 390.0
S14 A 25906 15551 30804 20453 35709 25356 38029 27679 39147 28800 15657 27836 403.2
Note: A=Standard
www.actreg.com | 11 | | 12 | www.actreg.com
ACTREG
MOBILE APPLICATION
The all-in-one ACTREG interface is a “must have” for the modern automation valve business.
Ideal for work, the ACTREG interface can be used to calculate torques with or without
safety factors and allows you to make your own con guration with ACTREG actuators.
You can also convert any unit of measurement, dimensions, torques, temperatures, and
material equivalences from most common standards.
The sleek, easy-to-use interface makes actuator and torque calculations quick and easy.
The user-friendly screen interface lets you see items at-a-glance, allowing you to convert
quickly while on-the-go.
We have also included some information about ACTREG and the entire product range. This
is a highly effective interface made by ACTREG. Anytime, anywhere, and in any situation.
New application
User-friendly interface
Calculate torques for iPhone

Download now!
Unit converter
ACTREG, S.A.U. (Headquarters)

Carrer de la Ciència, 45-47
08840 Viladecans
Barcelona (Spain)
Phone +34 93 661 44 10
Fax +34 93 654 33 93
for Android actreg@actreg.com
Download now!
ACTREG do Brasil, Sorocaba (SP) ACTREG Shangai Actuator Co. Ltd. ACTREG UK, LTD ACTREG North America
Avenida Liberdade, 4565 No. 125, Ji Ye Road Units 2 & 3 Henson Close 20675 Boul. Industriel
Bairro Iporanga - Sorocaba - SP SheShan Industrial Zone Telford Way Industrial Estate Ste. Anne-de-Bellevue, Québec
CEP 18.087-170 Songjiang District, Shanghai, China Kettering Northants NN 16 8PZ H9X 4B2 Canada
Sao Paulo, Brasil P.R.C. 201602 United Kingdom Toll Free: 1 800 667 4819
Phone: 0055 15 3228 1010 Phone: +86 21 57796818 Phone: 0044 1536412525 Phone: 001 514 457 5777
Fax: 0055 15 3235 9511 Fax: +86 21 57792426 Fax: 0044 1536521616 Fax: 001 514 457 1348
actreg@actregdobrasil.com.br sales@jc-valves.net.cn sales@actreg.co.uk trueline.sales@trueline.ca
For further information visit our website

www.actreg.com
© ERMA FIRST ESK
Edition ENGINEERING SOLUTIONS SA All rights reserved | Confidential | Pages 408
11/2016
www.actreg.com | 13 |
22/7/2019 HN 2140
PRESSURE & TEMPERATURE SWITCH
Data sheet
Pressure switch
RT
RT Pressure switches incorporate a pressure

controlled, single-pole change over swich where
the contact position depends on the pressure in
the connection port and the set value.
The RT series consists of pressure switches,
differential pressure switches and pressure
switches for neutral zone regulation, all for
general use within the industrial and marine
segments. The series also covers safety pressure
switches dedicated for steam boiler plants.
For installations in which operation is particularly
critical from safety and economic points of
view, the use of fail-safe pressure switches is
recommended.
The use of gold-plated contacts is also
recommended in such installations, provided
operation involves only a few switching cycles or
signal currents and voltages.
Features • Simple design • Long operation life time

• High accuracy • Available with all major marine approvals
• High repeatability
© Danfoss | DCS (jmn) | 2017.04 IC.PD.P10.4B.02 | 520B7913 | 1
Data sheet | Pressure switch, RT
Approvals
RT 30AW / RT 30AB / RT 30AS
RT 262AL / RT 263AL / RT 266AL

RT 33B / RT 35W / RT 112W
/ RT 19W / RT 19B / RT 19S
RT 31W / RT 31B / RT 31S /
RT 116 / RT 117 / RT 200
RT 265A / RT 260AL /
RT 260A/ RT 262A
RT 117L / RT 200L
RT 32W / RT 32B
Approvals
RT 1A / RT 121
RT 1AL
RT 110
RT 112
RT 113
RT 5A
RT 1
RT 5
• • • • • • • • • • • • • • • CE marked acc. to EN 60947-4/-5
• • • VD Tüv, Germany
• • • • Det Norske Veritas, DNV
• • • • Lloyds Register of Shipping, LR
• • • • • • Germanischer Lloyd, GL
• • • • • Bureau Veritas, BV
• • • • • • • • Registro Italiano Navale, RINA
• • • • • • • • • • • • • • • Russian Maritime Register of shipping, RMRS
• • • • • • • • Nippon Kaiji Kyokai, NKK
• • • • • • • • • • • • • • • China Compulsory Certificate, CCC

Note: All RT are:
in addition we refer to the certificates,
the copies of which can be ordered y CE marked in accordance with EN 60947-4/-5 for sale in Europe
y
from Danfoss
y Further, the RT 19 , RT 30, RT 35, RT 112 W, RT 33, RT 31 and RT 32 series is CE markd in accordance
y
with PED 2014/68/EU, category IV, safety equipment.
Overview/Survey
Range
0 5 10 15 20 25 30 [bar] Type
pe [bar]
-1 – 0 RT 121
0 – 0.3 RT 113
0.1 – 1.1 RT 112
0.2 – 3 RT 110
Standard pressure switches
-0.8 – 5 RT 1 / RT 1A
0.2 – 6 RT 200
1 – 10 RT 116
4 – 17 RT 5 / RT 5A
10 – 30 RT 117
-0.1 – 1.1 RT 112
Pressure switches for steam plant 0 – 2.5 RT 33B / RT 35W

approved by Vd TÜV 1 – 10 RT 30AW / RT 30AB / RT 30AS
2 – 10 RT 31W / RT 31B / RT 31S
5 – 25 RT 19W / RT 19B / RT 19S
5 – 25 RT 32W / RT 32B
-0.8 – 5 RT 1 AL
Pressure switches with adjustable 0.2 – 3 RT 110L

neutral zone 0.2 – 6 RT 200L
4 – 17 RT 5AL
10 – 30 RT 117L
Δp = 0.0 – 0.9 bar Differential pressure switches -1 – 6 RT 266AL
Δp = 0.1 – 1.0 bar -1 – 6 RT 263AL
Δp = 0.1 – 1.5 bar -1 – 9 RT 262AL / RT 262A
Δp = 0.5 – 4.0 bar -1 – 18 RT 260AL / RT 260A
Δp = 0.5 – 6.0 bar -1 – 36 RT 260A
Δp = 1.0 – 6.0 bar -1 – 36 RT 265A
2 | 520B7913 | IC.PD.P10.4B.02 © Danfoss | DCS (jmn) | 2017.04
Technical data When ordering, please state type The type designation
and code nos. and code number. for the letters below means:
A: Unit suitable for the medium ammonia
L: Unit with neutral zone
Pressure switches
Code no.
Regulation
range Adjustable/ Max. Max.
(pe = fixed operating test Pressure Type
effective mechanical pressure pressure connection
pressure) differential PB p’ ISO 228/1
[bar] [bar] [bar] [bar]

-1 – 0 0.09 – 0.4 7 8 G 3/8 A 017-521566 – – – RT 121
0 – 0.3 0.01 – 0.05 0.4 0.5 G 3/8 A 017-519666 – – – RT 113
0.1 – 1.1 0.07 – 0.16 7 8 G 3/8 A 017-519166 – – 017-519366 RT 112
0.1 – 1.1 0.07 7 8 G 3/8 A – 017-519266 – – RT 112
RT 113 0.2 – 3 0.08 – 0.25 7 8 G 3/8 A 017-529166 – – 017-529266 RT 110
for manual setting; 0.2 – 3 0.08 7 8 G 3/8 A – – 017-511066 – RT 110
cover with windows -0.8 – 5 0.5 – 1.6 22 25 7/16-20 UNF 017-524566 – – – RT 1
-0.8 – 5 0.5 22 25 7/16-20 UNF – – 017-524666 – RT 1
-0.8 – 5 0.5 – 1.6 22 25 G 3/8 A 1) 017-500166 – – – RT 1A
-0.8 – 5 0.5 22 25 G 3/8 A 1) – – 017-500266 – RT 1A
-0.8 – 5 1.3 – 2.4 22 25 G 3/8 A 1) 017-500766 – – – RT 1A
0.2 – 6 0.25 – 1.2 22 25 G 3/8 A 017-523766 – – 017-524066 RT 200
0.2 – 6 0.25 22 25 G 3/8 A – 017-523866 017-523966 – RT 200
1 – 10 0.33 – 1.30 22 25 G 3/8 A 017-520366 017-520066 RT 116
1 – 10 0.33 22 25 G 3/8 A – 017-520466 017-519966 – RT 116
4 – 17 1.2 – 4 22 25 G 3/8 A 1) 017-525566 – – – RT 5
4 – 17 1.2 – 4 22 25 G 3/8 A – – – 017-525366 RT 5
4 – 17 1.2 22 25 G 3/8 A 1) – 017-5094662) – – RT 5
4 – 17 1.2 – 4 22 25 G 3/8 A 1) 017-5046662) – – – RT 5A
4 – 17 1.3 22 25 G 3/8 A 1) – 017-5047662) – – RT 5A
10 – 30 1–4 42 47 G 3/8 A 017-529566 – – 017-529666 RT 117
RT 116 1
) Supplied with ø6 / ø10 mm weld nipple. / 2) With seal cap
for tamper proof;
cap and blank cover Pressure switches with adjustable neutral zone
Regulation Max. Max. test
range Mechanical Adjustable operating pressure Pressure
pe differential neutral zone pressure, PB p’ Code no. Type
connection
[bar] [bar] [bar] [bar] [bar]
-0.8 – 5 0.2 0.2 – 0.9 22 25 G 3/8 A 1) 017L003366 RT 1AL
0.2 – 3 0.08 0.08 – 0.2 7 8 G 3/8 A 017L001566 RT 110L
0.2 – 6 0.25 0.25 – 0.7 22 25 G 3/8 A 017L003266 RT 200L
4 – 17 0.35 0.35 – 1.4 22 25 G 3/8 A 1) 017L004066 RT 5AL
10 – 30 1 1 – 3.0 42 47 G 3/8 A 017L004266 RT 117L
1
) Supplied with ø6 / ø10 mm weld nipple
Differential pressure switches

Adjustable Max. Max. test
Regulation Mechanical neutral Operation operating pressure Pressure
range (Δp) differential zone range pressure, PB p’ connection Code no. Type
ISO 228/1
[bar] [bar] [bar] [bar] [bar] [bar]
0 – 0.9 0.05 0.05 – 0.23 -1 – 6 7 8 G 3/8 A 1) 017D008166 RT 266AL
RT 262 A 0.1 – 1.0 0.05 0.05 – 0.23 -1 – 6 7 8 G 3/8 A 1) 017D004566 RT 263AL
Differential pressure switch 0.1 – 1.5 0.1 0.1 – 0.33 -1 – 9 11 13 G 3/8 A 1) 017D004366 RT 262AL
0.1 – 1.5 0.1 – -1 – 9 11 13 G 3/8 A 1) 017D002566 RT 262A
0 – 0.3 0.035 – -1 – 10 11 13 G 3/8 A 1) 017D0027662) RT 262A
0.5 – 4 0.3 0.3 – 0.9 -1 – 18 22 25 G 3/8 A 1) 017D004866 RT 260AL
0.5 – 4 0.3 – -1 – 18 22 25 G 3/8 A 1) 017D002166 RT 260A
0.5 – 6 0.5 – -1 – 36 42 47 G 3/8 A 1) 017D002366 RT 260A
1.5 –11 0.5 – -1 – 31 42 47 G 3/8 A 1) 017D002466 RT 260A
Preferred versions 1–6 0.5 – -1 – 36 42 47 G 3/8 A 1) 017D0072663) RT 265A
1
) Supplied with ø6 / ø10 mm nipple. / 2) Non-snap action contacts (see spare parts and accessories, contact system 017-018166)
3
) With SPST and SPDT contact system for alarm and cut off function at 0.8 and 1 bar
Technical data The designation letters mean:

and ordering A: Units suitable for the medium ammonia. B: Safety units with external reset
W: Units for control purposes. S: Safety units with internal reset
Pressure switches for steam plant, PED approved acc. to EN 12953-9 and EN 12922-11
Code no.
Regulation
range Adjustable/ Max. Max.
Type
(pe = fixed operating test Pressure
effective mechanical pressure pressure connection
pressure) differential PB p’ ISO 228/1
[bar] [bar] [bar] [bar]
For rising pressure

0.1 – 1.1 0.07 7 8 G½A 017-528266 – – RT 112W
0 – 2.5 0.1 7 8 G½A 017-528066 – – RT 35W
1 – 10 0.8 22 25 G½A 017-518766 – – RT 30AW
1 – 10 0.6 22 25 G½A – 017-518866 – RT 30AB
1 – 10 0.4 22 25 G½A – 017-518966 – RT 30AS
5 – 25 1.2 42 47 G½A 017-518166 – – RT 19W
5 – 25 1 42 47 G½A – 017-518266 – RT 19B
5 – 25 1 42 47 G½A – 017-518366 – RT 19S
For falling pressure
0 – 2.5 0.1 7 8 G½A – – 017-526266 RT 33B
2 – 10 0.3 – 1 22 25 G½A 017-526766 – – RT 31W
2 – 10 0.3 22 25 G½A – – 017-526866 RT 31B
2 – 10 0.3 22 25 G½A – – 017-526966 RT 31S
5 – 25 0.8 – 3 42 47 G½A 017-524766 – – RT 32W
5 – 25 0.4 42 47 G½A – – 017-524866 RT 32B
Pressure switches for low pressure steam plant (pressure monitoring)- not PED approved
Preferred versions 0.1 – 1.1 0.07 – 0.16 7 7 G½A 017-518466 – – RT 112
Technical data Designation RT pressure switches

In general -50 – 70 °C
Ambient temperature Diaphragm version -10 – 70 °C
VD TÜV approved -40 – 70 °C
In general -50 – 100 °C
Media temperature Diaphragm version -10 – 90 °C
VD TÜV appr. -40 – 150 °C, see page 6 (Steam plant)
Single-pole changeover
Contact system switch (SPDT)
Alternating current:
AC-1: 10A, 400 V
Contact load
AC-3: 4A, 400 V
AC-15: 3A, 400 V
Direct current:
Contact material:
DC-13: 12 W, 220 V
AgCdO
(see fig. 6) Fig. 6
Special contact system See “accessories” page 15
Cable entry 2 PG 13.5 for 6 – 14 mm diameter cables
Solid / stranded 0.2 – 2.5 mm2
Flexible, without ferrules 0.2 – 2.5 mm2
Flexible, with ferrules 0.2 – 1.5 mm2
Tightening torque max. 1.5 Nm
IP66 acc. to IEC 529 and EN 60529. Units supplied with external reset.
Enclosure IP54. The thermostat housing is made of bakelite acc. to DIN 53470
Cover is made of polyamide.
Materials in contact with the medium
RT 263AL / RT 266AL
RT 260A / RT 262AL
RT 200 / RT 200L
Material Part W .no. DIN
RT 260AL
RT 260A
RT 265A
RT 110
RT 112
RT 113
RT 116
RT 117
RT 121
RT 1A
RT 5A
RT 1
RT 5
Stainless steel 18/8 Bellows 1.4301 17440 x x x x x x x x x x x x x x x
Stainless steel 17/7 Spring 1.4568 17224 x x x x x
Brass Housing 2.0402 17660 x x x x x x x
Brass Bellows ring 2.0321 17660 x x x x x x x
Free-cutting steel Flare connection 1.0718 1651 x
Deep-drawn steel
Housing 1.0338 1623 x x x x x x x x
(nick.plated surface)
Weld connect.
Non-alli. carbon steel C 20 1.0402 1652 x x x x x x x
for connection
Aluminium Gasket 3.0255 1712 x x x x x x x x
Weld connection Bellows

Case hardening steel C 15 1.0401 1652
connect.
Stainless steel Spring guide + screw 1.4305 17440
NBR rubber Diaphragm x
Deep-drawn steel (surface

Diaphragm housing
DIN 50961 weld connection 1.0338 1623 x
with welded connector
Fe/Zn 5C)
Spring thread Spring 1.1250 17223 x
Materials in contact with the medium, PED approved switches

RT 30AW / RT 30AB
RT 19W / RT 19B /
RT 31W / RT 31B /
Material Part W .no. DIN RT 33B / RT 35W

/ RT 30AS
RT 112 W
RT 32WB
RT 19S
RT 31S
Stainless steel 18/8 Bellows 1.4301 17440 x x x x x x
Stainless steel 17/7 Orifice 1.4305 17440 x x
Steel C 15 Connector 1.0401 1652 x x
Deep-drawn steel + Ni Bellows ring 1.0338 1623 x x x x x x
Stainless steel 17/7 Bellows spring 1.4568 17224 x x
Stainless steel Ring 1.4305 17440 x
Deep-drawn steel + Ni Housing 1.0338 1623 x x x x x x
Stainless steel Bellows connect. 1.4305 17440 x
Stainless, weldable
Connector 1.4301 17440 x x x x
freecutting steel
Deep-drawn steel + Sn Spring guide 1.0338 1623 x
Brass Housing 2.0402 17660
Brass Bellows ring 2.0321 17660
Function
Scale setting −−−−
Mechanical differential
Fig. 4. Contact function,

setting for rising pressure
a. RT 19, RT 30, and pressure switches I.Alarm for rising pressure given
with max. reset at the set range value.
When the pressure exceeds the set range value, II. Alarm for falling pressure given at the set
contacts 1-4 make and contact 1-2 brake. The range value minus the differential.
contacts changeover to their initial position Units with max. reset can only be reset at a
when the pressure falls to the range value minus pressure corresponding to the set range value
the differential (see fig. 4). minus the differential, or a lower pressure.

Fig. 5. Contact funktion,

setting for falling pressure
b. All other RT pressure switches I. Alarm for falling pressure given

When the pressure falls to the set range value, at the set range value.
contacts 1-2 make and contacts 1-4 brake. II. Alarm for rising pressure given at the set
The contacts changeover to their original range value plus the differential.
position when the pressure again rises to the Units with min. reset can only be reset
set range plus the differential (see fig. 5). at a pressure corresponding to the set range
value plus the differential.
Function Example 1 The range is 5 – 25 bar and the differential is fixed

(continuation) An extra cooling water pump must start if the at approx. 1 bar. The range scale must be set at
cooling water pressure falls below 6 bar, and must 17 bar. After cut-out of the burner, manual reset
stop when the pressure exceeds 7 bar. is possible only when the pressure had fallen to
the setting of 17 bar minus the differential: in this
Choose an RT 116 with a range of 1 – 10 bar and
case, 16 bar and below.
an adjustable differential of 0.2 – 1.3 bar.
The start pressure of 6 bar must be set on the
range scale. The differential must be set as the Example 3
difference between the stop pressure (7 bar) and The min. permissible lubricating oil pressure for a
the start pressure (6 bar) = 1 bar. According to gear is 3 bar. Reset must not be possible until the
fig. 3, the differential setting disc must be set on 8. reason for oil pressure failure has been investigated.
Choose an RT 200 with min. reset.
Example 2 The range value must be set while reading the
range scale. Manual reset is possible only when
The burner on a steam boiler must cut out when
the pressure has reached 3.2 bar (the differential
the pressure exceeds 17 bar. Automatic restart
is fixed at 0.2 bar or higher).
must not occur.
Choose an RT 19B with external reset. If extra
safety is demanded, an RT 19S with internal max.
reset can be used.
Functional description Fail-safe function for falling pressure

of RT units Fig. 5a shows a cross-section of a bellows
with fail-safe design element for the RT 32W with fail-safe function
for falling pressure. On rising pressure the
contact arm is actuated to break the connection
between terminals 1 and 2.
On falling pressure the contact arm is actuated
to break the connection between terminals
1 and 4. If a defect occurs in the bellows the
setting spring actuates the contact arm to break
the connection between terminals 1 and 4, as
in the case of falling pressure. This will occur
irrespective of the pressure on the bellows.
Fail-safe function for rising pressure

Fig. 5b shows a cross-section through a bellows
Fig 5a element for the RT 30W with fail-safe for rising
pressure. On rising pressure the contact arm
is actuated to break the connection between
terminals 1 and 2 .
If a defect occurs in the inner bellows the
pressure is led to the outer bellows. The outer
bellows has an area three times as large as the
inner bellows. The connection between terminals
1 and 2 becomes broken.
If a defect occurs in the outer bellows, there will
be atmospheric pressure in the gap between the
two bellows. This actuates the contact system to
break the connection between terminals 1 and
2. The important factor with the double bellows
design is the vacuum between the two bellows,
and that in case of bellows break, no media will
leak into the environment.
Fig. 5b
Pressure switches The RT 113 pressure switch can be used 3. Connection to the side of the tank
for liquid level to control the liquid level in open tanks. with the RT 113 below the liquid level
control RT 113 Fig. 6 shows in principle, four different types Where possible, this form of connection should
of installation. be used. If an air-absorbing liquid like oil is
1. With air bell (see “Accessories”) involved, it is preferable to 1 and 2. The resulting
For control purpose, the air bell should be range setting is the distance from the liquid
installed 20 – 40 mm below the lowest liquid surface to the centre of the diaphragm housing.
level. In addition, the tube between the RT 113 4. Connection in the tank with the RT 113
and the air bell must be absolutely airtight. If above the liquid level
only an indication is required, the bell can be This method is for use with air-absorbing liquids
placed 100 mm below the max. level. The RT 113 where connection type 3 is not possible. The
must be set at 0 cm wg and the differential disc shortest horizontal tube length is determined
on 1. as described in 2. A shut-off valve is installed
2. Connection to the side of the tank between the oil tank and water reservoir shown
with the RT 113 above the liquid level so that impurities can be drained from the water
The horizontal tube A must have a certain length reservoir through a bottom drain plug. Fresh
in relation to the vertical tube B in order to water can then be poured into the reservoir
ensure reliable control. The length ofA can be through a filling connector in its top.
found from fig. 7, using B and the range setting
pressure C.
Height from tank connector to pressure switch

Min. horizontal tube length
Fig. 6 Fig. 7
Application RT-L pressure switches are fitted with a switch

with an adjustable neutral zone. This enables the
units to be used for floating control.
The terminology involved is explained below.
Floating control
A form of discontinuous control where the
correcting element (e.g. valve, damper, or similar)
moves towards one extreme position at a rate
independent of the magnitude of the error when
the error exceeds a definit positive value, and
towards the opposite extreme position when the
error exceeds a definite negative value.
Hunting
Periodic variations of the controlled variable
from the fixed reference.
Neutral zone
The interval in the controlled variable in which
the correcting element does not respond
(see fig. 13)
The contact system in neutral zone units cannot

5. Setting knob be exchanged, as the contact system adjustment
9. Range scale Fig. 8 is adjusted to the other parts of the unit.
40. Neutral zone disc
Setting of neutral zone The range is set using the setting knob (5) fig. 8 The required neutral zone can be found in the
while reading the range scale (9). The pressure diagram for the unit concerned. The position
set is the break pressure for contacts 1-4 at which the neutral zone disc (40) must be set
(see fig. 13). can be read from the lower scale in the diagram.
The function can be seen in fig. 13.
NZ = NATURALZONE / DEADZONE NZ = NATURALZONE / DEADZONE NZ = NATURALZONE / DEADZONE
DIFF. RANGE
POSITION
RANGE
RANGE POSITION
POSITION
Fig. 9 Fig. 10 Fig. 11
Setting of neutral zone

NZ = NATURALZONE / DEADZONE NZ = NATURALZONE / DEADZONE
RANGE RANGE
POSITION POSITION
Fig. 12 Fig. 13
Range setting
Inlet pressure
Differential
(mechanical differential)
corresponds to the least
neutral zone setting.
The neutral zone. Inlet

pressure
may vary within this interval
without resulting in a make
function 1-2 or 1-4.
Example
Together with a VLT® static frequency converter,
RT 200L neutral zone pressure switches can be
used for the infinite control of a pump in, for
example, a pressure boosting plant.
In this case, the pump must be up and
downregulated at 32 m and 25 m wg.
Pressure gauge The RT 200L must be set using the setting knob
(5) fig. 8 page 9 at 3.5 bar (35 m wg) minus the
fixed differential of 0.2 bar.
Compressed air
Signal lamp for The range setting is 3.5 - 0.2 = 3.3 bar.
falling and rising
pressure
The neutral zone, 35 - 32 = 3 m wg,

corresponding to 0.3 bar, must be set on the
neutral zone disc (40) fig. 8 page 9. According
to the diagram fig. 12 the disc setting is 1 or just
over. A more accurate setting can be obtained by
using the test setup shown in fig. 14.
Fig. 14
Test setup for setting the pressure switch
Application Control and monitoring of pressure differentials elements and the set scale value. This unit is also
A differential pressure switch is a pressure available with an adjustable neutral zone (like the
controlled switch that cuts in and cuts out the RT-L which is described on page 9.
current dependent on the pressure differential
between the counteracting bellows
Setting The setting disc (5) becomes accessible when the

front cover is removed. The differential pressure
is set by turning the disc with a screwdriver while
reading the scale (9).
For differential pressure switches with a

changeover contact system, the contact
differential is given as the differential pressure
switches have a fixed differential. In units with
an adjustable neutral zone, the neutral zone disc
must also be set. See diagram in fig. 16.
Note:
5. Setting disc When installing, the low pressure connection (LP)
Fig. 15
9. Range scale must always be upwards
NZ = NATURALZONE / DEADZONE NZ = NATURALZONE / DEADZONE NZ = NATURALZONE / DEADZONE NZ = NATURALZONE / DEADZONE
DIFF RANGE DIFF RANGE DIFF RANGE

DIFF RANGE
POSITION POSITION POSITION
POSITION
Fig. 16
Function
Fig. 17
Contact function, setting
of falling differential pressure
a. Units with changeover switch (SPDT) I. Contacts make when differential pressure
If the differential pressure falls below the set falls below the range scale setting.
value, contacts 1-е2 make and contacts 1-4 II. Contacts make when pressure rises above
break. Contacts 1-2 break again and contacts 1-4 the range scale setting plus the fixed
make when the differential pressure has risen mechanical differential.
to the set range value plus the fixed contact
differential.
Range setting
Inlet pressure
Differential (mechanical
differential) corresponds
to the least neutral
zone setting.
The neutral zone and inlet

differential pressure may
vary within this interval
without resulting in
a make function 1-2 or 1-4.
Fig. 18. Contact function, setting of neutral zone
b. Units with adjustable neutral zone (SPDTNP) The contact function can be summed
If the differential pressure rises above the set up as follows:
value plus the differential, contacts 1-4 make. I. Setting disc set for falling differential pressure.
If the pressure falls by the amount of the II. Neutral zone disc set for rising differential
differential (which is fixed in this unit), contacts pressure.
1-4 break. If the pressure falls to the neutral zone
minus the differential, contacts 1-2 make. When
the differential pressure rises again by an amount
corresponding to the differential, contacts 1-2
break again.
Example 1 Example 2
When the differential pressure exceeds 1.3 bar, a The speed of a circulation pump must be
filter needs cleaning. The static pressure over the controlled to give a constant differential pressure
filter is 10 bar. of 10 m wg in a heating plant. The static plant
According to the ordering table on page 4, the pressure is 4 bar. The choice is an RT 262AL.
choice is an RT 260A (the RT 262A has a max. The differential disc (5) fig. 15 page 13, must be
operating pressure on the low pressure side set at 1 bar (10 m wg) minus the fixed differential
(LP) of 6 bar and is therefore not suitable for this of 0.1 bar, i.e. 0.9 bar. The neutral zone disc is
application). factory-set (marked in red).
Setting: Since a signal is required for rising
differential pressure, the setting becomes
1.3 - 0.3 bar = 1.0 bar.
Dimensions [mm] and

weights [kg] RT 5, RT 110, RT 112, RT 116, RT 117, RT 200
Special version with tamper proof

cap and blank cover
RT 5, RT 110, RT 112,
RT 13 RT 116, RT 117 / RT 117L, RT 5 RT 1A / RT 1AL
RT 121, RT 200 / RT 200L
RT 262A / RT 262A /
RT 260A / RT 260AL RT 5 RT 5A / RT 5AL
RT 263AL
17-660-15
17-660-15
17-660-15
: External reset
Danfoss
Danfoss
Danfoss
knob only for RT...B
RT 30AW / RT 30B / RT 30S L = 225

RT 19W / RT 19B / RT 19S L = 228
RT 33B / RT 35W L = 221
RT 112W L = 210
RT 31W / RT 31B / RT 31S L = 212
Weight: approx. 1 kg RT 32W / RT 32B L = 212
Spare parts and accessories
Version Symbol Description Contact rating Code no.
Single-pole changeover switch (SPDT) with

terminal board proof against leakate current
Standard 017-403066
Fitted in all standard versions of type RT1).
Snap action changeover contacts. Alternating current:
AC-1 (ohmic): 10 A, 400 V
For manual reset of unit after contact AC-3 (inductive): 4 A, 400 V
changeover on rising pressure AC-15: 3 A, 400 V
With max. reset Blocked rotor: 28 A, 400 V 017-404266
For units with max. reset.
Direct current:
For manual reset of units after contact DC-13: 12 W, 220 V
changeover on falling pressure.
With min. reset 017-404166
For units with min. reset.
Alternating current
Single-pole changeover switch (SPDT) AC-1 (ohmic): 10 A, 400 V
with gold plated (oxide-free) contact surfaces. AC-3 (inductive): 2 A, 400 V
Increases cut-in reliability on alarm AC-15: 1 A, 400 V
Standard 017-424066
and monitoring systems, etc. Blocked rotor: 14 A, 400 V
Snap action changeover contacts.
Terminal board proof against leakage current. Direct current:
DC-13: 12 W, 220 V
AC-1(ohmic): 10 A, 400 V
AC-3 (inductive): 3 A, 400 V
AC-15: 2 A, 400 V
Single-pole changeover switch that cuts in two Blocked rotor: 21 A, 400 V
Cuts in two circuits circuits simultaneously on rising pressure.
Direct current: 017-403466
simultaneously Snap action changeover contacts.
Terminal board proof against leakage current. DC-13: 12 W, 220 V
* If current is led through contacts 2 and 4,

i.e. terminals 2 and 4 connected but not 1,
max. permissible load is increased to 90 W,
220 V - - -.
With non-snap
Single-pole changeover with non-snap action Alternating or direct current:
action changeover 017-018166
changeover gold plated (oxide-free) contacts. 25 VA, 24 V
contacts
)At load types with low currents/voltages contact failure may

1
The switch contacts are shown in the position they assume on falling
occure on the silver contacts because of oxidation. In systems
where such a contact failure is of great importance (alarm etc.),
pressure/temperature, i.e. after downward movement of the RT main
gold plated contacts are recommended. spindle. The setting pointer of the control shows the scale value at which
contact changeover occurs on falling pressure/temperature. An exception
Contact systems for neutral zone units are not available as
spare parts. Exchange not possible, as the contact system is switch no. 017-403066 with max. reset where the setting pointer shows
adjustment is adjusted to the other parts of the unit. the scale value at which contact changeover occurs on rising pressure.
Switches
For Alarm application

For manual reset of unit after contact Alternating current:
With min. changeover on falling pressure. AC-1 (ohmic): 10 A, 400 V 017-404766
manual reset AC-3 (inductive): 2 A, 400 V
Gold plated (oxide-free) contact surfaces Full load current: 2 A, 400 V
AC-15: 1 A, 400 V
Blocked rotor: 14A, 400 V
Direct current
For manual reset of unit after contact DC-13: 12W, 220 V
ochangeover on rising pressure.
With max. reset 017-404866
For control application
Gold plated (oxide-free) contact surfaces max. 100 mA / 30 V CA / CC
mini. 1 mA / 5 V CA / CC
Part Description Qty.. Code no.
Covers: Polyamide With window 5 017-436166

Cover
Colour: Pale grey RAL 7035 Without window 5 017-436266
Setting knob Replacement Pale grey Ral 7035 30 017-436366
Seal cap to replace setting knob so that Black

Seal cap 20 017-436066
Setting can only be altered with tools
Seal screws
for cover and 1+1 017-425166
seal cap
For all RT pressure switches with damping c

Clamping band 10 017-420466
oil or other longer connections L= 392 mm
Pipe thread ISO 228/1, G /83 connector, nipple and AL

Conncetor with
washer (10 mm ext. 6.5 mm int. diam.) for welding or brazing 5 017-436866
nipple
on to steel or copper tubing
Connector 7/16 - 20 UNF connector for ¼ copper tube, brass, span of jaws 16 10 011L1101
Reducer Pipe thread ISO 228/1, G ½ A × G 3/8 , steel, span of jaws 22 1 017-421966
Pipe thread ISO 228/1, G /83 × 3/8 - 27 NPT with copper washer,
Adaptor 1 060-333466
brass, span of jaws 22
Pipe thread ISO 228/1, G 3/8 A × ¼ - 18 NPT with copper washer,

Adaptor 1 060-333566
Pipe thread ISO 228/1, G 3/8 × ¼ - 18 NPT with copper washer,

Adaptor 1 060-333666
Adaptor Pipe thread ISO 228/1, G 3/8 A - G ¼ A, brass, span of jaws 17 1 060-324066
Adaptor Pipe thread ISO 228/1, G 3/8 A × R3/8 (ISO 7/1) brass, span of jaws 17 1 060-324166
0.50 m Damping coil with 7/16 - 20 UNF connectors. Reducer code no. 060-019066
1.00 m 017-420566 is necessary if the damping coil is to be used with RT units 060-019166
Damping coil 1
1.50 m having a pipe thread ISO 228/1, G 3/8 connection. Damping coils with 060-019266
2.00 m several lengths of capillary tubes are available. Please contact Danfoss. 060-019366
Pipe thread ISO 228/1, damping coils with G 3/8 connector and 1.5 m
Damping coil 1 060-104766
copper capillary tube. Standard washers are supplied.
Armoured Pipe thread ISO 228/1, damping coil with G 3/8 connector and 1 m
1 060-333366
damping coil copper capillary tube. Standard washers are supplied.
Air bell for Air bell, 62 mm diam. ext. × 204 mm length. Pipe thread ISO 228/1,
G 3/8 connector and nipple (10 mm o.d./ 6.5 mm i.d.) for welding or
liquid level control 1 017-401366
brazing on to steel or copper tubing. The air bell is of brass CuZn 37,
RT 113 W.no. 2.0321.
Installation RT units have two mounting holes which Pressure connection

become accessible when the front cover is When fitting or removing pressure lines, the
removed. Units fitted with switch 017-018166*) spanner flats on the pressure connection should
must be installed with the setting knob upwards. be used to apply counter-torque.
When installing differential pressure switches,
the low pressure side (marked LP) must be
installed upwards. Steam plant
The other pressure switches in the RT series can To protect the pressure element against
be installed in any position, expect that on plant temperature in excess to the maximum
subjected to severe vibrations it is advantageous temperature of the medium 150 °C (RT 113 90 °C),
to have the screwed cable entry downwards. the insertion of water-filled loop is
recommended.
*) Contact system with snap-action contact.
See spare parts and accessories, page 13.
Water systems
Water in the pressure element is not harmful, but
if frost is likely to occur a water-filled pressure
element may burst. To prevent this happening,
the pressure control can be allowed to operate
on an air cushion.
Media resistance
See table of materials in contact with the
medium. If seawater is involved, diaphragm
pressure switches types KPS 43, KPS 45 and
KPS 47 are recommended.
Pulsations
The pressure switch must be connected in such
a way that the pressure element is affected
by pulsations as little as possible. A damping
coil can be inserted (see “Accessories”). With
strongly pulsating media, diaphragm pressure
switches types KPS 43, KPS 45 and KPS 47 can be
advantageous.
Fig. 1. Positioning of unit
Setting
The range is set by using the setting knob (5)
while at the same time reading the scale (9).
Tools must be used to set pressure switches
fitted with a seal cap.
In units having a fixed differential, the difference
between cut-in and cut-out pressures is of course
determined. On units having an adjustable
differential the front cover must be removed. The
differential disc (19) must be set in accordance
with the diaphragm.
5. Setting knob
9. Range scale
Fig. 2
19. Differential setting disc
Installation Selection of differential
To ensure that the plant functions properly,
a suitable differential pressure is necessary.
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
oscillations.
Differential scale values are guiding.
Fig. 3 Obtainable differential disc scale
Data sheet
Thermostat
RT
RT thermostats incorporate a temperature

controlled, single-pole change over switch where
the contact position depends on the temperature
of the sensor and the set scale value.
The RT series consists of thermostats with room
sensors, duct sensors and capillary tube sensors
for general industrial and marine applications.
Features • Simple design • Long operation life time

• High accuracy • Available with all major marine approvals
• High repeatability
© Danfoss | DCS (jmn) | 2017.04 IC.PD.P10.E9.02 | 520B7906 | 1
Data sheet | Thermostat, RT
Approvals
RT 2 RT 4 RT 3 RT 12 RT 16 RT 34 RT 101 RT 106 RT 120 RT 124

RT 23 RT 11 RT 7 RT 13 RT 102 RT 103 RT 107
RT 26 RT 16L RT 8 RT 14 RT 141 RT 115 RT 123
RT 108 RT 17 RT 8L RT 14L RT 140 Approvals
RT 140L RT 9 RT 15
• • • • • • • • • • CE marked acc. to EN 60947-4/-5
• • • • Det Norske Veritas, DNV
• • • • • • • • • • China Compulsory Certificate, CCC
• Lloyds Register of Shipping, LR
• • • • • Germanischer Lloyd, GL
• Bureau Veritas, BV
• • • • • • • • • • Russian Maritime Register of shipping, RMRS
• • • • • • • Nippon Kaiji Kyokai, NKK
Note: In addition we refer to the certificates, the copies of which can be ordered from Danfoss.
GL approval is conditional on the use of a ship’s cable entry.
Overview / survey
Range
-50 0 50 100 150 200 250 300 [°C] Type
pe [bar]
-60 – -25 –
Thermostats with cylindrical remote sensor
-45 – -15 RT 9
-30 – 0 RT 13
-25 – 15 RT 3, RT 2, RT 7
-20 – 12 RT 8
-5 – 10 RT 12
-5 – 30 RT 14
-5 – 50 RT 26
5 – 22 RT 23
8 – 32 RT 15
25 – 90 RT 101
20 – 90 RT 106
30 – 140 RT 108
70 – 150 RT 107
120 – 215 RT 120
150 – 250 RT 123
200 – 300 RT 124
Thermostats with room sensors, duct sensor -50 – -15 RT 17
and capillary tube sensor -30 – 0 RT 11
-25 – 15 RT 34
-5 – 30 RT 4
10 – 35 RT 115
10 – 45 RT 103
15 – 45 RT 140
40 – 80 RT 141
25 – 90 RT 102
-20 – 12 RT 8L
Thermostats with adjustable neutral zone
-5 – 30 RT 14L
0 – 38 RT 16L
15 – 45 RT 140L
25 – 90 RT 101L
2 | 520B7906 | IC.PD.P10.E9.02 © Danfoss | DCS (jmn) | 2017.04
Technical data
Designation RT thermostats
Ambient temperature -50 – 70 °C. See remarks on charge types page 9.
Contact system
Single-pole changeover switch (SPDT)
Alternating current: Fig. 6

AC-1: 10 A, 400 V
Contact load
AC-3: 4 A, 400 V
AC-15: 3 A, 400 V
Direct current:
DC-13: 12 W, 220 V
Contact material: (see fig. 6)
AgCdO
Special contact system See “accessories” pages 15 – 16.
Cable entry 2 PG 13.5 for 6 – 14 mm diameter cables.
IP66 acc. to IEC 529 and EN 60529. Units supplied with external reset.
Enclosure IP54. The thermostat housing is made of bakelite acc. to DIN 53470
Cover is made of polyamide.
Identification The type designation of the units is given

on the setting scale. The code no. is stamped
on the bottom of the thermostat housing.
Technical data When ordering, please state type

and code nos. and code number.
Types of charge
A: Vapour charge – sensor must
not be the warmest part.
B: Adsorption charge
C: Partial charge – the sensor must
not be the coldest part
Thermostats with cylindrical remote sensor

Adjustable differential Code no.
range*)
Max.
Setting range At lowest At highest sensor Type Capillary Type
range range tempera- of charge tube
setting setting ture length
[°C] [°C] [°C] [°C] [m]
-45 – -15 2.2 – 10 1 – 4.5 150 A 2 017-506666 RT 9

-30 – 0 1.5 – 6 1–3 150 A 2 017-509766 RT 13
-25 – 15 2.8 – 10 1– 4 150 A 2 017-501466 RT 3
-25– 15 2.8 – 10 1– 4 150 A 5 017-501666 RT 3
-25 – 15 2.8 – 10 1– 4 150 A 8 017-501766 RT 3
RT 107
-25 – 15 5– 18 6 – 20 150 B 2 017-500866 RT 2
with cylindrical remote sensor,
-25 – 15 2 – 10 2.5 – 14 150 B 2 017-505366 RT 7
cover with windows and hand
-25 – 15 2– 10 2.5 – 14 150 B 5 017-505566 RT 7
setting knob
-25 – 15 2 – 10 2.5 – 14 150 B 8 017-505666 RT 7
-20 – 12 1.5 – 7 1.5 – 7 145 B 2 017-506366 RT 8
-5 – 10 1– 3.5 1–3 65 B 2 017-508966 RT 12
-5 – 30 2– 8 2 – 10 150 B 2 017-509966 RT 14
-5 – 30 2– 8 2 – 10 150 B 3 017-510066 RT 14
-5 – 30 2– 8 2 – 10 150 B 5 017-510166 RT 14
-5 – 30 2– 8 2 – 10 150 B 8 017-510266 RT 14
-5 – 30 2– 8 2 – 10 150 B 10 017-510366 RT 14
-5 – 50 2– 9 3 – 19 150 B 2 017-518066 RT 26
5 – 22 1.1 – 3 1–3 85 B 2 017-527866 RT 23
8 – 32 1.6 – 8 1.6 – 8 150 B 2 017-511566 RT 15
25 – 90 2.4 – 10 3.5 – 20 300 B 2 017-500366 017-500466 017-500566 RT 101
25 – 90 2.4 – 10 3.5 – 20 300 B 3 017-500666 RT 101
25 – 90 2.4 – 10 3.5 – 20 300 B 5 017-502266 017-502366 RT 101
25 – 90 2.4 – 10 3.5 – 20 300 B 8 017-502466 RT 101
25 – 90 2.4 – 10 3.5 – 20 300 B 10 017-502566 RT 101
RT 106 20 – 90 4 – 20 2–7 120 C 2 017-504866 017-504966 RT 106
with cylindrical remote sensor, 20 – 90 4 – 20 2–7 120 C 3 017-505166 RT 106
cover with windows and hand 20 – 90 4 – 20 2–7 120 C 5 017-505066 RT 106
setting knob 30 – 140 5 – 20 4 – 14 220 B 2 017-506066 RT 108
70– 150 6 – 25 1.8 – 8 215 C 2 017-513566 017-513666 017-513766 RT 107
70 – 150 6 – 25 1.8 – 8 215 C 3 017-513966 RT 107
70 – 150 6 – 25 1.8 – 8 215 C 5 017-514066 017-514166 017-514366 RT 107
70 – 150 6 – 25 1.8 – 8 215 C 8 017-514466 RT 107
70 – 150 6– 25 1.8 – 8 215 C 10 017-514566 RT 107
120 – 215 7 – 30 1.8 – 9 260 C 2 017-5205661) 017-5211661) RT 120
120 – 215 7 – 30 1.8 – 9 260 C 5 017-5206661) RT 120
Preferred charge 120 – 215 7– 30 1.8 – 9 260 C 8 017-5207661) RT 120
120 – 215 7 – 30 1.8 – 9 260 C 2 017-520866 017-5214662) RT 120
120 – 215 7 – 30 1.8 – 9 260 C 5 017-520966 RT 120
150 – 250 6.5 – 30 1.8 – 9 300 C 2 017-522066 017-522466 RT 123
*) See also pages 5-6
1
) Thermostats fitted with neon 150 – 250 6.5 – 30 1.8 – 9 300 C 5 017-522266 RT 123
lamp connected to terminal 4. 200 – 300 5 – 25 2.5 – 10 350 C 2 017-522766 017-523166 RT 124
2
) Thermostats with tamper-proof
seal cap. 200 – 300 5 – 25 2.5 – 10 350 C 5 017-522966 RT 124
Technical data Thermostats with room sensor,

and code nos. duct sensor and capillary tube sensor
(continued)
Adjustable
differential range*)
Capillary tube Sensor
Setting range Max. Type length type**)
At lowest At highest
range range
sensor of charge Code no. Type
setting temperature
setting
[°C] [°C] [°C] [m] Figur
[°C]
-50 – -15 2.2 – 7 1.5 – 5 100 A - 1 017-511766 RT 17

-30 – 0 1.5 – 6 1–3 66 A - 1 017-508366 RT 11
-25 – 15 2 – 10 2 – 12 100 B - 1 017-511866 RT 34
-5 –30 1.5 – 7 1.2 – 4 75 A - 1 017-503666 RT 4
-5 – 30 1.5 – 7 1.2 – 4 75 A - 1 017-5037661) RT 4
RT 115 10 – 35 5
) 5
) 92 B - 1 017-519766 ) 2
RT 115
with room sensor
10 – 35 5
) 5
) 92 B - 1 017-519866 ) 3
RT 115
10 – 45 1.3 –7 1–5 100 A - 1 017-515566 RT 103
15 – 45 1.8 – 8 2.5 – 11 240 B 2 2 017-523666 RT 140
40 – 80 1.9 – 9 2.5 – 17 250 B 2 2 017-524166 RT 141
25 – 90 2.4 – 10 3.5 – 20 300 B 2 3 017-514766 RT 102
*) See also pages 5-6

**) See also fig. 1-5
1
) Bellows with built-in heating element which reduces the Preferred versions
thermal differential (220 V).
2
) Can be connected to 220 V and 380 V.
3
) Can be connected to 220 V.
5
) Special thermostat for ventilation plant.
RT 140 Thermostats with adjustable neutral zone

with duct sensor
Adjustable neutral zone
Mechanical [°C] *) Capillary Sensor
Setting range differential Max. Type tube type**)
At lowest At highest
length
Code no.
range range sensor of charge Type
setting setting temperature
[m] Figur
[°C] [°C] [°C] [°C] [°C]
-20 – 12 1.5 1.5 – 4.4 1.5 – 4.9 145 B 2 4 017L003066 RT 8L
-5 – 30 1.5 1.5 – 5 1.5 – 5 150 B 2 4 017L003466 RT 14L
0 – 38 1.5 / 0.7 1.5 –5 0.7 – 1.9 100 A - 1 017L002466 RT 16L
15 – 45 1.8 / 2 1.8 – 4.5 2–5 240 B 2 2 017L003166 RT 140L
25 – 90 2.5 / 3.5 2.5 – 7 3.5 – 12.5 300 b 2 4 017L0062661) RT 101L

*) See fig. 1-5
RT 16L
with room sensor
(Neutral zone thermostat)
Sensor types
Fig. 1 Fig. 2 Fig. 3 Fig. 4

Thermostat with Thermostat with Thermostat with Thermostat with
room sensor duct sensor capillary tube sensor cylindrical remote
sensor
Nomograms for obtained differentials A = Range setting

B = Obtained differential
C = Differential setting
13
Nomograms for obtained differentials A = Range setting

B = Obtained differential
C = Differential setting
Function a. RT thermostats with automatic reset Contact function

The RT thermostats are set according to the I. Contact changeover for rising temperature
function required on falling temperature. occurs at scale setting plus differential.
II. Contact changeover for falling temperatue
Contacts 1 – 4 break while contacts 1 – 2 make
occurs at scale setting.
when the temperature falls to the scale setting.
The contacts changeover to their initial position
when the temperature again rises to the scale
setting plus the differential (see fig. 9).
Scale setting −−−

Differential
Fig. 9 t
b. RT thermostats with max. reset I. Alarm for rising temperature given at the set
Contacts 1 – 4 make while contacts 1 – 2 break value.
when the temperature exceeds the set range II. Alarm for falling temperature given at the set
value. value minus the differential.
Manual reset possible only when the
The contacts changeover to their initial position
temperature has fallen to the range setting
when the temperature falls to the scale value
minus differential.
minus the differential (see fig. 10).
Scale setting −−−

Differential
Fig. 10 t
RT units with The method of operation of these units is based

vapour charge on the connection between the pressure
and temperature of satuated vapour. The sensor
system contains just a small amount of liquid
and this is brought completely to vapour form.
If the sensor in this type of unit is located coldest
in relation to the capillary tube and bellows
housing, the ambient temperature has no
influence on regulation accuracy.
Fig.11a
RT units with The thermostatic element contains

adsorption charge a superheated gas together with a solid
substance (always in the sensor) having a large
adsorption surface. This gives an advantage in
that the sensor can be installed either colder
or warmer than the remaining part of the
thermostatic element. However, the charge
is to some extent sensitive to changes in the
temperature of the bellows and capillary tube.
Scale correction Fig.11b

If the thermostat is to be used in ambient
tempratures that differ significantly from
the factory setting (20 °C), compensation Factor for scale deviation
can be made for the scale deviation:
Scale correction = Z x a
Z can be found from fig. 11c, while a is the
correction factor from the table.
Example:
Find the necessary scale correction for a RT 108
with a regulation range 30 – 140 °C.
Relative scale setting %

Setting: 85 °C
Ambient temperature: 50 °C
Correction:
Set value - min. scale value × 100 = %

max. scale value - min. scale value
85 - 30 × 100 = 50%
140 - 30
Correction factor from table 2.0 (a) Fig.11c

Factor for scale deviation (see fig. 11c): + 1.2 (Z)
Scale correction: Z x a = 1.2 x 2.0 = 2.4 °C
Corrected setting: 85 + 2.4 = 87.4 Range
Type Correction factor a
[°C]
RT 2 -25 – 15 2.3
RT 7 -25 – 15 2.9
RT 8/L -20 – 12 1.7
RT 12 -5 – 10 1.2
RT 14/L -5 – 20 2.4
RT 15 8 – 32 1.2
RT 23 5 – 22 0.6
RT 101/L 25 – 90 5.0
RT 102 25 – 90 5.0
RT 108 30 – 140 2.0
RT 140/L 15 – 45 3.1
RT units with The method of operation of these units is based

solid charge on the connection between the pressure and
temperature of saturated vapour.
The sensor system contains a fairly large amount
of liquid, of which only a small part is brought to
vapour form. If the sensor in this type of unit is
located warmest in relation to the capillary tube
and bellows housing, the ambient temperature
has no influence on regulation accuracy.
Fig. 11d
RT 115 for control The bulb sensor is heated by an element which is

of ventilation plant cut in when the thermostat stops the fans and is
in livestock buildings cut out when the thermostat starts the fans.
The for of operation is as follows:
If the room temperature is more than the value
set on the thermostat, 20 °C for example, the fans
run continuously (100% operating time).
If the room temperature falls to 20 °C, the switch
contacts changeover, the fan stops and the bulb
sensor heating element cuts in.
When the bulb sensor is heated up, pressure in
the sensor system increases and after a certain
time the switch changes over again thereby
cutting in the fans and cutting out the element.
If the room temperature falls more than 2 °C
under the set temperature - in this example,
lower than 18 °C - the fans stop completely.
The heating element is cut in as usual but can
no longer heat the bulb sensor sufficiently to
create the required pressure increase in the
thermostatic element to cut in the fans again.
Thus with a room temperature of less than 18 °C
the operating time is 0%.
An example is shown in fig. 13.
With temperature settings other than the
one shown, the inclined line in the diagram is
A. Series resistor displaced parallel. The line break point on the
B. Bulb sensor right of the diagram always corresponds to the
Fig. 12
C. Heating element set value. It is therefore possible to maintain a
stable room temperature and at the same time
RT 115 has two sensors, each of which is obtain periodic ventilation where the duration
connected to the space between bellows and of the ventilation periods depends on the
bellows housing; see fig. 12. One sensor is a difference between the actual room temperature
normal, external, rigid coiled capillary tube and the set temperature.
type, the other is a bulb sensor located in the By ensuring that the thermostat is always set
thermostat housing. at least 2 °C over the lowest permissible room
temperature, the thermostat will never allow the
room temperature to fall below the desired level.
[°C] Setting example
Ventilator running time in [%] 017-519766, 380 В 017-519766, 239 В 017-519866, 230 В
A: Phase input to fan

B: Control lead
Fig. 13 Connection diagrams for RT 115
Application RT-L thermostats are fitted with an adjustable Neutral zone

neutral zone. This enables the units to be used The interval in the controlled variable in which
for floating control. The terminology involved is the correcting element does not respond.
explained below. Mechanical differential
Floating control The interval between the values of the controlled
A form of discontinuous control where the variable in which the correcting element does
correcting element (e.g. valve, damper, or similar) respond.
moves towards one extreme position at a rate The contact system in neutral zone units cannot
independent of the magnitude of the error when be exchanged, as the contact system adjustment
the error exceeds a definite positive and towards is adjusted to the other parts of the unit.
the opposite extreme position when the error
exceeds a definite negative value.

Hunting
Periodic variations of the controlled variable
from the fixed reference.
Neutral zone setting The range is set using the setting knob (5),
fig. 14, while reading the main scale (9). The set
value is the break temperature for contacts 1-4,
fig. 15. The required neutral zone can be found in
the diagram for the unit concerned, fig. 16.
The position at which the neuttral zone disc (40)
must be set can be read from the low scale in the
diagram.
5. Setting knob
9. Main scale
40. Neutral zone disc Fig. 14
with scale
Example: RT 16L
Setting temperature: 24 °C
Required neutral zone: 1.9 °C
Using the setting knob,
set the thermostat on 24 °C.
The dotted lines in the diagram for the RT 16L
fig. 16 intersect each other on the curve for
position 2.8 and the neutral zone setting disc (40)
must be set to that position.
Fig. 15
Fig. 16
Setting Differentials
The mechanical differential is the differential that
is set on the differential disc in the thermostat.
The thermal differential (operating differential)
is the differential the system operates on. The
thermal differential is always greater than the
mechanical differential and depends on three
factors:
1) flow velocity of the medium
2) temperature charge rate of the medium and
3) heat transmission
The medium
The fastest reaction is obtained from a medium
having high specific heat and high thermal
conductivity. It is therefore advantageous to
choose a medium that fulfills these conditions
(provided there is a choice). The flow velocity
of the medium is also of significance.(Optimum
flow velocity for liquids is approx. 0.3 m/s).
Example:
Regulation of a central heating boiler
The temperature in an oil-fired central heating
boiler must be regulated by an RT 101.
Max. temperature 76 °C. Min. temperature 70 °C.
Differential 76 - 70 = 6 °C.
1. Connect the oil burner via thermostat
terminals 1-2.
5. Setting knob 2. Set the thermostat on 70 °C using the hand
9. Main scale knob (5), fig. 8.
Fig. 8 3. Set the differential disc (19) on 3. This figure is
19. Differential setting disc
obtained from the RT 101 nomogram, page 5.
The range is set by using the setting knob (5) When the plant has been operating for some
while at the same time reading the main scale (9). time an assessment can be made of whether
Tools must be used to set thermostats fitted the thermal diffrential is satisfactory. If it is too
with a seal cap. The differential is set by the large, reduce the mechanical differential of the
differential disc (19). thermostat.
The size of the obtained differential can be
Brass Stainless steel 18/8
established by comparing the set main scale [bar]
value and the scale value on the differential
disc, with the help of the nomogram for the
thermostat concerned (see pages 5-6).
Example
Unit: RT 120
Range setting: 160 °C
Differential setting: 2
It will be seen on the nomogram on page 6 that [°C]
by drawing a line from 160 °C on scale A, through
Temperature
2 on scale C, the value for the differential can be
read from scale B: 6 °C. Permissible media pressure on the sensor pocket as a
Selection of differential (mechanical differential) function of temperature
To ensure that the plant functions properly, a
suitable differential is necessary. Too small a
differential will give rise to short running periods
with a risk of hunting. Too high a differential will
result in large temperature variations.
Dimensions [mm] and weights [kg]
RT 101, RT 107, RT 120,

RT 123 special versions
with seal cap and blank
cover
RT 4
RT 11
RT 16, RT 16L
RT 17 RT 106
RT 34 RT 107 RT 2
RT 103 RT 120 RT 3
RT 115 RT 123 RT 9
Special sensor Special sensor

W. no W. no Material
RT 7 RT 270
RT 8, RT 8L RT 271
RT 10
RT 12
RT 13 2.0090
RT 14, RT 14L 1.4301 18/8 steel
copper
RT 15
RT 21
RT 23
RT 24
RT 26
RT 101, RT 101L
RT 108 RT 140 / RT 140 L RT 102 RT 124
RT 124 Weight approx. 1 kg Choice of suitable sensor pocket
RT 140, RT 140L
Capillary L Suitable L a1 d
W. no. Type tube length sensor pocket Material W.no
[m] [mm] Code no. [mm] [mm] [mm]
RT 2, RT 3, RT 7,
2, 3, 5, 017-437066 Brass 2.0321
RT 9, RT 10, RT 13, 112 G½ 11
8, 10 017-436966 18/8 steel 1.4301
RT 26, RT 120 80
017-437066 Brass 2.0321
RT 101, RT 101L 2, 3 112 G½ 11
017-436966 18/8 steel 1.4301
RT 8, RT 8L,
RT 14, RT 14L, 017-437066 Brass 2.0321
2, 3, 5, 8, 10 112 G½ 11
2.0090 RT 15, RT 107, 017-436966 18/8 steel 1.4301
(copper) 110
RT 123, RT 270
017-437066 Brass 2.0321
RT 101 5, 8, 10 112 G½ 11
017-436966 18/8 steel 1.4301
RT 14 10 150 017-436766 182 G½ 11
RT 271 10 180 017-421666
Brass 2.0321
RT 12, RT 13 2 210 017-421666 465 G½ 11
RT 108 2 410 017-421666
060L333066 110
Brass 2.0235 G½ 15
2.3 76 060L332766 160
060L332966 18/8 steel 1.4301 160 G½ 15
2.0240
RT 106
(brass) 060L333066 110
Brass 2.0235 G½ 15
5 86 060L332766 160
060L332966 18/8 steel 1.4301 160 G½ 15
Spare parts and accessories

Single-pole changeover switch (SPDT) with

terminal board proof against leakate current
Standard 017-403066
Fitted in all standard versions of type RT1).
AC-1 (ohmic): 10 A, 400 V
For manual reset of unit after contact AC-3 (inductive): 4 A, 400 V
changeover on rising pressure. AC-15: 3 A, 400 V
With max. reset 017-404266
Blocked rotor: 28 A, 400 V
For units with max. reset.
Direct current:
For manual reset of units after contact DC-13: 12 W, 220 V
changeover on falling pressure.
With min. reset 017-404166
For units with min. reset.
Single-pole changeover switch (SPDT) AC-1(ohmic): 10 A, 400 V
with gold plated (oxide-free) contact surfaces. AC-3 (inductive): 2 A, 400 V
Increases cut-in reliability on alarm and monitorin AC-15: 1 A, 400 V
Standard 017-424066
systems, etc. Blocked rotor: 14 A, 400 V
Terminal board proof against leakage current. Direct current:
DC-13: 12 W, 220 V
AC-1(ohmic): 10 A, 400 V
AC-3 (inductive): 3 A, 400 V
Single-pole changeover switch that cuts in two circuits AC-15: 2 A, 400 V
Cuts in two circuits simultaneously on rising pressure. Blocked rotor: 21 A, 400 V
Direct current: 017-403466
simultaneously Snap action changeover contacts.
Terminal board proof against leakage current. DC-13: 12 W, 220 V*
* If current is led through contacts 2 and 4, i.e.

terminals 2 and 4 connected but not 1, max.
permissible load is increased to 90 W, 220 V - - -.
With non-snap
Single-pole changeover with non-snap action Alternating or direct current:
action changeover 017-018166
changeover gold plated (oxide-free) contacts. 25 VA, 24 V
contacts
1)At load types with low currents/voltages contact failure may occure on the silver contacts because of oxidation. In systems where such a contact failure is of great importance
(alarm etc.), gold plated contacts are recommended.
Contact systems for neutral zone units are not available as spare parts. Exchange not possible, as the contact system adjustment is adjusted to the other parts
of the unit.
The switch contacts are shown in the position they assume on falling temperature, i.e. after downward movement of the RT main
spindle.
The setting pointer of the control shows the scale value at which contact changeover occurs on falling temperature. An exception is
switch no. 017-403066 with max. reset where the setting pointer shows the scale value at which contact changeover occurs on rising
pressure.
Switches
For Alarm application
For manual reset of unit after contact changeover Alternating current:
With min. reset on falling pressure. AC-1 (ohmic): 10 A, 400 V 017-404766
Gold plated (oxide-free) contact surfaces. AC-3 (inductive): 2 A, 400 V
Full load current: 2 A, 400 V
AC-15: 1 A, 400 V
Blocked rotor: 14 A, 400 V
For manual reset of unit after contact changeover Direct current

With max. reset on rising pressure. DC-13: 12 W, 220 V 017-404866
Gold plated (oxide-free) contact surfaces.
For control application
max. 100 mA / 30 V AC / DC
min. 1 mA / 5 V AC / DC
Switches (continued)
Part Description Qty. Code no.
Covers: Polyamide With window 5 017-436166

Cover
Colour: Pale grey RAL 7035 Without window 5 017-436266
Setting knob Replacement Pale grey Ral 7035 30 017-436366
Seal cap to replace setting knob so that Black

Seal cap 20 017-436066
Setting can only be altered with tools
Seal screws for

1+1 017-425166
cover and seal cap
For all RT thermostats with remote sensor. G½A (pipe thread ISO 228/1), oil
Capillary tube gland 5 017-422066
resistant rubber washer for max. 110 °C / 90 bar.
For RT 106 thermostats with remote sensor. G¾A (pipe thread ISO 228/1),
Capillary tube gland 1 003N0155
oil resistant rubber washer for max. 110 °C / 90 bar.
Sensor clip For all RT units with remote sensor L = 76 mm 10 017-420366
For RT thermostats with the sensor insert in a pocket. Tube with 3.5 cm3
Heat conductive compound to be filled in the sensor pocket to improve heat transfer
10 041E0114
compound between pocket and sensor. Application range for compound:
-20 – 150 °C, momentarily up to 220 °C.
For RT 14, RT 101 and RT 270

Sensor holder 20 set 017-420166
Sensor holder for wall mounting incl. four capillary tube clips.
Sensor pocket for RT thermostats with cylindrical remote sensor

Insertion
length d Connection pipe
Used for the following types Material Code no.
L [mm] thread ISO 228/1
[mm]
All except
RT 12, RT 23, RT 106, RT 108, 112 11 Brass 017-437066
RT 124, RT 270
All except
RT 12, RT 23, RT 106, RT 108, 112 11 Stainless steel 18/8 017-436966
RT 124, RT 271
RT 106, RT 124 2) 110 15 Brass 060L3271661)
RT 106, RT 124 2) 110 15 Stainless steel 18/8 G ½A 060L3268661)
RT 106, RT 124 2) 160 15 Brass 060L3263661)
RT 106, RT 124 2) 160 15 Stainless steel 18/8 060L3269661)
RT 271 182 11 Brass 017-436766
RT 108 465 11 Brass 017-421666

1
) Supplied without washer set
2
) Unit supplied with washer set See possibly page 13.
Installation RT units have two fixing holes which become
accessible when the front cover is removed.
Units fitted with switch 017-018166*)
must be installed with the setting knob upwards.
The other thermostats in the RT series can be
installed in any position, except that on plant
subjected to severe vibrations it is advantageous
to have the screwed cable entry downwards.
*) Contact system with non snap-action function.
See spare parts and accessories, page 14.
Fig. 7 Position of unit
22/7/2019 HN 2140
LEVEL SENSORS

2-1920-2002 EX ERMA BWTS Vol. lII

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

2-1920-2002 EX ERMA BWTS Vol. lII

Uploaded by

Copyright:

Available Formats

Equipment Operations & Technical

Vol. III – Suppliers’ manuals

© ERMA FIRST ESK ENGINEERING SOLUTIONS

Copyright ERMA FIRST ESK ENGINEERING SOLUTIONS SA

All rights reserved.

ERMA FIRST ESK Engineering Solutions S.A.

Schisto Industrial Park ( VIPAS ), Block 13,

Overall information and specifications

Vessel Name: CELSIUS ROSKILDE

BWTS model: ERMA FIRST BWTS FIT 1x2000 EX

BWTS Serial No: 10-2000RF-2-1003

Document No: 2-1920-2002 EX

Project No: 002-001687

BWTS capacity: 2100 m³/h

Max. power consumption: 252.23 kW

Cooling Water flow: 3 m³/h

Ballast water temperature range: -2° – 40° C

Minimum intake water salinity: 1.07 PSU at -2° C/ 0.9 PSU at 3° C

Average operation pressure: 0.5 - 5 bar

Approved for use in explosive

Max. allowable dosage concentration of

Holding time in tank prior to neutralization: > 1h

Max. allowable discharge concentration of

Max. Hydrogen gas generation: ≤ 1.6% vol. (40% LEL)

Max. differential pressure across filter, prior

Rev. Date Description Created Checked

00 22/7/2019 Original Volume lll of Operation Manuals I. LEONTI A. ADAMI

Power source replacement

Steps for safe replacement

Disconnect the cables in

Figure 1: Disconnect the cables

Open the cover and

Figure 2: Remove power source

Replace the power source

Power source tech.

Figure 3: Power source

Replacement time MUST NOT EXCEED 5 minutes

Replace the power source

Be careful of the polarity.

Figure 4: Replace the power source

Close the cover and re-

Figure 5: Replace cables

AUTOMATIC SELF-CLEANING FILTREX

Operating pressure: 1.5 bar

ACB® Automatic Self-cleaning Backwashing Filter OMM.73 ® OMM.73

ACB® Automatic Self-cleaning Backwashing Filter OMM.73 ® OMM.73

ACB® Automatic Self-cleaning Backwashing Filter OMM.73 ® OMM.73

10. MAINTENANCE AND SERVICING .................................................................................... 32 1. SCOPE

2. WARRANTY AND LIABILITY

ACB® Automatic Self-cleaning Backwashing Filter OMM.73 ® OMM.73

3. COPYRIGHT 4.2. CONVENTIONAL SIGNS USED IN THIS MANUAL

4. CAUTIONS AND WARNINGS FOR HS&E HAZARDS

ACB® Automatic Self-cleaning Backwashing Filter OMM.73 ® OMM.73

4.4. BINDING OF THE USER / OPERATOR

ACB® Automatic Self-cleaning Backwashing Filter OMM.73 ® OMM.73

5.2. ACB FILTER FEATURES - Very small backwash flowrate

- Made of few pieces

- Body made of Bronze-Aluminum alloy

ACB® Automatic Self-cleaning Backwashing Filter OMM.73 ® OMM.73

6. TECHNICAL DATA 6.2. NAMEPLATE

The ACB filter mainly consists of:

Refer to attached 13. APPENDIX for the actual limit of supply.

ACB® Automatic Self-cleaning Backwashing Filter OMM.73 ® OMM.73