M48 Aux Boiler Burner Nut 2-2

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Halla Engineering 8 Heavy Industries Co., Ltd
Hull Nos. S.2251226
Sunrod International AB order Nos. 114161417
Book Chapter Description Page No. IDIW No.
1 I Boiler commissioning documents

Boiler safety device procedure 1-4
Alarm and control settings 1-3
Instrument adjustment at commissioning 1-3
2 Technical data for Boiler, Burner

and Accessories 1-5
3 List of equipment and drawings

List of equipment. Loose supplied items.
Steam and feed water diagram
Water level control system
HFO supply for burners
Burner piping diagram
Main drawing boiler 1
Main drawing boiler 2
Boiler insulation drawing
Refractory principal
Arrangement for sealing air to inspection glasses
Installation of equipment for fittings
4 Boiler description and instruction 1-33

Maintenance table 34
Lubrication table 35-36
1 5 Water level control instruction 1-6
1 6 Burner and oil supplly operation instruction 1-12

Diesel oil igniter instruction manual 13-17
Installation of burner, oil supply and control equip. 18-21
3
Halla Engineering 8 Heavy Industries Co.. Ltd
Hull Nos. S.2251226
Book Chapter Description Page No. IDrw No.
Boiler main accessories

Water gauge glass
Safety valve
Safety valve drip pan
Safety valve HFO heater
Boiler accessories
Valves
Strainers
Steam trap
Fittings
Control valves
Feed water control valve MV5211
Oil pressure control valve 5911
Oil temperature control valve 591-20
Control valve 59111591-20 instruction manual
Atom. steam control valve DP17
Electric instruments
Water level transmitter
Steam pressure transmitter
Pressure switch
Oil temperature switch
Temperature transmitter
Limit switch
Pneumatic controllers
Temperature controller
Pressure controller
Controller 623 instruction manual
Filter regulator FR20-75
Instruments
Flow meter ARD
Pressure gauge SMF 16030
Temperature indicator SlKA
Halla Engineering B Heavy Industries Co.. Ltd
Hull Nos. S.2251226
Book Chapter Description Page No. I Drw No.
Control panel instruments

Safety device amplifier EPA-40
SESCON controller
Burner sequence control LAEl
Flame amplifier LAElO
Indicating panel
Water level control system

Piping diagram
Electrode stand
Electrode stand instruction
Water gauge glass
Water level transmitter (connection)
Electrical drawings
Instrument list
Boiler control panel description
Drawing part list Control panel
Cable gland list prod. 00027
Electric drawings
FO Pump start/ stop push button
Panel for boiler drum steam pressure switch
Panel for oil supply pressure switch
Panel for oil supply temperature switch
Combustion air pressure switch
Burner
Burner introduction
Burner index
Description and auxiliary equipment
Burner drawing part list prod 00012-00017
Burner piping diagram
DF455 Burner drawings
DF455 Burner drawings
F.O. meter manifold
Diesel oil igniter
FD fan Isilencer
FD fan motor MBT 225 M-2
Burner junction box
Mounting and assembly instruction
Commissioning
Technical data and characteristic curve
Viscosity diagram Fuel oil
Troubleshooting
Part list.
Maintenance
5
Halla Engineering 8 Heavy Industries Co.. Ltd
Hull Nos. S.2251226
Book Chapter Description Page No. IDtw No.
17 Pumps
Oil supply piping diagram
HFO pump station
FO return pipe
Ignition oil pump
lgnition oil pump instruction
F.O. pump SPZV 10 R 56
FO pump motor MBT 90 L
2 18 Heaters for pump units

HFO heater
-1
(. ~.
Description
2 19 Other equipment
Salinometer
Chemical dosing pump
2 20 Spare parts
Spares included in delivery
HAMWORTHY COMBUSTION
ENGINEERING LIMITED
O P E R A T I N G A N D M A I N T E N A N C E
I N S T R U C T I O N S
CLIENT: AALBORG SUNROD AB, SWEDEN
SITE: HALLA HULL S226
CLIENTS ORDER NO: 911417-75500
CONTRACT NO: 3707548

I -)
'
DELIVERY DATE: NOVEMBER 1995
(i )
(Disk 8 95AUC035.DRl
INTRODUCTION
The following data and descriptive literature relates ~Pecificallvto the Combustion Equipment supplied by
Hamworthy Engineering Limited. The extent of supply is detailed on the enclosed specification sheets.
-. . ..=
Although a very imwnant parI of any p r o w installation, this extent of supply only forms a small pan of
the overall plant. I t is therefore, irnponant that the instructions from the main contractors for plant operation
are taken as the governing criteria for operation and maintenance of that plant.
The following information is provided for the afeand efficient use of the combustion Equipment alone, and
should be wed in coniunction with that given by the main supplier. In the event of a m n f l i n of requirements
the main supplier should be consulted.
This manual mun be available for briefing, and for consultation by the operators. whose attention is panicularlv
(,:1 drawn to the sections oovering safeh/:
1- COMBUSTION DIVISION
ENGINEERING LIMITED
CONTRACT NO. 3 7 0 7 5 4 8 DATE: NOVEMBER 1995
SPECIFICATION
FUEL FIRING EQUIPMENT
WATER TUBE BOILER
FOR
HALLA HULL S 226
AAL.BORG SUNROD NO. 911417-75500

ENGINEERING LIMITED
SPECIFICATION OF SUPPLY
1.0 ATOMISING STEAM OIL VALVES AND FITTINGS
The principle components listed below have been supplied:
2 - Sets valves and instruments, each complete with:-

1.1 1 - 2' manual ball valve oil. Tag no. F03.
1.2 1 - 2' auto ball valve oil. Tag no. F04.
1.3 2 - %' instrument valves. Tag no. F15.
1.4 1 - 4" dial oil pressure gauge. Tag no. F11.
1.5 1 - 4" dial steam pressure gauge. Tag no. F12.
' 1.6 1 - Steam pressure switch. Tag no. F13.
t 1.7 1 - 1" Oil control valve. Tag No. FlO.
2.0 HAMWORTHY 6-VALVE PURGE UNIT
r
\
2.1
The principle components listed below have been supplied:
2 - Hamworthy 6-valve purge units, each supplied complete with:-
1 - 4"
fuel oil isolating valve with pneu. actuator, solenoid and
limit switch. Tag no. F05.
1 - 2' fuel oil drain valve mechanically linked to fuel oil
isolating valve.
1 - 2' fuel oil recirc. valve mechanically linked to fuel oil
isolating valve.
1 - 2' atomising steam isolating valve with pneu. actuator,
solenoid and limit switch. Tag no. F07.
1 - " atomising steam purge isolating valve with pneu. actuator,
solenoid and limit switch. Tag no. F06.
1 - 4" atomising steam purge isolating valve mechanically linked to
above valve.
1 - Set of mechanical linkage.
1 - Manifold block.
For further information on the purge unit operating principles, see

chapter 1 of this manual.
!,3 3.0 HAMWORTHY DF455 STEAM ATOMISED FUEL OIL BURNER
The principle components listed below have been supplied to be

assembled and installed on the boiler:-
3.1 2 - Hamorthy DF455 oil burners each supplied complete with:-

1 - DF455 air register complete with individual windbox, front plate,
carrier tube on central axis, and secondary air section.
1 - Primarylsecondary air dividing housing.
1 - Steam atomised fuel oil sprayer assembly (quick release type)
complete with cap nut, atomiser. quick release couplings and
flexible hoses.
1 - Sight glass assembly.
ENGINEERING LIMITED
2 - Swivel mountings for flame detector heads.

1 - Automatically operated combustion air damper complete with
pneumatically operated actuator driven through bowden cable
arrangement.
Principle burner assembly dimensions can be seen on burner general

arrangement drawing (chapter 2 of this manual).
ENGINEERING LIMITED
SPARE PARTS SCHEDULE
SDare Items
2 - Atomiser tip. Tag no. S39.
2 - Steam atomising sprayer. Tag no. 538.
2 - RARB photocell. Tag no. S23.
2 - Cap nut spanner. Tag no. S40.

ADDENDUM 401 I400
HAMWORTHY COMBUSTION SYSTEMS
BURNER PRODUCTS SAFETY NOTE
The following are important notes relating to the effective and safe
commissioning of the specific burner to which this manual relates and
must be strictly adhered to at all times.
General scope of amendment
It is essential to ensure. prior to commissioning. that all fuel control

valves. regulators. proportioningvalves and similar control devices are
set t o their minimum flow positions before any source of ignition is
introduced into the combustion space.
The initial fuel flow adjustments necessary in order to provide light up

conditions must only be made whilst the burner is off. Subsequent
lightup attempts being made each time progressing from a fuel lean
condition until a good light up is achieved.
!\'
Once adequate fuel flow exists to enable the burner to light then the
fuel flow to the furnace may be optimised whilst the burner is in
operation.
t3
Subsequent setting of the control devices must progress from a fuel
lean condition.
.....
.*.
BURNER DESCRIPTIONIOPERATION
Rev.No.
AI\LBOROSUNROD
nuw WYIIIWY -.I
Date 18.08.93
I
BURNER DESIGN PRINCIPLES AS RELATED TO THE DF BURNER
1.0 Basic Burner Design
In its simplest form a burner can be considered as consisting of two basic parts.
That is, a fuel gun and an air register. The basic requirements of each part can
be briefly described as follows:-
Fuel Oil Sorarer
Most of the requirements of the fuel gun are interelated, not only with
each other but to varying extents with those of the air register.
Nevertheless, for descriptive purposes they can be broken doom as follows:-
Calibration The determined fuel rate must be passed at the
specified input pressures.
Atomisation The atomiser design type and the operating
pressures must be selected so as to be capable of
producing a range of droplet sizes commensurate
with acceptable combustion over the specified
turndown requirements.
The relationship of fuel throughput and input

pressure. ideally should have characteristics
amenable to combustion control equipment.
SDrav Characteristics (Spray A n ~ l eetc.1

Good atomisation on its own will not necessarily
produce good combustion. It is also necessary tc
distribute the atomised fuel spray in such e
manner that facilitates rapid and intimate mixing
with the combustion air. This pattern of fuel
spray must also be compatible with the
aerodynamically induced flame stability of the
register design. The matching of the fuel spraj
with the combustion air also has a marked
influence on flame shape, particularly flame
length.
Combustion Air Recister

Again. .the requirements of the air register are interelated. but £01
descriptive purposes are identified as follows:-
a) Calibration The amount of air determined as that necessarj

for the complete combustion of the designated fuel
rate, must be passed at the design pressura
differential.
BURNER DESCRIPTION/OPERATION
18.08.93
Mixing Enerpy The register draught loss (R.D.L.) dete.rmines the

velocity and energy of the combustion air. This
must. therefore be sufficient to provide the
necessary airlfuel mixing energy to control flame
volume to suit a specific application.
Flame Stability The fuel and combustion air pressures necessary to
provide the mixing energy for acceptable
combustion, results in airlfuel mixture
velocities in excess of the flame propogation
speed.
This situation left on its own would produce
unstable flames. as it would be many burner nozzle
diameters downstream of the burner before the
mixture velocity and the flame propogation speed
reach equilibrium.
To overcome this acceptable condition, a
proportion of the combustion air, identified as
primary air, is highly swirled. This sets up an
adverse aria!. pressure gradient resulting in a
reverse flow along the axis and the setting up of
an internal recirculation zone just downstream of
the fuel gun, see Fig. No. 2 and 3. The
recirculated burning gases provide a continuous
source of re-ignition and thereby produce a stable
flame.
The proporation of primary air and the strength of
swirl must be sufficient to generate the required
stabilising recirculation and to also ensure that
the recirculated gases are within flanunable
limits.
Flame Shaue The primary air therefore provides the major

influence on flame stability.
The remaining combustion air, secondary air, in
ddition to reinforcing the aerodynamically
controlled stability pattern can be used in
control flame shape. The secondary air can be
swirled or unswirled depending on the required
flame pattern.
It is unlikely that the secondary air swirl is
ever required to be as strongly swirled as the
primary air.
Whilst it is possible to effect some change of
flame shape by adjusting the fuel spray or
combustion air pattern individually. Major shape
change require adjustment of both in order to
achieve optimum results be correct matching of
fuel to air.
BURNER DESCRIPTInNlOPERATION &I Doc No
I Date 18.08.93
1.3 DF Burner Desian
a) General Notes A practical burner design must therefore take

into account all the aforementioned requirements
of good combustion. In addition, the mechanical
and environmental factors must be catered for.
The mechanical aspects cover such design points as
assembly and erection features of the burner as a
whole.
Environmental factors are mainly ones of furnace

radiation to the exposed parts of the burner. To
counteract this problem. maximum use of refractory
materials and stainless steel has been made.
The DF burner has been designed and developed

taking all these major combustion, environmental
and operation requirements into account.
b) DF Burner Design Fia. No. 1

The DF burner was developed with particular
attention paid to the requirements for dual fuel
operation, either separately or combined firing.
Combustion air enters the register from the

windbox through the annular damper opening.
Within the burner air casing the flow is divided
into primary and secondary paths. The primary
flow is further divided by passing through and
around the axial flow air swirler.
The swirl component of the secondary air can be

adjusted by means of the secondary air swirler
blades. These are pre-set at the factory and
cannot be adjusted during operation. This
precludes mal-adjustment by unqualified
operators.
The internal division of the air flow enables

flame- shape control to be achieved by the
secondary swirl angle setting without materially
affecting the flame stabilising primary air flow.
The flow dividing ring also has the effect of

setting up zones of aerodynamic shear in the early
stages of the flame promoting rapid mixing of fuel
and air.
HAMWORTHY ENGINEERING LIMITED-
i l
COMBUSTION DIVISION 31
SCHEMCTIC OF
-
FLAME
OIL
ST&~ILISING
FIRING
4 MIXING l'ATLIS.rEeNS.
--.....-- -- Doc No
BURNER DESCRIPTIONIOPERATION
MLBOROSUNRM) I
Date 18.08.93
THE COMBUSTION EQUIPMENT W O R T H Y DF REGISTER

I
1.0 THE BURNER
The DF divided flow register derives its name from the principle of its
I
operation. Combustion air enters the register from the integral windbox. Within
the burner air casing the flow is further divided by pcrssing through and around
the axial flow air swirler.
The swirler component of the secondary air can be adjusted by means of the
' secondary swirler blades. These are pre-set at the factory a d cannot be
adjusted during operation. This precludes mal-adjustment by unqualified
operators.
The internal division of air flow enables flame shape control to be achieved by
the secondary swirl angle setting. without materially affecting the flame
stabilising primary air flow.
The flow dividing ring also has the effect of setting up zones of aerodynamic
shear in the early stages of the flame promoting rapid mixing of fuel and air.
Fitted to the front plate of the air registers a r e ( t y w i v e 1 mount assemblies

onto which the W heads are attached. Two RAR7 type detector head to monitor the
main flame. These are to be adjusted during commissioning to ensure that the
maximum signal is optimised. A tapping point is also fitted to the swivel mount
assemblies to allow for compressed air to be bled in to stop the misting up of
the W head lens. Through the centre of the burner register is located the oil
sprayer down which the atomising medium and oil fuel are passed. Captive in the
end of the sprayer. by means of a cap nut. is the atomising tip.
The sprayer assembly is positioned on the central axis of the burner and is
located via a sprung bayonet locking device.
Once in position, positive location of the sprayer is proved by a limit switch.
The oil and steam are carried from valve plate arrangement to sprayer by means
I
of flexiblee hoses. These are arranged such that it is impossible to connect oil
to steam and vice versa.
am -r -r DOC NO ) 9
..... BURNER DESCRIPTIONIOPGRATION Chpt 1 page 5
Rev.No. A
PALBomSUNRX) 1
Date 18.08.93
HANSEN QUICK-RELEASE COUPLINGS
Hansen Series HK Two-way Shut-Off Couplings positively seal both ends of line when
Coupling is disconnected.
Spring acutated valves in both Socket and Plug provide immediate and positive seal
against escape of gas or liquid with negligible spillage.
When connected. complete seal is effected by compression of '0'-ring in Socket against

outside
.- surface of Plug.
Hansen HK series couplings are QUICK CONNECTING - they a l l instantaneous

~ connection
or d i s c o ~ e c t i o nof fluid lines byhand, without tools. The connecting mechanism is
of the ball locking type, in which a ring'of stainless steel balls in the socket half
of the coupling locate in a precision groove in the plug; a spring-loaded release sleeve
on the outside of the socket controls the lockings balls, and is retracted by hand to
allow insertion or withdrawal of the plug. The ball locking mechanism is acknowledged
to be particularly robust and trouble-free. and gives a fast, smooth and 1002 secure
locking action. This type of locking mechnaism allows 360' swivelling of the couplin$
while connected, preventing kinks in the hose.
Hansen HK series couplings are SELF-SEALING -

:ocket and plug both incorporate spring
operated poppet type valves which give immediate, automatic shut-off of both ends of
the line on disconnection. and immediate, automatic flow through the coupling om
conection. This TWO-WAY SHUT OFF feature gives users substantial advantages:-
+ Loss of spillage of fluid on connection and disconnection of lines is negligible.
* The cost, bulk and complication of separate manually operated valves can be
avoided.
i Fluid line connections are foolproof - Hansen HK couplings cannot be wrongly or
only partially connected or disconnected: unskilled labour can operate them.
* Cleanliness in the working area is increased and risk of contamination of the
fluid being carried is reduced.
* Increased safety in handling inflammable, corrosive or other dangerous fluids is
assured by the virtual elimination of spillage.
~n important feature of IiK series design is that on connection the coupling is fullj
sealed by the socket '0' ring before the shut-off valves release the flow of liquid 01
gas: similarly. on disconnection, valves seal off both halves before the coupling seal
is broken. Thus spurt of fluid is impossible and spillage is minimal.
BURNER DESCRIPTIONlOPERATION
Date 18.08.93
The unique configuration of Hansen HK series valve assemblies gives an exceptionally

smooth flow path acrosss the coupling, ensuring substantial flow rates with minimum
turbulence and pressure drops.
-
Hansen HK series couplings are DEPENDABLE they are in use in thousands of hard working
applications throughout the world. giving reliable trouble-free service year in and year
out. HK series couplings have been known to stand more than 500.000 connections and
disconnections in fast moving production line applications with all original parts still
intact. This kind of faultless performance results from superb design and manufacture
from the finest materials to very close tolerances.
Hansen HK series couplings are VERSATILE -

steel mills, breweries, nuclear reactors.
shipyards, automobile plants, food manufacturers -
wherever liquids and gases are
handled Hansen HK couplings give sterling service.
Fluids successfully handled by Hansen HK series couplings include hydraulics oils.

comuressed air. vater. vacuum. steam. lubricants, beer, refrigerants. whisky, coolants
......
..... BURNER DESCRIPTION/OPERATiON
Date 18.08.93
INTRODUCTION
On shutting down an oil burner. a residual quantity of fuel oil will remain in the
sprayer. Were this to be left. a number of problems could arise.
The heat radiated from the combustion chamber could cause 'boil off' of the light
fractions of the oil and the residual fractions to carbonise. The carbon so formed
could cause blockages of the sprayer tube or the atomiser.
There may also be a tendency for oil to drip from the end of the sprayer on to the hot
refractory. This would result in the formation of carbon on the refractory. and
subsequently a deterioration in its condition.
The solutions to these problems are:

a) Remove the sprayer after shutdovn. This would. however, result in oil spillage.
and would also involve operators in unnecessary duties.
b) Flush or purge the oil from the sprayer on shutdown.
PURGE PROCEDURE
This is normally carried out by introducing the atomising medium, under pressure, into
the oil tube of the sprayer.
It can be done manually or automatically. The Hamworthy Engineering Ltd Purge Assembly
carries out purging automatically, and in conjunction with its controls the purged oil
is ignited. for safety. by introducing the ignition flame.
PRINCIPLE OF OPERATION
Standby
At this condition all the actuator solenoid valves are de-energised and all the
ball valves are in the closed position.
Furnace Air Pre-Puree
Whilst the burner management controls are executing the furnace air pre-purge all
the ball valves are closed except for the steam valve (A).
Firing
After the furnace air pre-purge and ignition sequence is complete the oil valve
(E) opens, the steam valve remaining open. and normal firing comences. Since
the vent valve (D) is mechanically linked to the oil valve, it too at this stage
is open.
In the event of either of the purge valves (B + C) not sealing, it will bf

evident from the discharge at the vent. The vent should be piped to a safe
visible point.
I Doc No w..
BURNER DESCRIPTIONlOPERATION
1 Date 18.08.93
4) Steam Purge
On burner shutdown the oil valve actuator solenoid is de-energised and the of
and vent valves close by spring return action. The steam valve remains open.
The closing of the microswitch on the oil valve actuator a l l w s the purge valv~
actuator to energise. via contacts on the purge timer. thus opening th,
mechanically linked purge valves.
Because the circuit for energising the purge actuator is via the microswitch o!
- the oil valve it is impossible for the purge valves to be open unless the oi
valve is closed.
During the purge period, the ignition is brought on to burn off the purged oil
After the prescribed purging period, the purge valves, which are operated by
double acting actuator, and the steam valve which is also opeated by a doubl
qcting actuator. are closed and the igniter is switched off.
The assembly is now in condition (1) at standby.

GENERAL NOTES
1) If the atomising medium is air not steam then for steam read atomising air.
2) Steam purging will only be carried out on a programed shutdown.
In. the event of "lock-out" for safety reasons no purge of the oil tube will b'
made.
3) Each actuator is fitted with NIO and NIC microswitches. These are used a s safet:
interlocks. For exact details consult the section on controls.
4) For multi-burner applications a bleed hole is incorporated in the steam valv,

ball to allow cooling steam through the atomiser at alltimes.
AUTOMATIC RECIRCULATION
When the burner is off it is necessary, when using heavy fuel oils. to recirculate oi,
around the ring main in order to keep the oil at the correct atomising temperature.
This may be done be adding an automatic recirculation valve to the purge assembly. Thi
valve is mechanically linked to the oil and vent valves. It is, however, closed v h e ~
they are open and open when they are closed. Hence whea the oil valve is closed oi
is allowed to recirculate, but when the burner is firing and the oil valve is open. tht
recirculation valve is closed. preventing oil recirculation.
Recirculation may also be carried out using manual change-over valves, or other system
involving automatically operated valves.
SERVICES
The actuators require an air supply. dry and filtered at 80-100 psig. The actuatol
solenoids are supplied to operate on the voltage as used for the controls, normall:
240150 Hz or 110150 Hz.
...... Doc No -2.3
..... Chpt I Page 9
BURNER DESCRPTION/OPERATION
Rev.No. A
Date 18-AUG-93
Method of adiusting I restricting steam ourge flow throuah the puree unit
The purpose of this mechanism is to optimise the amount of steam flowing through the purge unit
during the burner post purge cycle, thus ensuring better combustion at this time.
Access to the adjusting screw itself is made by removing the domenut (item 1) and loosening the
locknut (item 5). When the screw is turned fully clockwise this will effectively shut-off the purge flow
complet~ly.~ s ~ s u ~ ~ the
l i eadjuster
d, screw is ~ r n e danti-clockwise approx&tely one half tum
from &e closed position.
Safetv Note.
It is of the utmost importance that once adjustment has been made, the locknut and domenut are
filly tightened to ensure that steam is not permitted to escape.
Parts list. '
1). MI6 Domenut.

2). Copper washer.
3). 'Dowty ' seal.
4). Steam purge adjuster screw
5). M16 locknut.
SECTION THROUGH PURGE UNIT SHOWING STEAM

PURGE FLOW ADJUSTER SCREW ARRANGEMENT
BURNER DESCRIPTION/OPERATION Chpt 1
SAFE OPERATION OF THE HAMWORTHY COMBUSTION EQUIPMENT
With the advent of the Health and Safety Act it behoves manufacturers and users alike
to ensure that equipment can be. and is operated safely.
The information in this manual relates to the efficient and safe operation of the
equipment supplied by this Company. However, as the equipment represents a link in a
process chain these documents must be read in conjunction with those of the main
contractor.
At-all times the equipment should be installed and operated with due regard to sound
engineering and safety principles, this cannot be over emphasised when dealing with
inflammable or explosive materials, such as fuels.
The equipment has been designed to operate with the fuels and at the conditions
specified in the "Technical Specification Sheet". Proposed changes to any part of this
specification must be referred tothis Company for approval. as must any other questions
relating to the safe operation of the supplied equipment.
When reading the instructions contained herein always make reference to
instructions given by manufacturers of any associated plant.
Attend to fuel leaks as they are reported. Do not delay. Make no attempt to
operate the associated plant whilst fuel is escaping.
Keep the area surrounding the combustion equipment and its associated equipment
clear of debris.
Ensure fan inlets are guarded.
Do not leave control panels or junction boxes uncovered whilst power is ON.
Should it become necessary to do so in the interest of rectifying faults, then

only competent, qualified personnel should be involved, and covers must be
replaced as soon as possible.
Do not allow entry to combustion chamber or any gas or air ducting. for example.
to carry out inspection. unless the burner is isolated, the power switched off.
warning notices posted, and the plant is sufficiently cooled and vented.
Ensure that hot pipes such as steam or hot oil pipes are lagged. Restrict access
to any areas where hot metalwork or gases may be encountered.
Safety interlocks are necessary! Under no circumstances should they be

over-ridden. Once a fault on an interlock has been detected then that interlock
must be replaced before the unit is operated. Routine checking of interlocks is
described in the General Care and Maintenance Section E2.
If the plant is required for continuous operation ensure that sufficient spares
are kept in stock. Hamworthy Engineering Limited cannot guarantee himediate
delivery of any component. Failure to stock a particular itemmay result in the
unit being operated with temporarily disconnected or short circuited control or
monitoring equipment. thus creating a potential hazard.
Date 18.08.93
Do not make repeated attempts to light the burner. If a flame cannot be

established after two consecutive attempts. carry out an investigation into the
cause.
A succession of abortive attempts to fire the burner, may result in the build-up
of an explosive mixture at some point in the gas passes.
It is recommended that operators of the combustion plant are trained in

its use and principles of operation.
Doc No 2?
..... AUXlLLARY E Q U l P M E m Chpt 1 Page 12
DESCRlPTlON
Rev.No. A
.- - --
A4LBORG .. --
.SUNROD -, Date 18-AUG-93
PRESSURE AND TEMPERINRE SWITCHES
I
I Doc 30
Rev No. A
- - ... - - ..-
I Date 18-AUG-93
PRESSURE AND TEMPERATURE SWITCHES
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p ~is aawuc40
t m r me tWI scale nnqe. The r e a c t u r n
-1 0s med r m m n u m povrt m ~ m
~ to me s t m~ p s
alMtorm-deMbOndldnUIKabamntMacNm
and m u u s a n m) r a n on W c8m~ on the a o w u m a
m p m BI swm v w m o s c m m a n me
Inpaul prsuure c h a w . mus cwwp me r o t m r n 01 ma
b a w e date a m u r s '8' a,ma 1 n w r 8 p r u r u r s r e r u m
IC~W ns -I MIM. me m m e pate IO~IU awut w
5' to ns o m p m o n and resctvstrn a c u n
each nut 0s m ~ d e n n y a d l u n b c o v rmeNU

r -1s m q e
cc3-m CI me p r t o n m a t a convsned onlo r*o
repame roanonal movamnts OI me DiUme plpte ma
o m m at me 01 Ih. e m n u l m o a c m m t c n e s a c u n
ot me fixed - a n d I)pa r c w l mat r e a c f u a n m s s nor

a u t w o c d y occur 161m~rm01 a c r u a m m t sa d l w -
. - - - --
doar MI a u t m a u c a q rbacrua~e*mG me pressure or tam-
p m ~ n t e ~ r ~oanouma
ns ~~ol.t.~omtatetoirson~l
AUX~LLARYEQUIPMENT Chpt 1 Page 14
DESCRIPTION
Date 18-AUG-93
ASC& IRI~PX Pressure and Temperature Switches

incorporate the most wanted features in one design
SWRCH ASSEMBLY UNlT
Cover and garKel 101 aaiusnng

n u s IUmllhEd on Watsnwl a m
~ ~ p m s m p r o moaar
ot
cooper.hee.' alumonwm aissart

b c q -no wmng or c o n o v m
M O C ~ ~psmn
O ~ stop lor nlgn
surge prOleC,lOn
1 Doc No j"
AUXILLARY EQUIPMENT Chpr I Page l.5

DESCRlPnON
Rev.No. A
Date 18-AUG-m
25 rnw SAIM U I I A
40 m0.r UlM SA11A
--- .- .
... ---
1 1
~~
0.06 D.r S 8 m 58211 58228

0.10 bar SBIM SBllA S817.f
o
. l e. au
-- S~-B 1 M 581th SB17.f
1 1 1
~
0.35 O r SB1M SB11A 58121

0.5 On SBIM SBI1A SBI7.f
I Doc No 3\
...
...
..... ( Chpt 1 1 Page 16
AUXILLARY EQUIPMENT
DESCRIPTION
APseoRG SUNROC? -,
Date 18-AUG-93
QUICK SELECTION GUIDE -A
5 UIM SA11A %I28 25

7 UIM 5A11A SA17.6 3.5 S81M 5811A 58128
7 SAIM 5A11A SA128 3.5 581M 5811A 58128
CATALOG NUMBERING SYSTEM

SWITCH ASSEMBLY UNIT
S l r n I O I L I I LIUI" -rmM
o~o.dsnmI~-l -'W ImI

nmlunqvll ~ % v ~ l n n l o ~ l d r
PRESSURE TRANSDUCER ASSEMBLY
~~WYIY- E M P E R A N R E TRANSDUCER ASSEMBLY

1
n
Doc No > 2-.
...
.....
.....
. . ~
Chpt 1 Page 17
AUXILIARY EQUIPMENT
DESCRIPTION
Date 18-AUG-93
SWITCH ASSEMBLY UNITS

SPECIFICATIONS
The SWIIC~ asSemDhl badq is aiesaa. copper-free alummlum. AppmVmla: Most snndara unm are U.L. listed. FM and CSA
Generat P u w s e and Watenlgnt cover are cooper.free alum,- aporones areaoolodfor ASCO s n me process of appnpngfor
nwm sneet metal tna G o ~ o s ~ o ncover.%
~ w l alesaw copper- several Ewooesn approvals For aeta~ledapproval dormatlon
free s,mmum Gawets are Durn-N
Two%'condu~t nuof &thonapluganprovldea: for Pg16caole
-
on a s ~ e c l cutaloa n~mDercontact *our ASCO
~~~ ~ - dlstnauror
- -~~
~
glana refer to opnoml tealures b H w . Arnblmt 1.mp.raNns: -20°C. to +€Q°C. I-a'F, to

+ l4O0F.I
Oen.nl Purpou T y p . is aesngnea to NEMA 1 and meets 1P42 std.m
spec~licattons.
WatmIgM T y p . is designed to NEMA 3.3R. 4 ana m w t s IPS5 -
A lZ5. 250
Specficanons for lnamr IOUI~OOT use. -
90 W. 125 Vac 180 W. 253 Vac
E q l o s i o n p r w f T y p a deslgned to NEMA 78.7C. 7D. 9E. 9F 0,5 A. A. 2M
and 9G s ~ c r l i c a l ~ o nass well as NEMA 3. 3R. 4 ana 1P55f w -
(for SC Vpes: 0.4 A. 125 Vdc 0.2 A. 250 Vdc)
~ n d w r l o u l a wuse.
r All m l c n e s tumished mth screw rermmals. except factory
~GC--I.II~..L sealed unils 1'3' in founh dignl.
OPTIONALFVlNRES ~~a~nmhnD*rrldlhwmmmmnaurqcmsMo.abmr.rur4l~.~wlM~a~mDop
p . ~ t b m ~ l a Y I M m m W I I .
Doc No 33
AUXILLARY EQUIPMENI Chpt 1 Page 18
DESCRIITION
Date 18-AUG-93
PRESSURE TRANSDUCER UNITS

SPECIFICATIONS
Pressure transducers are bliy restea self-conlamea separate Maxlmum lluld lempmtuma:
~~o-assemb11e501 me aiaphragrnlptslon consrrusron. The Buna-N and nwprene alamragrns: +We C 1 + 180' FI.
\liton diaDhnams: + 120' C : mala d l s D h n m + IS0C.
In- ~ f e s i u r etransducer untn ainerenl nula media consul1your

ASCO dlslnbulor.
.....
..... AUX~LLARYEQUIPMEm Chpt 1 Page 19
DESCRIPTION
Rev.No. A
AALBORG --
. ..SUNROD-
... -, Dare 18-AUG-93
DIMENSIONAL DRAWINGS
Olmmmons m rnm compficte slntsner cmenng general pumose and
I
-1M-
s..
1a1
I. ----
.....
.....
W O R G SUNROO
.AUXILIARY EQULPMENT DESCRlPTlON
--- .
- Chpt I
RevNo A
.-
Date 18-AUG-93
Page 20
I N S T A L U I I O H OPERATION AND MAIKENANCE INSTRUCZIONS FOR

ASHFORD BARSTOCK NEEDLE VALVES AND MTLII-VALUE KANIFOLDS
INCORPORATING TYPE DO1 ASSEHBLY
:he i l l u s t r a t i o n s in t h i s p u b l i c a t i o n a r e i n t e n d e d to a s s i s t i n t h e m a i n t e n a n c e
of WE1 X O H P S O S ' S VALVES and say n o t exactly r e p r e s e n t t h e i t e m s s u p p l i e d .
!n accordance uich its ? o l i c y of continuous product development, t h e Company

r e s e r v e s :he r i g h t :o a l t e r d e s i g n s and n a t e r i 3 L s 3 c ics discretion.
The Y a n u i a c t u r e r a c c e p t s no L i a b i l i t y f o r :%e c o n s e q u e n c e s o i improper u s e .
:n c a s e of doubt, p l e a s e c o n s u l t t h e S a l e s 3epartment.
Doc No
......
..... AUXILLAkY EQUIPMENT Chpt 1 I Page 21
DESCRrPTION
Date 18-AUG-93
The f o l l o v i n g v a l v e s and m a n i f o l d s a r e c o v e r e d by t h e s e i n s t r u c t i o n s : -
-
m TIPE No.
S i n g l e needle valve W1. R01
Two v a l v e m n i f o l d s H18, H20, HZ3. H26
Three v a l v e m a n i f o l d s H30. H33. H36, HOO. H41
Five valve manifolds HSO. HS3, R56. H60. Rbl
Special needle valves Any s p e c i a l n e e d l e v a l v e o r

o r manifolds manifold n o t I n c l u d e d i n t h e
above and i n c o r p o r a t i n g t h e
W1 bonnet assembly.
Noce : The c e m " s p e c i a l " r e f e r s t o any non-catalogue item.
HE1 Thompson Valves s t a n d a r d -rerials a r e Stainless Stael. Carbon

S t e e l and Righ T e n s i l e B r a s s . (Hanganerne 8 r o a z e ) but t h e i n s t r u c c i o n a
a p p l y e q u a l l y t o v a l v e s and m a n i f o l d s conmcrucced from o t h e r m a t e r i a l s
auch a s Honel. R s s t e l o y and Gunmetal.
F i g u r e 1 shows a s e c t i o n a l View of a t y p i c a l bonnet assembly.

-- -- Doc S o
1 I
..... AUXILLARY EQUIPMENT Chpt 1 Page 22

DESCRIPTION
Rev.No. A
AALBORG.~SUNROD,
.. . -
Date 18-AUG-93
The v a l v e bonnet assembly i s i n a l l c a s e s t h e s a n e , consi.:ing of a

r i s i n g stem n i t h n o n - r o t a t i n g s t e m p o i n t r e c a i n e d i n a bonnet which is
screwed i n t o t h e v a l v e body o r manifold block. me bonnetlbodg j o i n t
is s e a l e d by means of a chamfer i n s i d e t h e body and a Locking p i n
p r e v e n t s a c c i d e n t a l disassembly.
h e stem p a s s e s o u t of t h e bonqec v i a a g l a n d which is s i t u a t e d below

the operating threads. Clockwise r o t a t i o n of t h e handwheel c a u s e s t h e
s t e m p o i n t t o s e a l o f f a g a i n s t t h e s e a t which is l o c a t e d i n t h e v a l v e
body o r manifold block. End c o n n e c t i o n s may be screwed. s o c k e c we1.d o r
bvcc weld.
H ~ d i f i ~ a t i o nt os any p a r t of Che v a l v e , i n c l u d i n g end c o n n e c t i o n s a r e

undertaken a t r h e s s e r r awn r i s k .
3.2 S i n ~ l ev r l v e s ( F i g u r e 2 )
S i n g l e Valves a r e provided w i t h one i n l e t p o r t and one o r more o u t l e t

p o r t s . The l a t t e r may, i n some c a s e s be f i t t e d v i t h venc o r b l a n k i n g
plugs.
Two valve manifolds a r c provided v i c h one i n l e t p o r t . one o u t l e t p o r t

and one venc o r t e s t connection.
One valve isol.tcs t h e o u t l e t and t e s t conneccion from t h e i n l e t w h i l s t

t h e o t h e r v a l v e t s o l a c e e t h e t e s c conneccion.
rr I- -- Doc No
..... AUX~LLARYEQXPMENT Chpt 1 Page 23
DESCRIPTION
Rev.No. A
N O R G SUNROD. -,
Date 18-AUG-93
Three v a l v e u n i f o l d r a r e provided wich NO i n l e t p o r e s a n d cvo o u c l e c

ports. Two valves isolace che Lnlecs from che ouclecs vhich are
c o n n e c t e d c o g e c h e r v i a a c h i r d v a l v e f o r e q u a l i s a t i o n purposes. T h e s e
m a n i f o l d s may a l s o be provided w i t h c e s c c o n n c c c i o ~o n t h e o u c l e c s i d e
of t h e i s o l a t i n g valves. Types 833. R36, R40. R41 are i n c e n d e d f o r
f l a n g e mouncing t o D.P. Transmitters and a r c p r o v i d e d w i c h two seal
rings and four 7/16" UNF mouncing bolts for chis purpose. Inlet
c o n n e c t i o n s on t y p e H33. H40 and H41 and i n l e c and o u t l e c c o n n e c c i o n s
on t y p e H30 a r e u s u a l l y screwed o r s o c k e t weld. I n l e r conneccions on
t y p e H36, H40 and H41 can be s u p p l i e d f o r mouncing of o v a l f l a n g e s .
F i v e v a l v e u n i f o l d s (Figure 5 )
Flve v a l v e m a n i f o l d s perform che same f u n c t i o n as the three valve

m a n i f o l d s d e s c r i b e d above. but a r e provide4 wich cwo ercrs v a l v e s v h i c h
isolate che t e s t conneccions.
KAhlJFAcTrnZR'S LIABILITY
Always ensure t h a t t h e valve o r manifold is used f o r c h e s e r v i c e f o r

which LC was purchased and chat ic is o p e r a t e d and maintained in
accordance wich these instructions. The manufacturer accepcs no
liabilicy f o r t h e coMequences of improper use. I n c a s e of doubc.
c o n s u l t che NEI Thompson Valves. Valves D i v i s i o n Chief Desimer o r
qualicy k s u r a n c e h m g e c .
Valves o r r u n l f o l d s not r e q u i r e d f o r i w d i a c e u s e s h o u l d b e s c o r e d
under c l e a n , d r y condicioru i n a c e w e r a t u r e c o n t r o l l e d s c o r e . Icea
which a r e s e a l e d i n p l a s t i c bags should noc k d i s t u r b e d u n t i l r e q u i r e d
for inscallation. Care ahould be taken t o e n s u r e chac f o r e i g n u c c e r
i s noc a l l w e d c o e a c e r chc c o n n e c t i o n s and any p r o c e c c i v e c a p s u h l c h
are f i t t e d should be kept in place. The mrmfaccurer accepcs no
l i a b i l i c y f o r chc coruequences of improper s t o r a g e .
", , 7
II I---
- Doc No
DESCR~FTION
Rcv.No. A
U O R G SUNROD -_
Date 18-AUG-93
Before i n s t a l l a t i o n . o p e r a t e a 1 1 v a l v e handwheels o r I - b a r s t o ensure

chat they a r e functioning c o r r e c t l y .
I n t h e c a s e of s i n g l e v a l v e s and a l l w n i f o l d s n o t i n t e n d e d f o r f l a n g e
muncfng to D.P. c e l l s ecc. select che i n l e t and connect to the
upstre.. pipework. (Valves a r e stamped v l t h a f l w arrow and m a n i f o l d s
a r c l a b e l l e d co i n d i c a t e t h e porting).
Connect t h e downstream pipework t o che o u t l e t porc.
I n chc c a s e o f f l a n g e mounted m a n i f o l d s , b o l c che o u t l e t f l a n g e c o t h e

inoccumenc t a k i n g c a r e chac t h e s e a l r i n g s a r e p r o p e r l y l o c a t e d i n t h e
grooves. T i g h t e n t h e f i x i n g b o l t s u n t i l che f l a n g e ' f a c e is f l u s h v i c h
che instrument f a c e chen connect che upacream pipework t o t h e i n l e t
Ports.
When velded conneczions a r e being made, ensure chac che v a l v e s a r e

h a l f r a y open.
The v a l v e s a r e c l o s e d by clockwise r o t a t i o n of che handwheel o r T-bar

and opened by a n t i - c l o c k w i s e cocacion. Never use e x c e s s i v e f o r c e o r
means o t h e r t h a n che handwheel o r T-bar t o o p e r a c e t h e v a l v e as t h i s
c a n d-ge t h e s e a t o r back-rear. Always e n s u r e c h a t i s o l a c i n s v a l v e s
a r c c l o s e d b e f o r e removing b l a n k i n g p l u g s o r o p e n r i n g v e n t screws.
From cime t o rime i c may be n e c e s s a r y t o c i g h t e n che a c t u a t o r bush i n

o r d e r co prevcnc leakage through t h e packing. Vhere v a l v e s have been
s t o r e d f o r Long p e r i o d s . che packing may have r e l a x e d and may r e q u i r e
c i g h c e n i n g a t t h e time of i n s t a l l a c i o n .
., v
I. I-I-
Doc No
.....
..... AUXILLARY EQUIPMENT Chpl 1 Page 25
DESCRIPTION
Rev.No. A
AALEORG SUNROD 1
Date 18-AUG-93
-
I t i s n o t p o s s i b l e t o re-pack t h i s v a l v e under p r e s s u r e . Ensure t h a t

t h e l i n e i n d e p r c s s u r i s e d b e f o r e a t t e l p t i n g this o p e r a t i o n .
S h u t t h e v a l v e b u t do n o t screw down t i g h c o n t o t h e s a c . Remove t h e

handwheel r e t a i n i n g n u t ( i t e m 101, l i f t o f f t h e handwheel ( i t e m 10) a n d
then use a spanner t o loosen t h e locknut ( i t - 8). If t h e v a l v e is
f i t t e d w i t h a l o c k i n g d e v i c e , remove t h e l o o s e i t e w .
w i t h t h e s p a n n e r t u r n t h e a c t u a t o r bush ( I t e m 7 ) i n a n a n t i - c l o c k v i s e
direction. If che stem c o n t a c t s t h e backaeac before the a c t u a t i n g
bueh is f r e e . screw i t down i n a c l o c k w i s e d i r e c t i o n c w a r d s che s e a t
and r e p e a t t h e above procedure. The a c t u a t o r buah c a n t h e n be l i f t e d
c l e a r a l l o w i n g t h e l o o s e f o l l o w e r ( i t e m 6 ) t o be removed.
The g l a n d packing ( i t e m 5 ) can be withdrawn by u s e of p a c k i n g p u l l e r s

and r e p l a c e d by a new see. Ensure t h a t a l l t h e o l d p a c k i n g is removed
and c h a t t h e r e i s no damage t o che stem, erc.
To re-assemble. follow the above procedure in reverse order. A

p r e s s u r e t i g h t s e a l is o b t a i n e d by a d j u s t i n g t h e a c t u a t o r bush i n a
c l o c k w i s e d i r e c t i o n u n t i l leakage s t o p s , when t h e l o c k n u t c a n be re-
tightened.
8.2 S c p h c e a n t of s e a (See F i g u r e i )
Before commencing chis operation, ensure chat che line is

de~reasuriscd.
Replacement may be achieved i n two ways :
a. By r e p l a c i n g che e n t i r e bonnet a s s e a b l y .
b. By r e m v i n g t h e stem from t h e banact and r e p l a c i n g i t w i t h

another.
I---
Doc No +l
...a.
...a.
AUXILLARY EQUIPMENT Chpt 1 Page 26
DESCRIPTION
Rev.No. A
-o"%N_RO". ._I
Date 18-AUG-93
-
bmec Beplacea~r In order to rmve the exiacing bonnet

assublg, a r c n c t t h e l o c k i n g p i n ( i t e m 18) and c u m t h e bonnet
(ice. 2 ) anci-clockwise f o r C.S. and S.S. v a l v e s o r clockwise f o r
brass valves. Insert the replacernt bonnet by reveniq thia
procedure and applying a maxima torque of 1 5 l b f - f c (20.5 N-m)
f o r C.S. and S.S. o r 12 l b f - fc ( 1 6 H-m) f o r b r a s s valves. P i c a
new bonnet l o d i n g pin.
Stem Replacement To remove t h e e x i s t i n g scem ( I t e m 1). proceed a a

above i n o r d e r t o remove che bonnet. Detach t h e handwheel s o c h a r
che scem can be e x t r a c t e d from t h e botcom of t h e bonnet by t u r n i n g
anti-clockwise. PIC che new seem and reassemble as described
above.
NOTE : In che case of m a t e r i a l s ocher chan b r a a s . a suitable

l u b r i c a n t should be applied t o t h e stem t h r e a d s p r i o r t o assembly.
Recommended l u b r i c a n t s a r e :
a. For oxygen s e r v i c e : Uoncedisou Fomblin RT 15.

b. For g e n e r a l applications : Thredgard 1060 (Crane).
This should o n l y bc necessary i f che manifold has baen detached f r o m

t h e instrument. &move t h e o l d s e a l s and r e p l a c e with a neu set. B o l t
chc m n i f o l d b.d once t h e ia9crumenC. applying s u f f i c i e n t t o r q u e t o
b r i n g t h e two f a c u cogether.
9.1 Remove o p e r a t i n g handle. l a b e l . nut and dusc Cap.

I- .I- -- Doc No
..... AUX~LLARYEQUIPMENT Chpt 1 Page 27
DESCRIPTION
Rev.No. A
AALBORG SUNROD, .j
Date 18-AUG-93
9.2 F i t l o c k i n g r i n g so t h a t i t s t a g p o i n c s downwards c o v a r d a che m a n i f o l d

body, ensuring char the tag i a aeaced against one 'flat' of the
bonnet.
9.3 F i t l o c k i n g n u t and s e c u r e .
9.b R e p l a c e d u s t cap.
9.5 F i t circlip.
9.6 L u b r i c a t e b o t h f a c e s of i n d i c a t o r arms and t h e n f i t over s t e m so c h a t

"dog-leg" f a c e s downwards. The i n d i c a c o r arm s h o u l d m w s i c on t h e t o p
of t h e c i r c l i p and t h e "dog-leg" s h o u l d be engaged i n t h e s l o t of t h e
l o c k i n g r i n g between t h e l e t t e r s "0" and "S".
9.7 Replace h a n d l e , l a b e l and n u t e n s u r i n g t h e i n d i c a t o r a m i s free t o

move.
9.8 Close the valve; t h e 90° bend in the louer part of the indicator
arm s h o u l d now be i n l i n e v i c h t h e " s h u t " l i n e of t h e locking ring.
A d j u s t r h e i n d i c a t o r a m v i c h p l i e r s i f necessary.
Doc No
I- I---
b3
.....
DESCRIPTION
Rev.No. A
AALBORES!-!N_RG". .J Date 18-AUG-93
TYPE H01
Li LI
Doc No
.....
DESCRIPTION * Rev.No. A
AALBORG SUNROD
Date 18-AUG-93
Engineering Manual
/E AUTOMATION SYSTEMS 4.100 E

?I
Doc No
.....
..... AUXILLARY EQUIPMENT Chpt 1 Page M
DESCRIPTION
Rev.No. A
Date 18-AUG-93
El-o-matic pneumatic actuators are available in w o model series.(Series "P' and

Selies 'E')
Each series has a special prelix in its model number to identify them as double-
acting or spring return.
( Double acting ( Spring - return

"P' Series I PO I PE
'E' Series ED ES
Description
El.0-matic actuators are pneumatic quarter.turn actuators. The design utilizes a
double rack and single pinion. A unique patented leature o l the El-o-matic
actuator is the application 01 three carbon filled Tellon' guide bands. on a
patented balanced piston which prevents melal.to.metal contact between [he
pistons and cylinder wall. elmmates wear, and enhances cycle lile.
Slandara units al 6 bar provide lrom 15 to 4.945 Nm. 01 torque and leature an
extended top shalt and a completely modular design which allows simple attach-
ment o l a variety ol control accessories. All units leature an integral solenoid
control block which properly directs supply air to the actuator. On doubie-acting
and spring.retum actuators the solenoid control block is available wilh independ-
ently adjustable speed controls lor both the
opening and closing strokes o l the actuator. El-o-matic recommends speed
Controls lor all actuator applications.
Installation
Et-o-matic actuators leature a female output drive which permits close coupling o l
Ihe valve/acYalor assembly and eliminates the misalignmenl that may olnerwise
be encountered with more traditional exlended output shalt designs. Drive cou-
plings are available lrom El-o-matic to adapt to the lollowing valve slem designs:
El-o-malic also olfers rugged. precision engineered mounting hardware to comple.

ment the close coupling concept. Mounting hardware is available lor new valve
installations or to relrolit actuators l o existing, in-line. valves.
44
m- ----
.....
DOC
NO
..... AUXILLARY EQUIPMENT

DESCRIPTION
Chpt 1 Page 31
Rev.No. A
,
AALBORG SUNROD .
Date 18-AUG-93
Actuator Orientation
The El-o-malic aclualor is normally installed with its major axis parallel l o the
pipeline. The aclualor can be oriented above. beside or beneath the valve without
affecting 11s operation.
Our unique lull machined pinion gear and square drive

mounling pattern allows reorienlation of the actualor l o accommodate inslallations
where physical obslruclions might otherwise be prohibitive .
NOTE: All El-o-matlc actuators leature a blowout proof s h a n deslgn. Thls

means t h a l the plstons must be removed betore the shaft can b e reorientated.
See DlSaSSembly IReassembly Instrucllons.
I Step I :
Step 2:
Delermine mode of operalion o l !he valve (normallyopen or normally closed)
Delermine deslred quadrant lor bracket allachment and direction ol mounting ol

Ine aclualor (in line or cross line).
I Slep3: Allach bra~kellaclualorlvalveassembly as lollows:
! Never disassemble a valve that is under pressure !
1 A ) Rolale valve slem to posilion necessary l o achieve desired operation
8 ) Remove handle nut, handle. lockwasher, elc. as required by mounting hardware

inslructions.
)I C ) Attach mounting brackel to actuator . do not tully tighten bolts at this
D) Insen coupling inlo drive sleeve 01 the aclualor making sure lhal the coupling
lime
engages properly.
E) Lower mounting bracketlaclualorlcoupling assembly onto valve. making sure

Inat male valve stem engages in coupling.
F) Secure brackel lo valve using cap screws and lock washers provided in mounl.
ing kil. Tighten securely.
G ) A l this lime make sure lhal the actuator is in the operational mode desired and
that lhe valve is in the corresponding open or close posilion: il nol:
1
.....
D o c No
... ..
...... AUXILLARY EQUIPMENT I Chpt 1 I Page 32
DESCRIPTION
1 Date 18-AUG-93
1. Remove the lasteners at the mounting brackev actuator end lhen rotate
acluator 90 degrees while still engaged with valve stem, or.
2.11 integral solenoid valve is present on double acting model. remove the
Solenoid assembly and inven it (turn it upside down) and remount.
N0TE:Some valves are manufactured so lhat they operate in only one 90

degree segment, a good rule o l thumb is lo mount lhe actuator lor counterclock-
wise rotation to open and clockwise to close the valve.
Air supply and electrical installation

1 . A. AIR SUPPLY:
El-o-matic actuators are laclory lubrlcaled. For optimum operation. the use
01 clean. dry air or gas is recommended. Lubricated air is not necessary.
6 . AIR SUPPLY PRESSURE:

Standard double-acting actualors requlre 1 lo 10 bar supply alr. Sprmg return
actuators require 3 to 10 bar supply atr
C AIR SUPPLY CONNECTIONS:
NO INTEGRAL SOLENOID - Double.ACtlng (Models ED 8 PD).
First remove dust plugs. then connect abr supply lmes l o oolh pons on me
alr manifold in lhe center of the actuator body.
The standard unit (CODE A) operates as lollows:

Air 10 Pon A: counterclockwiselopen
A i r to POR B: Clockwiselclose
standard lnvened
(Code A)
Rack and plnlon arrangement as v~ewedlrom above.

TO reverse actuator rolatlon. m e n plstons.
Ll-8
I- -- -- Doc No
..... AUXILLARY EQLnPMEm Chpr 1 Page 33
DESCRIPTION
Rev.No. A
-
AALBORG SUNROD,
Date 18-AUG-93
SPRING-RETURN (MODELS ES 6 SR) -Connect air supply line to NPT p a l (A).
The E1.o-Matic actuator stroke direction can be reversed. To reverse stroke direc-
tion remove both pistons, rotate lhem 180 degrees and reinstall. This will reverse
Ihe direction o l rotation 01 the output shan.
WITH INTEGRAL SOLENOID - Connect air supply line l o the pressure port on the
solenoid block.
0.RECOMMENDED TUBING SIZES:

In order to provide sullicient llow o l supply air l o lhe El-0-Malic actuator. the
following tubing sizes are recommended:
Achlalor Runs up to Runs over

Model no 1.2m 1.2
P-35.60
E.100.200 6 mm 8 mm
P.1100.2500.4000 6 mm 12 mrn
E. AIR CONSUMPTION:
The Following Chan shows the amount o l air consumed per 90 degrees 01 stroke i n
llr.lslroke:
Air consurnptlon ltrlstroke

1
Alr chamber Modal
"P"wries 1 35 60 150 280 500 750 11W 2500 4000
A 1 0.13 0.27 0.6 1.5 1.9 3.2 4.2 8.0 13.5
ki9
rr -- --
...
Doc Na
AALBORG SUNROD
.- - . .... - - . .
1
AUXILLARY EQUIPMENT
DESCRIPTION
-1 Chpt 1
Date 18-AUG-93
Actuator assembly modes

The Elo-matic actuator may be lield OR lactory converted to provide diflerenl
directional rotations and shalt orientations. The lour conligurations A.B.C.D. are
shown.
mounting I mounling
A standard spring to closecw B spindle t u r n e d 90 spring to chsecw
Spindle turned 90 mounling in line

D C Pmonsturnw 180' mounting across line;
Plstons turned 180' sprmg lo open-cm
NOTE: Code 'A" ISStandard.

All are vlews from above
-- .....
-- -- Doc No
s-0
-
..... AUXILLARY EOUlPMEhT Chpr 1 Page 35
DESCRIF'TION
--...--
Rev.No. A
AALBORG SUNROO
. -4
Dare 18-AUG-93
1. BASIC ACTUATOR
The El-o-matic anuator drive shalt rotates through a lull 90 degrees (some 'P'
Series models may be ordered with full 180 degrees o l rotallon). Rotation is
accomplished by leeding supply air in to the center chamber, lorcing the two
opposing pistons outward, resulting in counterclockwise rotation 01 the drive shall
lo the 'open' position.
For double-acting actuators closure is obtained by leeding supply air inio the end
cap chambers. whlch IOrCeS the pistons inward, resulting in clockw~serotation 01

Ihe drive shall.
For spring return actuators, closure is accomplished by means 01 springs conlained

within the end caps, which lorce the pistons inward when the supply air lo the
center chamber 1s allowed to exhaust.
t 1
AIR €XHAUST
iI the rolation ooposlte l o lhal described above is required, reler to Aclualor Orien-
tabon lor the proper procedure lo reverse lhe rotation.(P.5)
s- 1
-- .....
-- -- Doc N o
..... AUXILIARY EQUIPMENT Chpt 1 Page 36

DESCRIPTION
Rev.No. A
AALBORG SUNROD
- .- - - - ... .- ..J
Date 18-AUG-93
2. ACTUATOR WITH SOLENOID VALVES:
DOUBLE-ACTING - A i r is supplied to the pressure port on the solenoid block.

When the solenoid is energized the spring loaded plunger is withdrawn, allowing
the supply air to shift the spool wilhin the block, which opens lhe supply path to the
center shamber (PortA) 01 the actuator. Air trom the end chambers (PonB) 01 the
actuator is allowed to pass through the block and exhaust to almosphere.
When the solenoid is de-energized the Spring loaded plunger blocks the llow ot air
10 the center chamber 01 the actuator. The spool now shills within lhe block lo a
position which opens the supply Path to the end chambers (PortB) o l the actualor.
Air from the center chamber (PortA) of the actuator is allowed to pass through the
block and exhaust to atmosphere.
The double acting solenold assembly is responsive to electrical lailure. That is, it
.will return to its de-energized position upon eleclrical tailure and cycle the acluator
to the closed posilion provided the air supply is not interrupted. This action may be
reversed by inverting the entire solenoid valve on the alr manitold
Ii.e, de-energized condition will pressurize Port A).
Solenoid assemblies are available w ~ t hindependently adjustable speed controls

which can be used to adjust the speed O t operation lor the opening andlor closmg
stroke. If the speed controls are loo light, air will not pass and the unit will not
operate.
-......
"- -- Doc N o
b b
..... A U X L L A R Y EQUIPMENT
DESCRIPTION
Chpt 1 Page 37
Rev.No. A
AALWJRG SUNROD
Date 18-AUG-93
SPRING RETUaN . Air is supplied to the pressure porl on the solenoM block.
When the solenoid is energized the spring loaded plunger is withdrawn, which
opens the supply path to the center chamber (PorlA) 01 the actuator. Air from the
end chambers ot the actuator is allowed to pass directly through the block and
exhaust to atmosphere.
When !he solenoid is de-energized the Spring loaded plunger blocks the flow 01 air
10 !he cenler chamber ot the actuator, at the same time the air from A is allowed to
pass lo exhaust. The springs in the end cap ol the actuator, which were COm-
pressed on the opening stroke. can now extend, lorcing the pistons together and
providing the clockwise rotation ot the outpul shalt.
3. STANDARD STROKE TIMES:
Slandard stroke limes 01 the El-o-matic actuators are shown in lhe lollowing table.
Times shown are in seconds and represent average times under no-load conditions
w t h an air supply pressure 01 6 bar. Times shown are per stroke lor double acting
actuators. For spring return actuators. the opening stroke times may be slightly
longer: stroke times lor the closing (spring) stroke are dependent upon lhe number
ol springs used.
The ligures shown below are meant as an indication 01 obtainable speeds only
Faster or slower speeds are obtainable.il required, by using additional Control
equipment
35 . €4 150 280 500 750 1100 2500 40W

0.7 1.2 2.3 3.4
-E' series 25 40 100 200
0.5 0.5 0.7 1.2 2.3
II I--- Doc No
..... A U X ~ L A R YEQUIPMENT Chpt 1
DESCRIPTION
AALBORG SUNROD
Date 18-AUG-93
4. MANUAL OPERATION:
In the even1 01 air failure. Ihe E1.o-Malk adualor can be cycled manually. This is
accomplished by applying a wrench lo the exposed lop shall 01 lhe adualor and
lurning in the desired dlreclion. mh is not recommended on Model Sizes ~ 0 . 1 5
and larger or on spring return actualon. In lhls case. El-o-Matlc ollers an oplional
declulchable manual override syslem (Series MO)(See datasheet 3.402 lor details).
Warnlng: care m u s t be taken t o ensure that the actuator Is n o t

operated automatically whlle manual operation Is belng performed
NOTE: Alr must be allowed t o exhaust from the aclualor lor manual operat:on.
Thls requlres dlSconneCllng air llnes or provldlng l h r e r w a y vent valves at
Inlet pods.
II a routine cycle check is to be performed on a double-acting aclualor equipped

wilh the €1.0-Matic solenoid control block. the acluator can be cycled manually by
operating the inlegral manual override button on the solenoid body. Care musl be
laken to hold lhe bullon in the desired (il filled) position until the actuator has
cycled. Provided the air supply is still on. the actuator will cycle to its original posi-
tion as soon as the manually applied pressure on the button is released.
I Doc No -
Chpt 1 Page 39
Maintenance
CAUTION: THE ACTUATOR MUST BE ISOLATED BOTH PNEUMATICALLY AND

ELECTRICALLY BEFORE ANY MAINTENANCE IS BEGUN.
Periodic checks should be Perlormed to make cenain that all fasteners remain
lignt.
All actuators are supplied wilh sufllcient lubrication for their normal working life. It
required. recommended lubrication for all standard actuators is a Pensoil MP 705.
Consult El-0-matic tor lubricants used for high or low temperature applications.
Depending upon the conditions under whlch the actuator musl work such as
extendea duly. non-compatible operating media or aonormai operating conditions.
periodic replacement of internal Seals is recommended. Repair kits containing all
necessary seals can be obtained through any authorized El-0-matic distributor.
On spring return actuators. Ihe springs may need replacement alter extended duty
since springs may latigue. SPRINGS SHOULD ALWAYS BE REPLACED IN
COMPLETE SETS. Spring kits are available lnrough any authorized El-o-rnatic
distributor.
EL-0-MATIC RECOMMENDED SPARE PARTS
All soft seals. bearings. and non-reusable pans are included in !he El-o-matic
recommended spare pans kit.
Each kit includes
1- set o f guide bands 2- output shaft "0" rlngs

2- Plston "0" rlngs 1- nylon washer
2- end cap "0" rings 1- spring cllp retainer ring
2- shaft bearings
The spare pans kit is identical lor both the double-acting and the spring return
models. For the spring return models we recommend a set of spare springs for
each different model in additlon lo the recommended spare pans kit. Keep in mind
Ihat. when necessan. springs are to be replaced in complete sets.
- \$
-- -- -- Doc No
, DESCRIRION
Rev.No. A
Date 18-AUG-93
Troubleshooting
BEFORE DISASSEMBLING ACTUATOR FOR ANY REASON, CONSULT RE-
BUILDING INSTRUCTIONS CONTAINED IN THE FOLLOWING SECTION:
1. For solenoid controlled actuators:
A. If actuator does not lunflon. check l o ascenain that:
1. Valve is tree l o rotate. This can be done as described above in 'Manual Op-
eration'.
2. Actuator is the correct size.
3 . Speed control screws are loose (ifscrews are lightened all the way, acluator
wdl not operate).
4. Correcl voltage is supplied to solenoid (valve coil is lagged with correct
voltage).
5 . Sufficient air supply is available at inlet to control block. Inlet pressure to
control block on a 512 solenoid valve should be a1 least 2 bar. When check-
ing supply pressure. place gauge in line a1 control block inlet and monitor
gauge tor unexpected pressure drops.
8.I1 proper voltage and air pressure have been verlfied and valve is free proceed
as lo~lows:
1. Turn on slgnal vollage. Check solenodd lor clicking sound.

2 . 11 no sound is detecled:
a) Caretully unscrew solenoid and solenold stem lrom Block.
B) Reapply signal voltage and observe solenoid plunger. I1 i t does not
relracl, replace solenoid.
3. 11 solenoid funclions, remove solenoid valve block and place on bench.
Connect to reduced air supply. and correct vollage. Switch signal voltage and
check air flow. Air should flow out only one output pon when solenoid is
energized.
(Slight back pressure may be required to shill the valve spool. This may be
generated by obslmcting the outlet pons).
C. II the acluator lunclions But exhibits leakage, or power loss accompanied by

leakage, proceed as lollows:
1. Check vollage. Vollage must be within 10% ot the specitied voltage (low
voltage w ~ lcause
l leakage out ol the back ot the solenoid and burn out !he
coil).
11
-- -- -- Doc N o
.....
..... AUXILLARY E Q U I P M E N T Chpt 1 Page 41
DESCRIPTION
Rev.No. A
m
_"I
R --...
G -- -,
SUNROD
Date 18-AUG-93
2. Check air supply. Be Cerlain that no sharp drops occur as unlt is cycled. Loss
01 pressure can cause incomplete shifting ot the spool valves in the block, or
at one ot the Piston seals ot the actuator. A leaking piston seal will usually
leak on either cycle.
On spring return actualors, piston seal leakage wlll show at Pon B of the air
manitold flange.
The recommended procedure in the case above is to replace the spool valve
O-rings first. If the leakage persists rebuild lhe actuator using a tanory-
Supplied repair kit.
3. For actuators without a solenoid control block or il block and solenoid are
operating correctly, remove the actuator from the valve.
! Never disassemble a valve that is under pressure I
Apply air pressure (0.5 - 1 bar lor double acting. 2 - 5 bar tor spring relurn) to see
it il will cycle under a no load condition. I1 acluatorworks properly then the prob-
lem is in the valve. Consult the valve manulacturer for assistance. It the actuator
does not cycle then disassemble as per "Actuator Disassembly' Instructions
below. and Check tne tollowing:
NOTE: Actuator should not be removed from the valve under pressure.
A. Make sure thal all internal porting is tree and clear ot any obstructions.
0. Make certain thal the aclualor has lubricalion.and that there is no solidilied
grease between the pinion ;Ind the piston racks.
1 It the actuator has no lubrication. apply generous amount of grease. If aclua-
tor is prepared lor high or low temperalure operation. consult El-o-matic lor
proper lubricanl.
2. It solidilied grease between the pinion and the piston racks is present. clean.
dry, regrease and reassemble.
C. Verity that actuator pinion shan andlor pistons are not bound. If bound. reas-
semble per Rebuilding Instructions.
0. It unit exhibits excessive amounts ot backlash, check teeth on piston racks tor
wear. If worn, replace pistonlgear rack assembly.
E. In spring relurn aCIUatOrS. check lor misplaced or broken springs. It springs are
broken, check body bore for scoring.
SPRINGS SHOULD ALWAYS BE REPLACED IN COMPLETE SETS.
I . It sprlngs are broken, replace springs.
12
...
.....
..... AUXlLLARY EQUIPMENT 1 Chpt 1 1 Page 42
DESCRIlTION
..-- --...-- .-
A4LBORG SUNROD
Date 18-AUG-93
2. 11 body bore is sarod. replace if necessary.

Also replace piston O-rings (contained in Repair Kil).
F. If actuator is free. valve is tree and control lock (it used) is shifting air propedy.
reassemble the actuator and retest. II unit still fails to operate, consult
El-o-malic.
Rebuildina Instructions
For indentificalion 01 all numbered pads discussed below.see the actuator data
Sheets 1.101 and 1.101.02 at the end of this manual.
Actuator Disassembly
Belore diassembling any actuator be sure that a complete seal kil is available and
that the kit has been checked lor pans.
Each kit includes

1- set of guide bands 2- output shaft " 0 rings
2- Piston " 0 rings 1- nylon washer
2- end cap "0" rings 1- spring clip retainer ring
2- shall bearings
1. Disconnect the air supply and electrical service to the actuator

2. Remove the actuator and its mounting bracket trom lhe valve.
CAUTION: BALL VALVES AN0 PLUG VALVES CAN TRAP PRESSURIZED

MEDIA IN THE CAVITY. ISOLATE THE PIPING SYSTEM IN WHICH THE ACTUA-
TORVALVEASSEMBLYISMOUNTEDANDRELIEVEANYPRESSUREONTHE
VALVE.
3. Remove the actuator mounting bracket (and actuator switch box, positioner
and other accessories if provided) from the actuator to begin repair. (Note
position 01 removed mounting brackel and accessories lor easy reassembly).
4 . Remove solenoid control block (it so equipped) by removing the solenoid block
bolls. Use care to retain the solenoid block seals.
5. Each end cap (P3.E4l is fitted Onto the body (1) with a ?e.l of end cap bolts.
Remove all end cap bolls (P24 €36) from both end caps by loosening them
evenly and a tittle at a time. Alter the screws are removed, gently pry oft each
end cap being careful not to damage the end cap O-rings.
5-S
r- ir-r Doc No
.....
DESCRIPTION
Chpt 1 Page 43
Rev.No. A
/\ALBORGSUNROD j
Date 18-AUG-93
CAUTION; IF THE ACTUATOR IS A 'SPRING RETURN' MODEL. UNIFORMLY

LOOSEN ALLENDCAPSSCREWSONEACH ENDCAPTWOTOTHREE
TURNS AT A TIME. IN SEQUENCE. TO R E L I N E PRE-LOAD OF THE SPRINGS.
ON ALL ACTUATORS WlTH SPRINGS USE CAUTION WHEN REMOVING END
CAPS.
6. The two pistons (2) can now be removed by rotating the actuator shan.
driving the piston assembly outward until the gear rack and pinion have disen-
gaged.
7. Remove and discard retainer ring (P20.E35) (not a reusable pan!) and the
washer (21) from the shall.
8. Remove the shalt (pinion gear) through the bottom of the body
9. Ail rebuilding kit O-Rings (P16-19.E25-29) guide bands (P14-15.E10-1l)and

bearings (P9-10.E12-20) may now be installed, if all the actuator sudaces are
clean and free o l grit and scratches. it the inside wail of the body is scored the
actuator will leak aner rebuilding. New 'unscored' pans should be oblained
from the tacfory. Light tracing, barely detectable to touch, is acceptable.
10. Lubricate the standard actuator thoroughly with grease. Apply a light film of
grease to all O-Rings.
11. if convening over to a 'high temperature' actuator, or rebuilding an existing

one, consult El-o-matic for proper high temperature silicone Or graphite base
grease.
CAUTION: IF THE ACTUATOR IS A 'SPRING RETURN" MODEL, UNIFORMLY

LOOSEN ALLENDCAPSCREWSONEACHENDCAPTWOTOTHREETURNS
AT A TIME. IN SEQUENCE. TO RELIEVE PRE-LOAD OF THE SPRINGS. ON
-
LARGER ACTUATORS WlTH SPRINGS'USE CAUTION WHEN REMOVING END
CAPS.
Doc N o

DESCRIPTION
Rev.No. A
-RG SUNROD
Date 18-AUG-93
Actuator Reassemblv
1. Replace the top and bonom shall bearings.
2. Replace the pinion gearlshatt in the body through the bonom 01 each actuator
m y . The bonom hole in the actuator body is a larger inside diameter than the
top hole in the body.
3. Very carelully align the pistons square to the body
4. Align the pinion gear so that the leeth on the center gear will 'pick-up' the
pistons assembly's rack teeth when turning the top exlension 01 the center gear
clockwise (CW).
5. TQ ensure proper mesling of teelh, rotate the center gear 45 degrees (or two
leeth) counter cl0CkWiSe (CCW) lrom ils normal position with the piston assem-
blies located at the body ends. Normal position is that position which provides
the proper oulpul shall orientation required.
6 . With the piston assemblies in !he body, gently push each piston into the body.
Turn the top shalt extension clockwise (CW). At the proper point 01 engagement
between !he center gear and piston assemblies. both piston assemblies will
move loward the center 01 the body when turning the lop shalt extension of the
actuator clockwise (CW).
7. Once the pinion gear and pistons are properly engaged, ensure lhat smooth
movement and 90 degree operalion can occur wilhoul moving the pistons oul 01
the actuator body. This is imponantl
8. Replace the actualor end caps taking care l o properly seal 0.Rings.
9. Replace the washer over the top shan extension.
10. VERY IMPORTANT

lnslall the NEW shalt clip onto ils maling groove on the top shalt exlension.
(The removed shaft clip is not to be reused). When propedy installed !he shalt
clip should rotate lreely within the groove.
60
Doc No
.a IrnI.L
.....
..... AUX~LLARY E Q U I P M E N T
DESCRIPTION
Chpt 1 Page 45
RevNo. A
PALBORG SUNROD
Date 18-AUG-93
S ~ r i n aReturn Actuator
'Em SERIES (Mndal ES)
For delails see data sheets 4.202. 4.204.03 and 4.204.04
1. When replacing springs In a spring return actuator, ensure that the springs are
replaced in their idenllcal position in the spring pack lrom where they were re-
moved.
2. 11 a spring return actuator is being repaired due to a failed spring. REPLACE all
the necessary springs in this adualor, as well as any other pans which may
have been damagad.
3. TO change springs remove nut cover (39). locknut. washer and O-ring. (38.22.29)
4. Remove lhe spring retaining socket bolt (37) using hexagon wrench Nr. 3
5. Remove andlor replace springs as indicated by spring return lorque chart. Be

sure that all springs are located correctly in end cap (5) and the spring pack
retainer (9).
6. Repeat Steps 3-5 lor other spring pack
7. Re-assemble in reverse order.

Note: 11 Aluminium paru heva a shranuls pro-Uealmenl
21 Thsrs pans are also coremd with tho imndard coallnp lininh
31 Tho actual pans u d will vary dspandinp on Woo aslullor & and d m
I. Bod"
I PI.,",,"
3. Endro..,duuMo.'aanG
4. E,,dcor.rLP""mI.luln
5 c.ntl.tmr.m.n
6 G.llll'l
8 SP"""
I ~.n~~sabum
10 8mmobum
1, -
I, -
,I -
I. Bo.lmpll#lp
I6 8.4#8n~sIw
16 OllnpP~Slon
I, o.,mpco..,
18 o onpsnah
9 D.,,npS"."
20 SP'."OC~~P
II wsnw
I Boll
11 K."
24, Ene~ormBdIDA
aa
all
w
n
1 a,.....
AALBORG SUNROD
Chpt 1
Rev.No. A
Page 49
* ~ ~ ~ ~ ~ 9 " ~ N ~ D E s . x E T ~ ~ N
Date 18-AUG-93
EL.0-MATIC ACTUATOR WITH SWITCH BOX - LDN
rr
.-. ..
-r -- Doc No
-
.....
.....
.
Chpt 1 Page 50
Rev.No. A
MLBORG~
SUNROD
...- ..d
Date 18-AUG-93
lP65 RATED 3/2

SOLENOID VAL VE SERIES SOW
The series 900 forms part of a m p e of directional control valves

desigced t o troi: diract!v i x o :he Don cl rha smaller models of sprlng
return li4 turn Pneumsric Act1;ators t o pravide eificient and reliabla
c o m o l . Manual overrida is provided as stanaara for screwdriver or
iever opsrarion. Producsd from a polyemld meulding and complete
w i t h e stainless s1eeI mounting bolt this mooel is ideally suited as 3
l o w cost general purpose solenoid.
Temperature range 40 :o + i OO'C
CONSTRUCTION
VAL'iE BCC? : 'CLYAM13 ::LASS F!LLED
C3IL BODY : EPOXY ENCAPSGUTED
INTERNAL SEALS : SYNTHET!C RU89ER
BANJO B C i T : STAINLESS STEEL
PNEUMATIC CHARACTERISTICS
:.IAXiMLiM ??ESSiiRi : iO 9AR
MINIMUM FRESSWE : 3EPEhDS ON i(€?!JRN S?SlNG FORCE
FLC'N COEF3CIEkT : PORT 1 . 2 IOIA :2 1 Kv 0.7 Cv 0.05
: i O R i 2-3 tDiA i 5i i(-r i .O Cv 0.07
ELECTRICAL CHARfiCTERiSWS
PCWER C;XSUCIPTICN .C: 3. j \/A ihclc 0.7; ?'/A !!nrush!
DC 1 . 5 :'JAT:C
RESPONSE TIME 5ms
1NSULAT;ON CLASS . -
CfiCERlKG CCDES
MATER~~ C3DE
L VOLTAGE CODES :
A : 242'1 500.50%z 5 : 1 :CV DC
E : P3L'IMIC 3 : 220'1 EO13Ocr G : 48V OC
" ! !CV 50dG hz
L r! , 24V DC
-
9 .
.
sav jG&OH:
.?!I i0:ao "2
J
'
:2v x
i l l ?roouc:9 are designad for

,naualrlal raquirsments and
100% iunc:lonallv :astan pr:ar
10 ~OIPIIC~.
Conforrnanca teat cenlflcma
918 avsl!sole an requaat.
I Doc No
AUXILIARY EQUIPMENT Chpt 1 Page 5 1
DESCRIPTION
Date 18-AUG-93
SERIES " E SPRING RETURN ACTUATOR TORQUE (In Nm.)
mm; mu.
VALVE AUTOMATION A 1.104.04 Jan. 93
SYSTEMS - . .. . .... ....... .
,
-
Doc No
AUXILIARY EQULPMENT Chpt 1 Page 52

DESCRIPnON
Rev.No. A
Date 18-AUG-93
ACTUATOR DIMENSIONS
Mr.: M.
VALVE AUTOMATION 1.103.104 Jvna '92
SYSTEMS . . - 3 . s . 1 , - - ..,. 18, """M r.,-d
i
C
p,
Doc No
DESCRIPTION
Rev.No. A
A4lsORG SUNROD
.- ... - - -j
Date 18-AUG-93
TECHNICAL DETAILS. SERIES " E ACTUATOR
"I: : DN
lALVE AUTOMATlON t.iozm
iYSTEMS June '92
. , - c = . , , - .-., ,. m, , .."",,,.,w.4
NFORMATION
ONLY
Aluminium Alloy
Alumlnlum Alloy
Drive Shall Aluminium Alloy
End Cap ED Alumlnlum Alloy Q ASII&O. DIN 1725
End Cap ES Aluminium Alloy
Sprlng. Inoar Slsel
~ ~~
Spling. mid Steel

Spring, avler Sled Clarrc; DIN 17223
Spring holder Sled C45. DIN 17200
Guide Band Nylslmn
Gulds Band Tellon +Carbon
Bearing Bush. Boltom Nylalron GS
Beaning Bush. Top Del#in
Thrvrl Washer Dslin
Washor Nylon 6
Washer Nylon 6
0, ring. Body Nilrils Rubber
0, ring. Pirlan Nilnle Rubber
0. ring. Shall Top Nilrile Rubber
0. ling, Shall Bollom Nllriia Rubber
O-ring En0 Cap. ES Nllllle Rubber
O.ring End Cap. ED N~llileRubber Bum N
Washer Sleal SAE 1012
Spling Clip Sled MIL. R.212488
En0 Cap Ball. EDlES Slainlsrr Sleel 304
Limil Stop Boll Slasl 8.8ASTM F568
Sleel SAE 1012
Nu1 Cover Polyelhylens
slop screw Slalnlerr Sleel
51a*1e90 s l e d
;'I RocolnmendedSpare Pans (Repair Kil)
hola ( I ) Epoxy coal 010dcc lo dlrg 4 204 02

Nolo (2) h s l d anodored
Nals 131 Della Tons
NOIO 14j Zinc p i m a and pasrlvatoa
Nole (5) Chrome plated
Nols (61 C45 rleal or A151 304 r ~ s m l u rlool
s shall opmnai
DOUBLE ACTING SINGLE ACTING

rr i r -r DOCNo
.....
..... AUXILLARY EQUIPMENT Chpt 1 page 59
-
DESCRIPTION
Rev.No. A
MLBORG SUNROD
Date 18-AUG-93
1 VALTAC
)
-
--.....
p-
.....
-- Doc N o

DESCRIPTION
Rev.No. A
MLBORG SUNROD
Date 18-AUG-93
'Pressure up to220 bar

High Vacuum
'Temoerarure -40°C to +300°C
'for derails see page 33
FIGURE 1566 in stainless steel

Body. Ball and Handle Stainless Steel AlSl 3 1 6 / A S T M A 1 8 2 F-316
Ends and Stem Slainless Steel AISI 3 1 6 L l A S T M A 1 8 2 F-316 L
Bolts and Nuts Stainless Steel AlSl 3 0 4 /ASTM A 1 8 2 F-304
Seats and Seals PTFE 2 5 % glassfibre reinforced 1Slandlrdl
Stem Seals PTFE carbon filled (Standard1
FIGURE I544 in Carbon Steel

Body and Ends Carbon Steel ASTM A 1 0 5 N I D I N 1.0460. phosphated
Ball and Stem Sta~nlessSteel AlSl 3 1 6 / A S T M A 1 8 2 F-316
Handle. Bolts and Nuts Steel. zinc plated
Sears and Seals PTFE 2 5 % glassfibre reinforced ISmndardl
Stem Seals PTFE carbon filled Islandardl

2 2,
-- -- -- Doc No
.....
..... AUXILIARY EQUIPMENT
DESCRIPTION
Chpr 1 Page 61
Rev.No. A
.---
AALBORG SUNROO
-- ; Date 18-AUG-93
SERIES 15
STEM
REDUCED BORE
.
3 Handle Nu1
SWI
SWD
a
/
23
21.7
11
28 35
27.3 ' 34.1
14 21
' 44
42.8 j 48.7
25
50
~
32
~
'
! 61
.~
60.7
38
5 'Stern Relamng Nu1
6 Slem Seal Washer
8 Stem Seal
10 ,Body seal 1
11 'Sear
M
12
1A
Bodv
Bull Weld End
I6 Body Bolrr
!7 Bodv Nuls
,3
rr m r
.....
-- Doc No
$I'
..... AUXILLARY EQUlPMEm

DESCRI~ON
Chpt 1 page 62
Rev.No. A
A4WRGSUNROD . . 1
Date 18-AUG-93
TECHNICAL I N F O R M A T I O N
i SPECIFICATION I
MATERIAL
,
I STAINLESS =EEL
/ C
! sg
Si
i Mn
SS
I
I:%\
S C<
%
M
O
%
Ni
% .
i aIS1316L A S T M ~1 8 2 ~ 3 1 6 ~50.03
1 I W 2.W 0.OL5 0030 16.50-18.50 2.W-2.50 1 1 W-14W/
I
:
1
1151 316
US1 316
AlSI 3Od
&STMA 182F.316
ASTMA351 CF4M
ASTM A I 8 2 6304
!
,
SO07
50.01
10.07
I W
1 50
1 00
2.00
1.50
2.W
0,045
0.045
0,045
0.030
0.030
0 030
16.50.18.50
I8.W.2O.W
1 7 00.20 00
2.W-250
2.W.300
10.5013.50
10.00.12.00
8 5O.IO.W
i
; CARSON STEEL I
,
' ASTMA 105N101N I0460 ( 0 1 8 0 . 2 2 0.150.35 0.3W6O OO1O 0.040
: I CmSTEeL
!
i
ASTMA216 WC8IOIN GS45 I S.30 0.60 1.00 0040 0.045
!
NOOUUR CAST IRON
SG 4031GGG 4 0 3 ! 3401.65 2.2.2.55 0015 0080 0 006 4 05
Seat Material
PTFE 25% glassfibre reinforced. oxygen-free s ~ n t e r e dl ~ m o a r a ~

PTFE 33% carbon filled
PTFE virgin
Oelrin for higher pressures (see graph Page 3 3 )
P o l y m i d l V e s p e l for higher lemperatures (see graph page 3 3 )
Body seal Material S t e m seal Material
PTFE 25% glassf~brer e ~ n f o r c e d R PTFE 2 5 % glassf~brereinforced R

PTFE vlrgtn T PTFE 25% carbon f ~ l l e d C
PTFE 33% carbon filled C P o l y m ~ d Vespel V
Graph~te G Graphtte G
Nltrlle Rubber N
Vtlon 0
Kv-Cv-Values for VALTAC Ballvalves with reduced bore
1 5 20 25 32 40 50 65 80 100 150
Series ON
/ A - A 1' 1 116- 1 112- 2. 2 112- 3- 4- 6-
KV = The volume of wafer in rnl!hr. that wdl pass through a gwen valve wglh a pressure drop of 1 bar.
Cv = The volume of water in gallon/rnm that wdl pass through a glven valve wlfh a pressure droo of 1 PSI.
Maximum allowable torques on stems I

ON
8-15 , 20 1 25 / 32 i 40 ; 50 I 6s 1 80 !loo 1 1501
1/4" - 112"' 314" : 1" , 1 114" 1 1 : 7 : 2 1/2" ! 3" ! 4" 1 6"
Nm 25 25 ' 50 50 90 ' 90 : 180 / 450 '450 ! 600
above refer to ball valves wllh reduced bore.
1') L,
I- I-
.....
-- Doc No

DESCRIPTION
Chpt 1 Page 63
Rev.No. A
AALBORG SUNROD )
Date 18-AUG-93
PRESSURE-TEMPERATURE G R A P H
Series 15 - Series 25
Polymad Vesuel 4s no1 sumtable for steam : condensate serv~ces

jj
mm m--- Doc No
..... AUX~LLARYEQUIPMENT Chpt 1 Page 64

DESCRIETON
Rev.No. A
AALBORGSUNROD 1
Date 18-AUG-93
OPERATING TORQUES SERIES 15

Based on water at ambient temperature
I I !
1160
I I /I
80
I
!
I
870 -
:
-.
-'"
z.-
580
!
!
! i 1
20 290 20 290
I PTFE CARBON FILLED 1
PTFE GLASS FILLED! - .
Sreaktorws \\\!
5 10 15 20 25Nm
Breaktorque
5 10 15 20 25 30Nm
20
Breautorque 2!zE5 10
VIRGIN PTFE
15 20 290
25 Nm
..
--.....-- -- Doc No
AUXILIARY EQUIPMENT Chpt 1 Page 65
DESCRIPTION
Rev.No. A
AALBORGSUNROD
- .. .- ..
Date 18-AUG-93
installation and maintenance instructions for VALTAC Ball Valves
SERIES 25 SERIES 15
i T-Piece. Bar. Screw
2.3 1 Anttstatrc Oevtce
1. General
The valve may be fined in any position in the
pipework.
Before installing, the pipes must be flushed clean
of din. burrs and welding residues.
Stern Seal Follower
The pipe must be free of tension.
2.lnnallation of threadad connections Series 15

and 2 5 Valves
7 . 3 1 Gland Washer Using conventional sealant. such as hemp core.
PTFE. etc, apply the wrench only on the valve ends.
Tiahtenina bv usina the valve bodv or handle can
8.1 !Washer l e i d to s e h k damage.
3.lnnallation o f Welding Ends Series 15 and 25

Spot weld the valve into the piping. Remove bolts
(16) and body nuts (17) with the exception of one
bolt and nut which remain in ~ o s i t i o n
but slackened
off. Pivot out the centre siction with the valve
i n open position. Secure seals (11) against falling
out (e.g. with tape). Aher completion of the welding
operation, swing back the centre section, replace
the bolts and nuts and tighten them.
4. Innalladon o f tho Series AF. Fireaafe

The firesafe series valves are installed without
disassembling. When welding be careful not to
overheat the ends. as otherwise the seats (11) will
be damaged. For this reason we recommend
electric welding with the valve in open position.
, ..
3
:. .:..
Doc N o

DESCRIPTION
Rev.No. A
Date 18-AUG-93
S E R I E S AF 15 S E R I E S AF 25
5.Puning i n t o Operation
Open the ball valve. flush plpe rhoroughly agam. Replace complete body (1 2) in open position
I f there is a leakage berween body (1 2) and ends. between the ends and tlghten bolts and nuts. Check
tighten bolts and nuts (16 and 17). for ease of operation.
6.Replscement o f Septs and Seals in Series 1 5 7.Replacernentof Seetaand Seals in Series AF 15
and 25 Valvsr and 25, Firesafe Valves
Set valve in open position and remove complete Set ball valve in open position and remove body
body ( 1 2). bolts (1 6) and body nuts (1 7).
Close the valve and remove seats (1 1). ball (9) and AS the oody and the flanges are locarea by a tongue
body seals (10). For series 25 also remove centre and groove connection. push the llanges 3-5 m m
ring (18). Be careful not to damage the ball. away from the oody ( 1 2). so that the booy (1 2) can
Remove handle nut (3) and handle ( I ) and unscrew be removed.
stem retaining nut (5). All other operations are rhe same as for series 15
Take off stem seal washers 16) (forseries 25 remove and 25.
stop plate (4)).remove stem seal follower (7). Push
stem (2) into the valve body (12) and remove Asanrnbly
carefully. AF 15
Clean all pans, especially the sealing surfaces of ~ uoner PTFE stem seal (81to the oonom of the stem
ends and stem. (2) After msenmg tne stem (2) mto the body (1 2).
add one grapnlre stem packing (8 2). then tne stem
Ausrnbly seal follower (7). the lockplate (7 1). w o stern seal
washers (6). the stem retamng nut (5) and the
Put one stem seal (8) on stem (2) and insen the stem handle (1). secured wlth the handle nut (3)
from the inside of the body. (1 2)
AF 25
Add to the stem (2) two funher stern seals (8) (for Put one PTFE stem seal (8) and one washer (8.1) to
sires DN 8 0 lo ON 150 add three oiecesl then add the bonom of the stem (2). After insening rhe stern
stem seal follower (7) and two stemseal washers (6) (2) intothe body (1 2). add onewasher (8.1) and one
(orstopplate(4)forseries 25). Sizm D N 8 t o DN 15 graphitestem packing (8.2). then the packing gland
have n o stem seal washers (6). (7.2). the gland washer (7.3). the stop plate (4) and
Replace stem retaming nut (5) and t~gnten'l.Be sure the stem retaining nut (5).
to avola rotatlng the stem (2) by applymg a su~table
wrencn. Replace hanale (1) ana hanale nu1 (3). 8.Maintenancn
lnsen ball (9). sears (1 1) and body seals (10). For The ball valves are mainrename-free.
serles 25 msen also centre rlng (18).
'Torque figures for stem only, before assembling ends.
ON
'
!
8-15 i 20 25 I 32 ; 40 1 5 0 / 65 ! 80 / lool 150
! 114. - 1~2.: 3 4 - i I- ! I 1/4-11 112- i 2- 12 1 ~ 2 . 3.
~ ! 4- i 6"
~m 2 1 2 1 2.5 ' 2.5 i 4.5 ' 4.5 1 7 / 15 1 15 ! 15
above refer to ball valves w ~ reduced
h bore.
I Doc No
DESCRWTlON
I Date 18-AUG-93
Industrial vesture gauge. Sutabk (or all gaseous and llquld

rnedii that will not obsbuct me pressure system or stlack c
ow
alloy pa-.
N a l n l skw
1WandlWmm
-ncy-
1.0perDIN 16005
osrion
DIN 16064.'16005
nnOr
-.
100 mm: 0 0.6 to 0 ... 1000 bar
160 mrn: 0 ... 0.6 to 0 ... 1600 bar
or equbalent omer units pressure or vacuum
Standard ranges per DIN 16128
Worldno Pns8um
Steady: Full scale value
fluchlatlng: 0.9 x lull scale value
Short time: 1.3 x lull scale value
O M n a tanpentun
Ambient: TMlN -25 S:to TMAX +60 S:
Medium: WAX + 60 9:(soldered lube)
+ 100 9:(brazed tube) Window
Tempsratume m Inshment glass
Additional efror when temperature ol lhe pressure element
deviates hom +20 9: -rinO
Cam ring (bayonet type) bezel black finish steel
Rising temperature: +0.396/10 9:
Falllng temperature: -0.3W10 S:
Percentage of me bue scale value
Omer pressure connection
w- WoDsctlon
IP 45 per DIN 40050
Material: Cu4loy
Threaded enby per DIN 16288
G'hA22mmW
R.Mgl.nt9-a-
Rararlmnt 1Wmmsbe
< 100 bar. Cu-alloy. Ctype, son soldered FeaWrlm 8cslea in 9:for reMaemnts R 744. R 764. R 40. R 11.
2 100 bar Stainha Beel 1.4521, hellcsl type, brazed
Morant
-
Malerlal: Cu-alloy, wear pa- argentan
Dbl
White aluminium rrllh Meck lettering per DIN 16109
Black elumlnlum polnter

Car
Black finish steel case
I Doc No
AUXILLARY EQUIPMENT
DESCRIPTION
k+= Chpt
I Date
1
18-AUG-93
5n
-- -- -- - Doc No
.....
DESCR?JTION
Rev.No. A
--...--..
AUBORGSUNROD J
Date 18-AUG-93
muuinmanrr
-pup.sOsbnWhMd*~3posl(lona:
OFF; T h e p s a s u m m e d l u m h b u n d . n d m ~ ~
iscrrnmtlnambknt-
ON ThspraMureOauO.h~loms~n*dlM.
VENT m ~ n p u r p e h L t o l s ( a d t u t l h e ~ ~
is rmed am tln medlum can a9.Ds [mo lhe ambient
atmosDhem.
I Doc No
AUXILLARY EQUIPMENT 1 Chpt 1 1 Page 70

DESCRIPTION
i
1 Date 18-AUG-93
No preuum hlghaman indkated by ma d n g Presvlre

symbol V musl M sOplied to ma gauge during hydmitmk may require -re gauge3 ofa mnJbw(lons r w n m nith
pressure tesl of me JySem. Omembe me gauge must be -led nalimal sandads andlor k d sdew mda Thb mud be
or r e m d during m i operalion. CMSidersdanddearty~~rrhanplsdnganader~sUch
In me case of diaphragm w capsule gauges. care shculd be taken gauges. Your WlKA m a MU be pleased to assig In wlectlng a
10 accidantally I- ~ retain upper and bvm
the b d L mat ruitabk prassure gauge muJd
dbphragm housing.
NO aaempLs smuld be made to m o r e a p r e s s u W gauge. m a
pressure system must be tobW rdlwed ifthe gauge can nct be
isolaled omomenrise.
Remainder of the praswre medlum contained in the preuure
element may be ham&aus a m k This should be W e r e d and tasting
h e n handling and ¶ulw the removed preawra gauge.
DIN 16008
Bourdonmbe pressure g a w . Safely requlnmene and testing
gauge.
Dm 1610s
m e maximum d n 9 OreJSura fw hi* me or-* gauge is preuum gauge d m 01da-s 1.0.1.6.2.5. and 4.0. and
suitsble, or a h Ule mlnlmum d n g praJure in me casa of dual de mdng,
vacuum w ampound gaugm Is indlcalsd on me dial by
conespmding marks V. Flumaling pressure aiways reduces the DIN 1625.5
me.imum dn g01 me gauge. cansunma dam S I I ~
pnswm Elask ekment p e w r e gauges D e m m &&-m. in*bm
m l n g to me -re omma d d . and o m w n
~onedzsrmngmayb. ~rupsaedBY cloJ(ng me -ling wvka DIN 1 6 m
and relievim ma aauw horn pauum. The WMer musl IaU&in RBuum gauge mnneQlng and
stc-m
m am s w nga
w should d n in ib o r i g i d padmg undil
-- -- SYNCHRO"
-.-VALVES
- ..- . .
--
Maxon SYNCHRO* valves precisely control fuel flows to burners by means of
micro-adjustment. Three designs are available: SYNCHROC* butterfly valves.
SYNCHRO@ poppet valves and SYNCHROm oil valves.
PRINCIPLE OF OPERATION
SYNWRO* Val- POYKM I W J ~ Id n ~ ~ m n ~ ~ tdf t ~ l ( ~
IIOW ' : ~ ! r o l u s q a SWM OI .I~IV,~.MI ,.olw,
IIIIIIW
:.'illl "llllU 11111 U*I.LI,I I..",, .I:i.llll.I"~.(I,.
o w lflrlw lXYlllili ~ I I ~ I Wca*lil~u.j
I ~ dknv l;.dllil~lllv
screw5 lo bear agalnn h x i h cam rtrips lo form a
IMI JelwminsS lb mDHon impan- lo a p l w c a b n g
o m r g a l thn valve. Alter a -lime aalunmm lo
eslal~lshIhB deslrm 11O1 a! each pmtun. me cam
: dS5emDly can be ralalm manually or aulomalically lo
lwollle luel 11O1.
Prerniom ddimmenl ol llle fuel mpul al earn at m

e
wmls can easily be m h
an~~ndonen!
- I l . ~ ~ l t l l ldnge
ly hdly da~uslable.
SYNCHRO' buncrnr vakes deslqnam -M- 01 -s-
dl= Olfemi In RD 1 112 l h r o q h ON JM).Thay lealure a
I u I I ~ o wbulltllly valve m y w m ratNngs UP to 1.7 bar.
SYHCHRO' poppal vakes - desqnalm "P. rn a
~ ~ w e t - l yValve
w l w grealer flow c ~ l r o m
l smaller
s m s mey are onarm in RO 1121nro11qhRP 2 i n w m
plersure ratingo up lo 1.4 mr.
I rr l rm r Doc No
. ..
tD,
SVNCHHW
POPPET
VALVES
P-TYPE
%:, )
-. .-
-4
. :..
SYNCHRO*
OIL
VALVES
0-TYPE
! I
Doc No 2
3
Chpt 1 73
RevNo. A
Date
SPECIFICATIONS
ASSEMBW NUMBERS
I -
HIGH PRESSURE SYNCHRO* BuOmr r . k l tSHPI NPL Y AND S muEd- I
SPECIFICATIONS
ASSEMBLY NUMBERS
SELECTION CHART FOR UGHT OIL SYNCHRO. VALVES

ACCESSORIES
LFSS the c l m l l vhm valves laves mmn8mum

1.*'11h.,
FQ SPDT switm aclim at niw I M n mmlmum. SWIW

"0. 01- Stan SWllcn assembly.
FQ SPDT mmbimlim high.lOl lire limit Switch S p c i E I
m. 016189.
ADJUSTABLE STOP
m
A t valves w be s m l i e d wim aaiuslaole 'open' p m t -

lion SPOT swash M. 3Om48 slamara cam Q M.3W040
k r totally enclorar cam (roc iil$ratm).
I Doc No ..+
DIMENSIONS IN mm (unless stated otherwise)
POPPET VALVES
STAWARD CAY ASSEMBLY TOTAUY ENCLOSED CAY ASSEMBLY
OIL VALVES
STANDARD CAM ASSEMBLY TOTAUY ENCLOSED CAM ASSEMBLY
!! I S 0 711 (a Do a P f W in ESP c4 NPTJ.

Z P i p s m m s ~ o r 10m M U sramma B E l . else# um 314- H 1.
~o. is0 i l r .
t 5 7 m M n q n ranwature vastom.
SPECIFIC ADJUSTMENT INSTRUCTIONS SYNCHROO VALVES
SYNCHROe valves can be used on their OW, controlling the fuel flow to a burner.
SYNCHROa valves can also be used in combination with an air valve to form a
MlCROAATlOQ valve. To adjust the air valve of the MICRO-RATIO@ valve, see page
4.100.8.1.
1. R ~ c r m p l a m h w n m e U n ~ C a m ~
am IM an aqtang vrem m e t c l o d r w LNI
lltMra mu amce ol caslmng l N w qnmnerr o
6111141111 lllls WuyJ
2. AdW ws psrare ~ e p u ! a aas r a ~ ~ ~lorr m
um
bmor mlnnp tube. see SPBCI* S ~ U P~ m m -
tms. F%MWp w s t 11 necenarv.
3 Upkl m a h bmw-a at .- as r o l h
Flrs. m SYNCMRO* valre lo itg mmlmum senmng.
man am^ w am hm corresPondlng m
a ) name ~gnnmat bura ( mmay
~ r k u ~ m s mHl ~
l a k a ~ M n 3 d t h e Y r e v tC a r v u ~ M n g u l
s w uml nanm b e c o w Kl1ceadly rlm IUI"
prple or cmm w m a slight yellorr tap) men . s h i v
Mar m, urs* od untl ma name becomes im#u When saMied with a d j m m l a !MI pes~lim,turn in
DI"n all h i numbered mlil lhey are me same
as me one iue set.lMlun nan Suew W M r -
wise- one lull lun.
S l w l y lum SYNCHRO* valve cam towards me next

pn~lim. readiming lhe sogw as necessary lo main-
Slowly wn SYNCHRO* valve loward llul na.1 puu- tain paper llame.
lun -la w a m l r y ttm lvane rmurrlv. a w l eutimy
W . l a u l l l ~ l l l uA
m # u . W l y1 %"lvv
d ~ ilusllul lI.rlu tI,,l1)1,I ,I", ..,.
111 1,1111 111 ,111 l U l l l l l l l l l , ~ N.l,,*b A!.
wcJt b M l e l a l , y w IINCS~lmn imal
IIMstllsdlnmg
CAUTION: If Dunera go out, dole shut-on v w e i M e d SCrem in at leas1 IM1 far lo p e v e n pmslble
damage to flexible cam nrips i w d e me SYNCHRO'
YalYB.
If m r y Ium m a SC~WWCIcckwiSB to hold cam

temporarily. . ,
Anor adimlim V u m tull ranqe, allow h u ~ c ew

oven lo ieach-nwmai ~ a t i n g ~ e m a ~ and u r ere-
fine aeivslmern as needeJ Iw MI m n d i l i w . Always
a e + u a o ~ ~ y u w h e ~ ~ o ~ ~ p m n ~ m a ~
M i lhe SVNCHRO* valve has ~ e e n5.31. For
example. t u n n to @lbn m. 2 MlDIa anempling lo
adiml m
e m. 2 s u w .
COMPONENT IDENTIFICATION
POPPET-MPE SYNCHROe GAS VALVE

WITH STANDARD CAM ASSEMBLY
IlOE
M-TYPE BUTIERFLY WITH
SYNCHROo GAS VALVE
V-PORT GROOVED RISING STEM

TYPE SYNCHRO" OIL VALVE
WITH STANDARD CAM ASSEMBLY
Installation Instructions
- Support welght 01 plplng lndependewly. Do n0l lessens the c h a m 01 inlemal lbw lurbulence being
place anv Maxon Fbw Canlml Valve in a oD*18 Seluo in the oiuina manilolds and conlml valve.
- .
- ~ h &RUM ilow &o*lon lhroi8gh '.P" and " - 0
~
bind. ~ r i v d ppe
e hangers andlor s p a c i a i s u ~ r t
lor related manrlolds. poppn-lype valve% llm s l lbw 0niy m direciion
- Maxon c o n n n l q ba¶a and llnkage auPmbllor malchiw the arrow cast into valve body. 11 neces.
are deslgned to locale andlor posillon lh. sary, valve body may be mlaled p r inslruclions
m n t m l o m a t o r lor as inleraclbn wah the Fbw uwen on oaue 7016.
Conlml valve assermy. mey are n ~merdedlo - insial~nowionlro~ vaiver aretully and maintain
suppofl the welghl 01 the conlrol molor. Swcml adequale dlmenslonal clearance lo allow lull
ProvlSiM will be requued lo support the WBW 01 slroke and lravel of the valve's conlml lankage
Ihe control operalors. lnlemal drive mechanism wilhin a control molor
- Use 01 plpe heavler lhan schedule 140 can may be damaged iflinkage is restricfed as 10cause
cause Inlerlerence wilh b~llerllv-Ivca
, ..~-
FlDw Control
~
Valves and reslrwf the v a i i lrorn full openiw.

~- -~
bindim in hiih or low llow --...
~
msilian.
~
CAUTION: All Flow Control Valves are deslgnedi

-Plow Control Valves prWlde the means to
lor lhrollllng sawlce only and are not Intended
adlun lluld andtor gas tlows. They shauld be
for t l g h ~S~UIQI.
mlalled wilh a1 leasl lour ome d~arnelerlemlhs ol
stra ght p~pei x ~ o r eand an& the valve hi - Main sysiem shut-o~tshould always use a
manual "leak-11gh1" upsinam fuel Cock.
Mounting Instructions for motor operator on Series "CV" Flow Control Valves
For Ihose Series CV' Valve assemblies lurnished wilh
connecling base and linkage. Ihe accompanyiw diagrams
illuslrale mounting procedures relative lo each specilic lype
operator. M941 or M944
First, mounl your conlrol motor lo connening base in (7616BR Crank)
accordance wilh diagrams al righl.
Secondly. delenine il your electric operalor travels muntwilh Iwr rhon miis
a d null a1 i-dlUtpd 0 b r .
/C+
n.*
I,i JRI
iLlnbq.sld.
lhrough 90°0r 180' mlaliins. Then arrange connecling
linkage and rotor crank arm as shown below for your
SpeCiliC operator.
I I I 4
Barber-Colman
EA50
MDY"lwilhlh.ee~WU
rind nuUalihwlh'
Cn* iU n h w Old. 1
PennNohnson
MBO. M81
(MD3-600Crank)
90° Control Motor 160' - IBcr Control Molor

.....
..... 1 page 80
RCVNO.A
AALBORG SUNROO
Date
Adjusting Instructions
Nollce: Only generalued !nsNuc!mns can be p v d e d 3. Check the1 any alr handllng dampem are
here Oetarled adjuShnp mnstmamns are pmwded w#h properly posltloned and locked info operating
each jndrvrdual Maxon h m s r a w o r mxer Sysfem msilmns.
4. b~sconne*the aulomatlc control motores
General Instructions llnkage tmm your wntrol valve's oueratino crank
Imponant: Do not dlocard paclclng materials arm by loosening the control m l o i s conn;c(ing
untll all loose Items are accounted for. rod lrom lhe burner's loaole linkana
lnltlal adjuslmenl should & o
;n;
To prevent damage in transl, some wnneaing aCCOmpttSh8d durlng a "manual" controt
.
base and linkaoe w m n e n l s mav be oarXed
~ ~
separateiy andsnipped loose~wilhyour new Maxon

7 -
~~ - mode.
5. Stan all system-relatedfans and blowers.
Flow Control valve^ Check lor proper molor rolalion and impeller
The Flow Co%lr; Value is normally only a pan ol direclion. Verily lhat all control interlocks are
Ywr complete combuslion system. Addilmnal pipe working. Allow air handling equipment to run lor
train accessories andwntrol wmmnems mav' be adequate purge ol your manilolds.
requared lor a complete syslem i&tallato"
Read complele Instructions bafore proceeding. I CAUTION: DO not by-pass control Dane1 tlmers -I
and lam~llarmyoursell wnh all the system's I typically conlrolllng sequentlat operations. J
equipment componenls. Verily lhal y w r equipment 6. Wlth MICRO-RATIO* Valve comblnatlons of
has been installed in accurdance with lhe original alr and luel valves. the mtnlmum dlfferenllal
manufacturer'swrrem instruclbns. pressure settlng ISinltlally established w i ~ h
CAUTION: tntltat adiustment and IlgM-otl ot the air valve only.
burner systems should be undertaken only by A. By disconnecling lhe linkage between the air
tralned and experienced personnel famlllar w ~ t h bulterlly valve and interconnected luel
combusllon systems. wllh controVsafeW vaivep). Ihe mlnlmum and marlmum l ~ m ~01l s
clrcully, and wllh knowledge ot the oveiall travel on the alr valve may be aeternuned
Installallon. lnstntctlons provlded by the For example. a combustion system may
need the air valve lo be 15' open lor the
company andlor lndlvlduals WsDonslble lor the
manufacture andlor overall ~ n s t a ~ ~ a01
complels system lnwrporatlng Max& burners
t~on -
"minimum'sellina and- !he 'maximum'
- .
reqblrements are sat~slledwdh the alr valve
lake precedence over these provlded by Maxon. Open lo 60' By marnmg lhese pomls on the
I1Maxon lnstmctlons conlllct wllh anv codes or air valve's indicatingstrip, you are ready lo
regulations, contact Maxon ~ o r p o r a ~ i obefore
n reconnect the SYNCHRO Fuel Valve's
attempting stan-up. iinkaoe 10 the air
- valve.
..
B he-next step involves adjusllng the
connecllng llnkage beween the alr valve
and the luel valveis) so lhal each luel valve
For initial adjuslmenlandlor burner start-up: travels 11slullquadran1range (I a. lmm
1. Close a11 burner fuel valves and cocks. Make mlntmum 10 maximum). whtle h e ar valve
swms lrom ds P~B-determmed mmlnum ana
maximum msilions.
conlml devices and lme& are operable and C. W I I ~ series TV.. valves end series '0"
lunclionino within lhelr resoeclive selllnaY adlustablo-gradlent Flow Control Valves.
ranges ~e sure all air andluel mando& are the minimum llow position is set bv lheir
mlnlmum slop screw m ~ adluslaible
s sop 1s
Ight and that ten pons are plumed d not b e m
l0Cal.W on the sde of the screw camer 01
Series '0- Valves and at the base ol crank
arm 01 Seues %V- Valves Suewlng 'in'on
Ihe mumurn stop screw produces a physlcal
slop on lhe quadrant's lravel that pmh.blls
vawe lrom bang completely closed 011
Adjusting instructions
NOTE: I1tiring chamber is 01 refractoryconslrucilon. 16. Reflm adjunmem as needed, always turning
allow your mrner system to operate at this low s e n i i Valve so that positlon indkalor matches suew
lor the necessary dfyl~~re-aul tlme period bairn adlusted.
recommendedby the chamber or retradoly FO; &re luel. tum screw In (cloclm~se).or
manufacturer.Then continue ad.imments 01 Flow less tuel, turn screw out ImunlercMdmse)
Control Valve. It SUeWS must be lurned in llush wllh camer
; Again, wilhout moving valve. bring 63 and all casting, increase tuel pressure a M re-adpsl.
remaining adjusting screws down to the same 17. Reuem ~rocedure for anv other ~WIS.
level as #Z suew. Illawmximale ore-set 18. cycle &msr tmm mlnlmum to mulrnum and
gradient was madeedier. the remaining screws retlne adjustment. It necessary. Ahvays set
will already be at or bebw appropriate levels.) Flow Contml Valve to the numbered pos~tbnyou
15. Progresslveiy work your way up l h r w g h each wish to adipsl.
adjustlnp screw posnlon, devebping a smooth For Ooeratbn with interruDledoibl tas
pmgresslonsbpefmm your first screw to the .. ~ - ~ .~
maximum wsaion. Imrn mini&rn to maximum and back several
NOTE: TOadjist'the flame at any poslton, you must tunes to verily the ltame is mamlainea
m v e the Flow Control Valve to the number you 19. Reconnect llnkage to control motor, plug all
desire to adjust. This aligns the adiustno screw test connections, replace equipmenl m v e r a p s
directlv on too ol the fuelvalve oluker. A resunina
aalus;ment 01 the screw is direilly $plied to the tuel
-~
and limhten linkaoe screws.
20. he& out overall system operation by cycling
~~ ~
vake plunger and its lnterconnecledvalve oody through 11gnl.ollat minimum. Imerruptlng p ~ b t .
linkage. and allow temperature contml syslern locycle
CAUTION: 011 llames are hlphly radlam. use burner lmm minimum to maximum a M return.
21. Recheck all safety system Interlocks tor
eye pmtenlon and avoid prolonged vlewlng.
proper setting and operation.
I, PreDare 10 shut onoll aulcklv it there Is a
noticeable drop In oll pies+uie or II lgnltlon
does not occur.
WARNING: Test every UV lnnallalon tor
dangerous spa* excllatlon from lgnlton and
NOTE: To avoid possible damage to cam stnps. I other msslbie sources o l direct o?reflecled UV I
always turn all higher-numberedscrews in as tar as tadlation. Use only gas-IlgM scanner
connecrlons.
Ihe lasl one adiusted.
22. Betore system 11placed Into ~UII sorv~ce.
lnstmn Operator personnel on proper stan.up.
operalbn and Shukdown ot system. Establish
wrmen instrudbns tor lhelr fuure reference
Doc No ?,..lid
Page 85
AUXILIARY EQUIPMENT DESCRIPTION Chpt
Rev.No. B
..-- - -.,.- * Date 04-MAY-95
KINETROL.
ROTARY 114 TURN ACTUATORIADD-ON UNITS
Installation, Operation and Maintenance
ACTUATORS
INSTALUTION
I. ~ k o* ~ - s ~ r a v t o r
N m m owm w m
MU' dmm ISOWWCW d m ~ f f l s ~ m r ~ d d ~
OM0
01-A
4
4
wx0.5
M4 x 0.7
Xrm
Bmn W E UNF
- 'W
-
4. ur.upp*
4.1. - m m P a * s n a m m s n d a s b a k D u l d b s ~ m
a a p h , I ~ m u P m ~ - U ~
02 4 M4 x 0.7 8mm 838 UNF Yw tumgUrmkprWnrmaLMlmOr~
W 4 Wx0.8 lOmm 1 W U N F W 4.2 A k ~ y t o O I A f f y A a c m a m m ~ ~ r a a a n ~ u s l s ~
05 6 M5 x 0.8 IOmm 1032UNF W' aMdry.LubricatBd~mavbsuu*ltoD/AwyAsmutMM
07 4 MB x 125 16mm n r 2 4 UNF W MUST NOT be used tor atr s u m to P m a or VP
08 6 MB x 1.25 1Bmn %a-24 UNF W Cornenen
09 4 MlO x 1.5 ZLmm W.24UNF 4h'
12 4 MI2 x 1.75 2 m m 'h20UNF 'Y.i
I4 4 M18x 2 m m SI8UNF 1W
4 W4 x 3 Smm %-I4UNF I'M
-
I8
l6 a M30 x 3.5 janm I ' l i l 2 UNF 2.
m u 010 has 4 M4 Manros hmes.
-
Mountlnp M h SO. DIN utrt.Pa
M a d M ~ l i s ~ N l u n u r .
Wel rum 2 is d m Namw v m e -@g.
Numk mm
odd otholes r s o mma d m a a PCD
cotam2 a W X O . ~ 8mm 36mm
051 6 ou 4 MS x o.a 8mm 42mn
071 a o n a MB x I ~hnm 50mm
-
Wlh092
102
121 6 I22
4
4
4
M8x125
MI0 x 1.5
MI0 x 1.5
13mm
lBmm
16mm
7Cmm
1 m m
IOanm
141 h 142
161 - 4
4
M12 x 1.75
M20 x 2.5
Mmm
32mm
1 m
165mm
m:e s m w met mu numbs 01 ~ 0 rn
1 an, rn abghtd
m y .
CAWION: NEVER HAMMER OR USE OTHER LNDUE FORCE ON
ACTUATOR DIECAST CASES. D W G E TO IWTERNAL
SEAUNG FACES WILL RESULT
SEAL REPLACEMENT INSTRUCTIONS

-- -- -- Doc No
< ) \
..... Chpt I Page 84
AUXILIARY EQULPMENT DESCRIPTION
Rev No B
..-- --...-- ..
AALBORGSUNROD J
Date 04-MAY-95
3. REASSENELY ACTUATOR
3 . 1 . h &sf.w W a n d imib.WA ca%9 katvaa Him
.~
5iGnE 232 R T \ i s e m t memwaha K I N ~ O or
L mw
Cammg. (In e n m q w . M Comvg tmJt sadml obahabb
hwn imnmrJa. m..may M wed ar s u m e . 1
CAUTION: EXCESS SEALANT, il n m e d inuda case.WILL
DAMAGE SEALS. R m aU el-
-ah, lrom lnvde we.
3.3. 1 m e n v e n e i n l o o ~ c s u h d . P v l v q i t l o e a v l u a r e m d h
~~nmm*ylshtnrea.w~mu~vladaslx~dvw
e m d d-mn inm caw lntmut damage.
SPECIAL NOTICE: maw m r m w hu m w h&a
3.6. Tighten case mlo me falanemum:

w OMO 4 IW. m m 0.06 m ~g
01 10 lbf. ins 0.12 m kg
O1A :o lbf. im 0.12 k g
02 10 lbf. inn. 0.12 m kg
m l o lbf. iN. 0.12 m ma
05 m
IW.ins. 02m kg
07 20 lbf. ins. 0.23 m kg
08 70 ibf. ns. 0.8 m kg
w €4Ibf. ins. 0.7 m kg
10 M) lbf. inr. 0.7 m kg
ii lbl. &. 02m6
~ ~
I0 12 IM) lbf. ins. 1.2 m kg

12 30 IW. ~m.0.35 m kg 14 120 lbf. i ~ 1.4. . m kg
14 ' 30 lM. ins. 0 3 35 kg 16 aw lbf. ins. 10 m kg
16 1Wlbl.im. I2 mkg 18 1050 lbf. iN. 12 m kg
18 1M)lW.im. 1.2 mkg-M8suda 3.7. Rotam vans rnanudhl lo check m m a t am mps awsy
re 253lbf.im. 2.0 mkg-Ma- seaant e m e d intmary.
3.0. Amw s e m tima fa~ e L bolas m apphine lea ak m.
PNEUMATICALLY CONTROLLED POSITIONING ACTUATORS
-
..... Chpt 1 1 Page 85
AUXILIARY EQUIPMENT DESCRIPTION
AALBORG SUNROD
Rev.No. B
Date 04-MAY-95
--.- czz,, 8-
EXPLODED VIEW OF A T*PICAL STANDARD ACTUATOR

- Doc No ,)3
.....
...a.
_ AUXILIARY EQUIPMENT DESCRIPTION Chpt 1 Page 86
---
AALBORGWNROD
w-.,,""
d Rev No. B
Date 04-MAY-95
~ b . m , ~ o r
-by-
5.2 THE OBIH.7MS OF SEinNQ UP ( S N )-
hafmufax4MWtm~mUItba-b.Nnnr
-- -- -- 8
..... Doc No
Chpt 1 Page 87
AUXILIARY EQUIPMENT DESCRIPTION
..-- --...-- ..
ANEORGSUNRM) J
Rev.No. B
Date 04-MAY-95
ama
8F) R O l O M FORCE WANE LEVER LOaaNQ SHRlS
tk+8~~bmp-bvlrmbeaflpoaHlon
~ o n a * m h l r a w f .
S M -are&
(.) A k + z e d m r m m U m ~ ~ h e i m e r ~ m ~
l a o . M b n i m ~ . ~ m d ~ d t h m
dqmpm.pmbly-crrraprmmmmn*
SaS-Sram
(a) ul*r~!YtmtM-~Ur*Lk~th..nddm
rmmmn
(b) mj-a*-DndDn-+'J.
(C) 9 . e L n t h . a l n ~ a c n * n d ~ t h . ~ ~ m m a n u O U y ~
a*cmlOl~~~mgq.dnitnmerbs~o!meSYn
Q~pmimnWo(lth~dlMd.rd~sSm.
(a Tlphcmhcunlosbirgmr*.
5.3.7. urn nd Rmlga raycnam
(a) %I pa .dlumnsn( a UId &mmkm 'R' is abovt 7.5mm.
(b) Car*da*mnbd~mm~d.ph~chambsrs(
s * m e m n b d p n r a r s m a r a v 3 ~ ( o r ~ ~
-).
(c) SWlldlma*~ekmmemnh..
(@ ~~~m.dirsBmm~muaumh~mrspulmd
atmlw.
-
. .I;, !)
Doc No .. :.(.
..... Chpt 1 Page 88
AUXIL.IARY EQUIPMENT DESCRIPTION
Rev.No. B
-RG-sv.N.NROD ..3
Date 04-MAY-95
Range and z e r a s e t t i n g is done u s i n g t h e p o s i t i o n e r a d j u s c m n t . I n catre o f

b l o c k a g e due t o c o n t a m i n a t i o n t h e a i r b l e e d c a n be a d j u s t e d externally w i t h o u t
d e t a c h i n g unit. The I / P u n i t lnay bs d e t a c h e d R o n t h e p o s i t i o n e r l e a v i n g t h e
diaphragm assembly a c t a c h a d t o t h e p o a i t i o n e r .
R e f e r t~ Fig. 1. Supply air e n t e r s through f i l c e r ' A ' . Tc j a s s e s chrough

t h e r e s c r i c s i o n ' 8 ' i n t o t h e diaphragm chamber 'C'. The chamber 'C' is
exhausted co t h e c o v e r enclosur:, chrough t h e n o z z l e 'D'. The exhaust ?om
' t h e nozzle is r e s c r i c c e d by t h e f l a p p e r ' 5 ' which is p r e s s e d a g a i n s t che n o z z l e
exhausc by :he f o r c e oP che c o i l ' F ' . 2 . e f o r c e is ? r s d u c e d by cke 3-20 sH
c.ar-enc r e a c z i n g on t h e magnecic ?:=id ? r J d u c s d by :he r a g n e c 'G'. ?he
res::lction o f che n o z z l e by :he C a p p e r praduces a 3ack p r e s s u r e i n c3e chamber
' C ' . whicz a c r s a s t h e c o n c r o l s i g n a l p r e s s u r e .'or t h e p o s i t i o n e r .
2. OPERATING CONDITZONS
2.1 The U P u n i s s h o u l d be s u p p l i e d ,with c l e a n . d r y . o i l f-ee a i r .
2.2 Supply p r e s s u r e silouid be r e g u i a r e d and berueen 60-80 2s:

(4 -5.j bar). For lower p r r s s u r e . c o n s u l t K i n e t r o l .
2.3 T e m p e r a w e range -20 co 40'C
3. SirrrNC RANGE AND Z a O
Range and z e r o a r e n o r m a l l y adjusced on t h e p o s i t i o n e r . Range may be a d j u s t e d

o n t h e I/P using t h e p r e s e e pocenciometer, however c h i s is i n t e n d e d f o r f a c t o r j
s e t t i n g and it is n o t n e c e s s a r y f o r t h e u s e r t o a d j u s t i t .
To a d j u s e range and z e r o remove che p o s i t i o n e r c o v e r and f o l l o w adjustment

i n s c m c t i o n s l o r che posi:ioner ( s e e f i g . 2).
Flow r a t e of air i n c o t h e supply p o r t s h o u l d be i n :he range 2.5 - 3.j l/min.

free air.
The air f:ow can become blocked by concamination. T h i s c a n be c l e a r e d withouc

removing che u n i c from Che p o s i t i o n e r . The a i r s u p p i y s h o u l d be d i s c o n n e c t e d
o r switched of:. The n e e d l e valve should be unsczewed and c l e a n e d . 4ef:c
and screw f u l l y i n . Connecc a i r supply. I J n s c r w n e e d l e v a l v e ( r o t a t i n g
counter-clockdise) :o 4 Cusn g i v i n q a f l o w r a t e i n t j t h e u n i t of 2 . j -
3. j llmin. f-ee a i z .
Al:arnacively Tssec t h e uni: vizh :he 30 ? s i ai: s u p p i y and :he ?Iml 5 s ; n a l

cannected. then c s r e P ~ i l gl p e n :he neeCle 7alve m c i l :he ?os;zioner noves
co 90' f u l l y open.
I/? uni: i s derached a:m :he )osi:ianer a s a : m i ; by -rmovinq :yo sc-tws '.4'.
7% d i a p h r a q l e s s e a b i n Texains aczacced :o :he ;os::iocer. 2:ec::icni
c o n n e c t i o n s and ai: s u p p l y l u s t he .-?mved b e f o r e d e t a c h i a q u n i t
'9
I
t: AUXILIARY EQUIPMENT DESCRlPTION
Date 04-MAY-95
6. DISASSEMBLY AND INSPSCTLON OF FV\CNET/COIL ASSEMBLY (Refer t o Fig.lr)
6.1 Detach cover by removing two attachment screws. Detach magnet/coil

assembly Prom I / P base by removing two f i x i n g screws ' 0 ' .
6.2 It i s very important t h a t the c o i l i s COKPLETELY fzee t o nove i n t h e

magnet. (The f o r c e produced by the c o i l a t 20 mr\ s i g n a l i s only about
10 gm. )
6.3 To check For Fzee movement detach magnec/coil assembly Prom base a s i n
Ir above. Stand assembly on f l a t s u r f a c e (non-magnetic) with c o i l and
f l a p p e r upwards. Apply 4 mA s i g n a l t o t e r p i n a l s ; c o i l should r i s e by
I - 2 m ( f u l l t r a v e l ) . Remove 4 rm\ s i g n a l ; c o i l should f a l l back t o bottom
of t r a v e l .
6.4 11' c o i l i s not f r e e t o move, the magnet may be decacbed fzom c o i l mounting
' block. Magnet gap should be checked For dirt o r s w a r l . Great c a r e should
be e x e r c i s e d i n r e f i t t i n g mounting block and c o i l t o magnet.
FIGURE 3. I/P CONTROLLER DISASSBMBL Y
DIN PLUG
I/P ASSEIQLY
S
mXMllEti SCREWS
H5 x 16 SIKS
MWNTIffi SCREWS
M3 x 10 SIKS
rmHm.2 : N(gYm-2 XV-4 m . 2 NIIif-2 j XV(ZWN.2 I NlZlQNlI.2 lN(2WObZ7~2
f f L~SDIUN ~ m 7 ~ . O N~I ~ I O P I S Y ) N I ~ Q I 8 . n ~ 1 1 8 0 g 1
m
( m m 1Y1 9) I l B D 740 91
W L I 1.12Nlll4g) 1.12N(114gI 1.l2Nlll4p) lSINll70g) I.67N(lmg)
R E O Sm Im 0.9 m 4 m 5 m
m h 3 6 m 3.6 m 3.6 mn 6 m 6mn IS m
016m Ol7m 0.4 m 0.6 m
WE
OT 3L7tl m'
Oabm
- 1- I
- -
Doc No I 0.)-
.....
..... Qp( 1 Pa& 131
Rdo. A
AALBORG SUNROD
Dare
Engineering Data
AlllBORG SUNROD.
Date
Precautions
Construction
-- --
--..... 9
..... AUXILIARY EQUIPMENT
DESCRIPTION
Doc No
Chpt 1
ib
Page 133
..-- - -...-- ..
AALBORGSUNROD 3 Rev.No. A
Date 28-JUL.Y-95
Technical Features
Appllcalion
me RAR... semnwm P ~ O I ~ d~e~wI aI m a e u w tor me supemson
01 Y ~ I I O ~ b u m q 00 l a m s .
Design Fealurns
Summary of Types
Mounllng and lnslallation Gulde
Ordering
UMYllng ~ l m l I-t RAR..
: It I. :OK%
I
L e 90 LAEIO
,"- 1 , -a .> LAE:

Compact pressure switch
for gases and air
Type G W d 4
Prwaum llmiter
7Lp. 0-4 and N E A 4
Double fmnaum witch
7Lpe G W 4 4 l G W 4 4
for and air
---..
me ~ pressure sw.lcn. lhe w
..--..
or gas ourners. venulauon and mr-con-
N U o r e a u r e l m . l e r s a n a t h e W amonlng systems.
GW-A4 dWOle pressure nntches are
SLllaOle tor swlchlng a c.rcul on. on or
Over 10 the set setwml in CfrcuUwhere
the actual Dressure var es.
The Dressure mlches can be used as
over~ressurewsnestor k~non-agres-
w e gases ano ecnn WI comousion
gases as per DVGW wor6sneel G 26011
The s w ~ l c h mw nt can oa re1 ouncdv
~~ ~~ ...-,
ana easdy bfmea~s ot a cal Oraled knoo
w01ho.l havlng to m e a Dressare gaLge.
The 08ess~le Swlches are leslw n
accoraanc~w!lnDIN 3398 a m a%&.
'ere0 wm B&.DVGWano meamororec
nternalma.~in aa me maoar aar.con.
Functions Technical data
M a o ~ e r a m -ure
g See lecnnical summary
remce,anre ranges Amom1 :emoerahlre -154: 10 -60%
M m l m lemperalure -154: lo 4 0 4 :
E ecslcal dl screw :etmmals ,.a ?G 11. vo.tage XOV-

23s Ive s,es&re Tnec~rcut~soloc~w 01 :onneaton Swcntng caoacrf: 3nmc 5 A. na~ctwe3A cos 9 0.6
-e see-omma, value is excemmor not Degree ol orolectron P S J
3za nec "men .ne cause ol malfuncnon
-as Zeen .ectled 'he system can onv h universal seal lo: cables between
oe ta*en m o ooeramn m a n a a ov .5mm dma
Soecfalcaoe .n el.
g w n l#gnl.angle0 ug as wf D NJ3650.
P l ~ loml
3.D n ana eann ma contact
U B A 4 swnrcnes and lmks when me Senmg lolerance ?IS% lscale calmalea :vhllsl pressure 1s lncreasmg]
oressuie increases.NB44mmhesano
IOCXSw e n me Dressure decreases.
jeoarately a i o maeoendenlhl Bovl wnllst o r e k ~ r e

,s lncreasmg
sw lcnmg mecnanlsms are s ~ b ~ c alom P-l oDens
,he Same medwm and lne Dressure ol P.2 closes
:hs rnedlum. wh11s1pressure is decreasmg
P-I closes
r.-.-.-.-.-.7 P-2 opens
-- .....
-- -- Doc No 1 10
Chpt I Page 136
RevNo. A
Date 12/04/95
Assembly a n d installation
instructions
RnrumcoM.Rlon
Rot/. inlerm mreaa as 3 e r ?IN2999
ocalm cenlrally on w n o m lace :~nner
conneclmsw~mRo 'ainlernatlnreaoan
en or m n t s a a ana an 0 - m a uanae fan1
Measuring jot*:
TPe measuring !omcan oereclaC32 w a
G : screw d u on~ raauesl
mesa Olne. wss8ole hoes afas:enm~

.wlh 5e.l-:a00 ng screws an 3n an5 W
0 ale or s m a r U 6 3 I or on a ha 1
(LK 76) w m longer M 4 bolts. Laleral las-
lenlng oywayol~neslolzisalsoooss~ole.
lnlermediale insmllauon locauons :.:?A

(please s o m b U e when oraermgt-
The swolcnmg poml changes oy aopror
0.5 mbar il the slandard vernlon is Ins-
lalled nonzonlally.
Compact presaum switch
for gaaea and air
7LmGW4
Rssrum limiter
7Lm 0-4 and NBA4
Doubta pcaswrsarritch
7LW GW-A4/GW-A4
Technical summary I mtar = 1W Pa=O.l kPa a10 mm water column
When ordering, a h * quote:

I. Version
2. lnslallaldon location
(see assembly and tnsrallatlon mstrucnonsl
3. Specid equipment
IdevIce plug. plug connecllon. screw plug1
Ordadng a u r n m :
Types GWlOA4
Order no. 172690
Insfallation venical
Karl Dungs GmbH & Co.

h s m e h 1229
Talaphon~(01181) 804.0
Telefax (071 m ) 804.166
Telex 7248 898 dung d
I ORAUING PART LIST
I
I A a l b o r g Sunrod AB Telephone +46-8580-24300
I Box 9 0 7 Telefax +46-8580-27801
1 175 29 J a r f a l l a Telex 19268 SUNROD S
I Sweden
Project: 11-417 Name: HALLA LAURIN Revision: - - .

H u l l no.: 9226 System name: 2 X CPH-18 T/H class: DNV
P r o d u c t : 00012 STEAM ATDH.BRN Drawing: GS-301365A
Pos. A r t i c l e Qty Function Type P r e s s Dim Weight Drawing

Data
:, FO1 7150027 1 p c s STEAM ATOHIZED BURNER OF455 0.00 1
DRU. 3707547-01.1-2. DF455 ONLY BURNER DRAWING (RH)
DRY. 3707547-03 DF455 BURNER UITH MECH. COMB. CONT.(RH)
ORU. 3707547-11 VALVE PLATE ARRANGEMENT (RH)
V o l t a g e 22OV AC
2 p c s BURNER TO BOILER CWNTER FLANGE 2-0001115
1 p c s STEAM ATOMIZE0 BURNER DF455

DRU. 3707547-02.1-2. OF455 ONLY BURNER C.A. (LH)
DRU. 3707547-04 OF455 BURNER UlTH MECH. CO4iB. CONT.(LH)
DRU. 3707547-13 VALVE PLATE ARRANGEMENT (LH)
V o l t a g e Z2OV AC
F16 OOHAMUD 2 p c s CDHBUSTION AIR PRESSURE SWITCH 2-0001115
F16A 7000000 2 p c s NIPPLE FOR F16 AND F16B 0
2 p c s TEST VALVE FOR F16 AJ1844 PNlOO BSP3/8
2 p c s MANOMETER COUPLING MAV10- SR3/8" BSP3/B8'
P i p e O.D.= 1 0 mn
2 pcs PHOTOCELL
RAR 8
2 ws JUNCTlMl BOX
2 p c s L I M I T SUITCH BURNER GUN NOT I N POSITION 2-0001115

ZE-022-2G OMRON 747145073
2 p c s BURNER GUN 2-0001115
F21A OOHAMUO 2 p c s BURNER NOZZLE 2-0001115

DRAUlNG PART L I S T

H u l l no.: 5-226 S y s t e m name: 2 X CPH-18 T/H Class: ONV
P r o d u c t : 0 0 0 1 2 STEAM ATOM.BRN Orauing: GS-301365A ( contirmed )

-
Pos. A r t i c l e aty Function Type Press Dim Weight Drauing
Data
F2lC OOHAMUO 2 pcs F L E K I B L E HOSE FOR O I L TO BURNER 2-0001115 0.00 1
INTERFLEX U 5 0 4 6 9 8
HANSON C W P L I N G PLUG 4 K 26C 8 5 1 4 3
HANSON C W P L I N G SOCKET 4 H 2 6 C B S 1 4 3
j F210 OOHAMUO 2 p c s FLEXIBLE HOSE FOR STEAM TO BURNER 2-0001115

INTER FLEX U 5 0 4 6 9 8
HANSON C W P L I N G 4 K 26C BS192
HANSON C W P L I N G SOCKET 4H 2 6 C 0'3192
) F22 7000010 2 DCS COMBUSTIONAIR FLOU CONTROL DAMPER 2-0001115
F22A OOHAMUO 2 p c s BURNER LOAD ACTUATOR 2-0001115
F22B 7601008 2 p c s F I L T E R REGULATOR FR35/M
Complete u i t h o u t p u t p r e s s u r e gauge 0-400 kPa

R e d u c e d pressure r a n g e 1 5 0 - 4 0 0 k P a
F22B.1 OOJUCK 2 p c s PRESSURE INDICATOR

0 - 4 BAR
2 pcs STOP VALVE FOR F I L T E R REGULATOR
2 p c s L I M I T SWITCH DAMPER OPEN
2 p c s L I M I T SUlTCH DAMPER CLOSED
1 p c s lOM *
lOMM PACK CERAMIC FIBRE
331204431
6 p c s TAMPING CLAY FOR BURNER OPENING

FOR TUO BURNERS
KOPOS 6 6 0 7
2 5 kg/ p c
2 p c s TEST VALVE FOR PRESSURE INDICATOR AJ1844 PNlOO B S P 3 / 8 0.82
2 p c s PRESSURE INDICATOR FO TO BURNER SMFlOOZO/G BSP3/8" 1.20
Range 0 - 1 6 kgf/cm2
I ) I.1
DRAUING PART LIST
Project: 11-417 Name: HALLA LAURIN Revision: .

H u l l no.: 5-226 System name: 2 X CPH-18 T/H Class: ONV
Product: 00012 STEAM ATOH.8RN Drawing: GS-301365A ( continued )
Pos. A r t i c l e Qty Function Type Press Dim Weight Drawing

Diameter lOOmn
FT3G 7500733 2 pcs STOP VALVE FOR PRESSURE GAUGE AJ1891 PN400 BSP1/Z1' 1.02
GI1 7401000 2 pcs TEMP. lNDlCRTOR FO TO BURNER SlKA 2718 BSP1/ZU 0.40
Range 0-160 deg C

I n s e r t length 100 mn
2 pcs POCKET FOR TEMP INDICATOR POCKET 2718 BSP1/2" 0.20

1 =llA7401105
Material stainless steel
For i n s e r t length=lOOmn
G70 7600500 2 pcs FO TEMP TRANSMITTER

INCLUDING POCKET G70A
Length=lOOmn
POS NO. G70A Pocket m a t e r i a l 552343
Pocket connection R1/2" Lz16Omn
I -
I DRAUING PART LIST

I
I Aalborg Sunrod AB Telephone +46-8580-24300
1 Box 907 Telefax +46-8580-27801
I 175 29 JBrfaLla Telex 19268 SUNRW S
I Sweden
Project: 11-417 Name: HALLA LAURIN Revision: - - -

H u l l no.: S-226 System name: 2 X CPH-18 T/H Class: DNV
Product: 00013 STEAM ATOM. BURNER OIL/STEAM PIPE UORK Drawing: GS-301365A
Pos. A r t i c l e Qty Function Press Dim Ueighc Drauing

Data
FO2A 7000010 2 pcs PURGE BLOCK ASSEMBLY 0.00 1
2 pcs SHUT OFF VALVE 0.00 1

VALVTAC AF1544 S/U 3/4"
2 pcs AUTO SHUT OFF VALVE FUEL OIL 0.00 1

VALTAC 1544 3/4", EL-0-MATIC ES25
2 pcs SOLENOID VALVE FOR SHUT OFF VALVE 0.00 1

EL-0-MATIC 301C 220V AC
F04B OOHAMUO 2 pcs LIMIT SUITCH FO SHUT OFF VALVE 0.00 1

EL-0-MATIC LDS
2 pcs AUTO SHUT OFF VALVE FUEL OIL 0.00 1

VALTAC AF1544 3/4" EL-0-MATIC ES40

2 pcs LIMIT SUITCH FO SHUT OFF VALVE 0.00 1

EL-0-MATIC LDS
2 pcs AUTO SHUT OFF VALVE ATOM. STEAM 0.00 1

VALTAC AF1544 3/4", EL-0-MATIC ES40

FO6B OOHAMM 2 pcs LIMIT SUlTCH PURGE SHUT OFF VALVE 0.00 1
EL-0-MATIC LDS
2 pcs AUTO SHUT OFF VALVE STEAM PURGE 0.00 1

VALTAC AF1544 3/4", EL-0-MATIC ES25

EL-0-MATIC 301C 22OV AC
2 pcs AUTO SHUT OFF VALVE FUEL OIL RETURN 0.00 1

VALTAC AF1544 3/4"
ORAUING PART LIST

H u l l no.: S-226 System name: 2 X CPH-18 T / H Class: DNV
Product: 00013 STEAM ATOH. BURNER OIL/STEAM PIPE UORK Orauing: GS-301365A ( continued )
Pos. A r t i c l e aty Function Type Press Dim Ueight Drawing

Data
2 pcs FUEL OIL FLOU CONTRDL VALVE 2-0001115 0.00 1
2 pcs FUEL OIL PRESSURE GAUGE 2-0001115

UlKA 212.20.100 3/81' 0-20 KGF/CMZ
2 pcs ATOM. STEM PRESSURE GAUGE 2-0001115

UlKA 212.20.100 3/8" 0-11 KGF/CM2
2 pcs A T M . STEM PRESSURE SUITCH 2-0001115

ASCO SAllO/TGlOA21 1/41' NPT FEMALE CONNECTION
4 pcs STOP VALVE FOR PRESSURE INDICATORS 2-0001115

NEI TOHPSON RP 1/4" 001
I ORAUING PART LIST
I
I Aalborg Sunrad A8 Telephone +46-8580-24300
I Box 907 Telefax +46-8580-27801
I 175 29 J a r f a l l a Telex 19268 SUNRW S
1 sueden

n u l l no.: 9226 System name: 2 X CPH-18 T/H Class: DNV
Product: 00014 DIESEL OIL IGNITER Orauing: GS-301365A
POS. A r t i c l e Qty Function TYP~ Press Dim Ueight Drauing

Data
>
FlOO 7100001 2 DCS IGNITER RKlOO/101 20.00 GS-200154A
'.
operating pressure 6-15 bar
2 pcs CABLE FOR INGNlTER
2 pcs IGNITION TRANSFORMER
Pouer 22Ov/10 OOOV
6 pcs SOLENOID VALVE
6 pcs BALL VALVE
R1/4"
2 pcs PRESSURE GAUGE
Range 0-25 bar

Diam. 40mn
Connect i o n BSP1/8"
2 pcs VALVE FOR PRESSURE GAUGE
2 pcs NIPPLE FOR NOZZLE
2 pcs NOZZLE
3,OOGph. 450eg
4 pcs ELECTRWE
4 m HIGH VOLTAGE CABLE
4 pcs RAJAH PLUG

ORAUlNG PART LIST
Project: 11-417 Name: HALLA LAURlN Revision: - - -

P r o d u c t : 00014 DIESEL OIL IGNITER Drawing: GS-301365A ( conrinued )
Pos. A r t i c l e Qty Function Type Press Dim Ueight Drawing

Data
F116 7100012 4 p c s FLEXIBLE PIPE 110407A PN25 BSP1/4" 2.00 1
R1/4"
L e n g t h 1.2m
) F117 7100013 4 p c s FLEXIBLE PIPE
R1/4"
L e n g t h 04.11
\
) F136 7000027 2 p c s JUNCTION BOX
F22B.1 OOJUCK 2 p c s PRESSURE lNOICATOR

0 - 4 BAR
DRAWING PART LIST
1 A a l b o r g Sunrod AB Telephone +46-8580-24300

I Box 907 Telefax +46-8580-27801
I Sweden
Project: 11-417 Name: HALLA LAURIN Revision:

P r o d u c t : 00015 ATOMIZING STEAM PRESSURE CONTROL Drawing: GS-301365A
Pos. A r t i c l e Pty Function Press Dim Ueight Drawing

Data
2 p c s PRESSURE INDICATOR ATOMlSlNG STEAM BSP318" 1.20
Range 0-10 k g f / c n S
D i a m e t e r lOOmn
2 p c s VALVE FOR PRESSURE INDICATOR PNlOO BSP3/8
2 o c s STEAM TRAP ATOMIZING STEAM PN40 BSP1/Z1'
2 p c s STEAM TRAP DRAIN AFTER SHUT OFF VALVE PN40 BSP3/4"
2 DCS ATOMIZING STEAM PRESSURE CONTROL VALVE PN25 BSP3/4I1

FLOW 115 KGIH, P l r 7KG/CM2, P2= 5,5 KG/CM2
Steam Flou: 115 k g l h r .
P I = 7,O bar 1 P2 = 5,5 b a r .
E q u i p p e d w i t h BLue S p r i n g (Range: 2.5-7.0 b a r e).
KVS = 10.
2 DCS STRAINER FOR ATOMlSlNG STEAM VALVE FIG 1 4 PN40 R3/4"

~ -
I -
I DRAUING PART LIST

I
I Aalborg Sunrod AB Telephone +46-8580-24300 96-09-24
I Box 907 Telefax +46-8580-27801
I 175 29 JCrfBlLa Telex 19268 SUNROO S
I Sweden
I

Hull no.: S-226 System nam: 2 X CPH-18 TIH Class: DNV
Product: 00016 FO FLOU METER MANIFOLD Drawing: GS-301365A
Pos. A r t i c l e aty Function Type Press Dim Weight Drauing

Data
F70 7999997 2 pcs FUEL OIL FLDU MANIFOLD PN25 0.00 GS-301364
F71 7500333 4 pcs SHUT OFF VALVE AJ3540 PN40 DN25 5.00 1
) F71A 7500333 2 pcs SHUT OFF VALVE AJ3540 PN40 DN25 2.50 1
F73 7400526 2 pcs FUEL OIL FLDU METER TOTALIZER ARO25/1223-AZ PN25 DN25 24.00 1
Conplete w i t h p i s - s e n s o r contact, 1 Litrelpuls

Temp max. 180 deg C
I ORAUING PART LIST
I
I Box 907 Telefax +46-8580-27801
1 175 29 J a r f a l l a Telex 19268 SUNROD S
I Sweden
Project: 11-417 Name: HALLA LAURIN Revision: - .

H u l l no.: S-226 System name: 2 X CPH-18 T/H Class: ONV
Product: 00017 FD FAN EQUIPMENT Drawing: GS-301365A
Pos. A r t i c l e Qty Function TYP Press Dim Weight Drawing

Data
1 pcs COMBUSTION AIR FAN HCSB-050-63-1 0.00 V3614619.C
I F30 7150031
Capasity 18700 NnWh, D e l i v press. 5200 Pa
Motor pouer 52 kW type MBT2OO M-2
Speed 3585 rpn
1 pcs COMBUSTION A I R FAN HCSB-050-63-1
Capasity 18700 N W h , D e l i v press. 5200 Pa

Motor pouer 52 kU type MBT2OO M-2
Speed 3585 rpn
2 pcs INLET DUCT UlTH PROTECTION NET 3-9824954
F3O .B OOFLAKT 1 pcs SILENCER 3-9824954
F30.01 OOFLAKT 1 pcs SILENCER 3-9824954
F30.C OOFLAKT 1 pcs FWNDATION FOR SILENCER F30.B 3-9824954
F30. C1 OOFLAKT 1 pcs FWNDATION FOR SILENCER F30.Bl 3-9824954
2 pcs COMBUSTION AIR FAN FLEXIBLE DUCT 3-9824954
F31A OOFLAKT 2 pcs COUNTER FLANGE FLEXIBLE DUCT 3-9824954
F32 OOFLAKT 12 pcs VIBRATION PADS 3-9824954
F33 OOFLHKT 2 pcs FLEXIBLE DUCT FAN INLET 3-9824954

0.0 FOR lGNTOR
1
F25 Pack ceramic fibre to be
installed between h
counter flap and bwm.
COMPOSITE SECTION THROUCH BURNER
FOR CORRECT ORIENTATION OF WINOBOX
SEE SHEET No.2
CDMPOSITE SECTION THROUCH BURNER
FOR CORRECT ORIENTATION OF WINOBOX
SEE SHEET No.2
v-v
COMBUSTION
AIR INLET -
I
I
C-C 0-0
WINOBOX AND DAMPER FRONT

4 R
FLOW
C-C
a- * ~ K ~ ~ l i l E ~ l f S l l 0 3 1 6 ~ t Y D m 1
5. EE DEE1 3 FIR Sarrill L E K W D E L B N
I W T E : - T L F Y . I . ~ O ~ ~ O ~ ~ T * I ~ ~ . ~ C % ~ L W
iDETERMlNlNC
I
TUBE LENGTHS. 1
SECTION Y-Y
LllL
1 1 I
INLET
nY CW.
INLET
RY cm.
Qa 45 50 61
STEAM
INLET
$ OIL
INLET
+ I !!T!l
no. I
I
I PT. No. INO. OfFl
I I
DESCRBRW
I a-
0 74631325 1 C'FEHALESYELBOW
n 853799 I @ 3/4- E W N TEE -1 b)
R4' R I G FOR P 853799 2 R 3 4 ' UXXAtON MW.E OmO bl
C W f f i A T E DUlN
NOTES
ASTM A105 TO
FITT!NX -
SOCKET bEI.0. S 3 8 0
ANSI B16.11
NSTlMNT
P~~ - TO BE FEN N STEEL E F S T O RBE b F l T T M S
OA ECUVALENT
FASTEERS - BOLTS AN) NlTS - BS 4190 :1967

.* MASERS - BS 4320 :1968
OIL W S -
TAELE 40/101 TO BS 4504 :1989
(TO BE H U l E O YlIH K X E S OFF CENTRES
RETURN -
RSSa TEST HYORAUlCNLY TEST PEWOW TC 39 @M
FOA30rn
-
FNSH ALL EXTEBUL %IFACES
TO W W S PROCESS OtC6
W -
R GREY FMOl
STEAM
INLET
6 OIL
INLET
$
NOTES
O
EBm ALL S W E a E S
MATERIN
STEELYWX -- RATE - BS 4360.434: 1955
PIPEWMb: - TLBE - API % CQE - SCH 4 0
-
F I T I I G SOCKET M O . SDI &3
ASTM A105 TO !*I Bi6.II
INSTIMNT
PIPEWOFX - 70 a RJJ IN
OR EWVALENT
s m EMTO TLDE R FI~TMS
iii-
RETURN
FMSH - ALL EXTEWN -ACES
TO WORKS PROCESS Om
-M R G'E* FWW
ABB Electrical Motor dimension
Motor type MBT 225 M-2 f D FAN
Power 52 kW
Speed 3550 rpm
Efficiency 93 %
cos cp 0,9
Nominal current 82 Amp
Start current 580 Amp
Starting time 4 sec
Insulation class F
Protection grade IP55
225 2 356 61 446 445 222 - - 25 311 75 360 75 149 237 55 55

E EA EG EH F1] FA" G GA GB GC H" HA HC HD K L
1) Deviation Bearing size: D-end 62141C3

A, B js 14 N-end 6214lC3
C. CA +O -2
D, DA I S 0 m6 Electric connection Cable size max ZI 70 mm2
F, FA I S 0 h9
H +O -0.5 Flange opening 2 x FL13
Marked according to IEC 34-8
,/-
1
Instruction Direct driven centrifugal fan
Installation and maintenance HCBB, HCBT. HCRB, HCSB
- -
No. 95-03 HC an 1 1:2
ABB Flakt lndustri AB

Instruction
Radial fan HCBB. HCBT, No. 9503-HCan1 1:2 -
Page 1
739 HCRB. HCSB
Safety instructions
This instruction includes warnings. These indicate the risk for accidents, which cause or can cause personal
injuries. Accident risks are arranged into three categories depending upon their probability and the severity
of the results of an accident.
Technical warnings indicate the risk for failure.
1- DANGER indicates that an accident will rnif the reflations are not followed. The subwwnt
accident can lead to serious personal injury, possibly fatal, or serious damage to property. 4 )
1- Caution! Caution i n d i m that an a N may possibly onuif the reflations are not followed. The accident
can lead to serious personal injury, possibly fatal, or serious damage to property.
1
1- Imporlmt indicates that an accident may possibly OCCUT if the reflations are not followed. The accident
can lead to personal injury, or damage to property.
NOTE!
I NOTE indicates the risk of an aaident if the regulations are not followed.
Noise
In a m r d a n a with the EEC Machinery Direaives 891392EEC the maximal sound pressure level, measured
at a distance of 1 m, and the sound power level shall be specified. The maximal sound pressure is measured
in a position direct in h n t of the inlet or outlct of the fan.
l e HCBB. HCBT, HCRB and HCSB series of tans are the values spccitied in the table below.
~ ~ ~ i i c atobthe
Mcasurcmcnt methods AMCA 300. IS0 3744. IS0 9614-1 and BS 848 have been used.
Sound power level (dB(A) I Sound pressure level dB(A) 1 Sound pressure level d B ( 0
I ?n I 117 I c1-m
Instruction
Radial fan HCBB. HCBT. -
NO. 95-03-HC an1 1:2
HCRB, HCSB Page 2 112.0
General
- Rotating parls are balanced dynanucally and the fans have baen mechanically tested before
delivery.
- Unless otherwise specified, max. operating temperature is 100°C.
- Ambient temperature for cooling of the motor is max. 40PCunless otherwise v i f i e d (see
instruction issued by tbe motor manufacturer).
1- Always use ear p r o t d o n when a fan is in operation.
Installation
1. Fan delivered without a base frame
a) Fan to be bolted onto beams:
1. Ensure that the foundation is even.
2. Tighten the bolts with the torque specified in Table 1.
b) Fan to be mounted on a concrete foundation by means of grouting sleeves or anchor bolts:

1. Align the fan stand carefully (i015nun) on the foundation @lam shim on the grouting
sleeves or anchor bolts as required).
2. Inject the concrete underneath the stand and tighten the bolts when the grout has set
See Fig 1).
I ImPr-t! I Careful alignment reduces or eliminates the risk for stresses that may give rise to deformation of
the stand and damage to the fan.
I Tlghtenlng torque Nm I
Thread Steel 8.8 untreated Steel 8.8 Fzv Steel A 4 4 0
Not lubricated Not lubricated Not lubricated
-
M 10 Table 1
M 12 64
M I6 230 157
rr ?n 1-m den YM
,----dFTd Recess for muting
Figure 1
Instruction
Radial fan HCBB. HCBT. NO. 9s-O~HCan1 1:2 -
Page 3
\b 1 HCRB, HCSB
2. Fan delivered with base frame and anti-vibration mounts
1. Ensure that the foundation is even. If not, the load might be unequally divided between
the AN mounts. the result of which wuld be lost, or impaired, function of the fan.
2. Tighten the bolts of the A N mounts,
Changing the direction of discharge

The direction of discharge can be changed on many HC-fans, see figure 2.
-1 Ensure that the fan casing is secured by means of wooden blocks, for example, before the bolts
are loosened .
- Loosen all nuts (1) and turn the casing. The direction of discharge is limited by the location (
of the bolt holes.
Figure 2
Fitting
1. Retighten all nuts of the casing (check the gasket for damage).
2. Examine the clearances acc. lo Fig. 3 amuud the entire inlet
3. Change the clearances by loosening and adjusting the motor, then retighlen the
motor bolts acc. to Table 1.
Instruction
Radial fan HCBB, HCBT. NO. 95-O~HCan1 1:2 -
HCRB. HCSB Page 4 i IIL
Impeller
Fan size
Figure 3
Fitting of accessories
General
I) In order to avoid damage to the fan, e.g. due to -ion
flexible connection is fitted beoueen fan and ducl
in the duct, we --end that a
Fans with vibration shall always k provided with a flexiile connection.
Fabric duct for gas temperature mar. 70°C

1. Fit the fabric duct as shown in Fig. 4.
2. Tighten the strap onto the fan inlet and measure the maximum length of the flexible duct.
3. Ensam that the a.dimension is 10-30 mm shorter than the length of the flexible duct. Then
tighten the sUap onto the dun.
Flue gas duct for gas temperature over 70°C

Fit the flue gas dud as d c s c n i above for the fabric duct. Please note the position of the inner
m
wearing plate in relation to the direaion of gar flow.
Casing side
Inlet
Figure 4
D U ~
Direction of discharge
Instruction
Radial fan HCBB. HCBT. NO. SS-O~-HCan1 t:z -
,bl13 HCRB. HCSB Page 5
Guards
Roteaive s x e n s must k provided when the inlet or outlet ofthe fan is not connected to a duct.
Guards delivered by ABB Flakt lndustri AB comply with EG directive regarding machine safety,
It is important, therefore. that authentic guards are used.
Inlet vane control

The inlet vane control unit HXAG, which is available for either right-hand and left-hand
operation, can be mounted direct onto the fao as shown in Fig.5.
The unit must not be mounted onto fans standing on anti-vibration mounts
unless they are designd for this additional load. The inlet vane control can be equipped
with actuator, which is to be installed in acwrdance with the suppliers instruction. d3
Special insuuclions for fining and maintenance are delivered together with the HXAG inlet vane
control.
Impeller -
Inlet vane control 0 0 Figure 5
Right-hand design Left-hand design
Electrical installation
Must always be Earrid out by an authorised electrician. For installation of the motor. see
instrunions issued by the manufachu'er.
I ImW-t I A safety isolating switch should always be installed in order to guarantee safety during
work on the fan.
The safety switch is not included in the fan delivery.
Instruction
Radial fan HCBB. HCBT. NO. 95~3-HC an1 I:Z -
HCRB. HCSB Page 6 )114
Trial run
a) Before the trial run, verify:
0 Caution! 1. that guards are fined on inlet andlor outlet which is not connected to duct.
2. that bolts are tightened and that the fan is properly aligned and anchored.
3. that the impeller rotates without abnormal noise.
4. that the motor has been connected in accordance with the instructions issued by
the motor manufacturer.
5. that the flexible connections are fitted correctly (no sues allowed).
6. that the weight of connecting ducts is not supponed by the fan.
7. that the fan mounted on anti-vibration mounts is not loaded with equipment that might
damage or impair their function.
8. that the ducts an:lkee from loose objects, and that permission to sfart up has been given
by p e ~ n n errspoasible
l for the operation.
'[1
‘ 1( Always use ear protection when a fan is in operation.
b) Start the fan and verify:
1. that the impeller rotates in the correct directio~*Fig. 6.
2. that the level of vibration docs not exceed 7.1 mmls RMS, measured on the motor.
3. that no abnormal noise is heard from fan or motor,
4. that the inlet vane control, if installed, works in the way intended.
Replacement of impeller or motor

1 Caution ! 1 E-e that the safety isolating switch is open If an isolating switch has not been installed,
the power supply must te d i s ~ ~ ~ e cby d authorised electrician before work on the fan
t ean
commences.
:h
i/
Impeller and casing must k handled with care to prevent injury to personnel.
Removal
1. Loosen the connectionsof inlet and outlet ducts.
2. Loosen the nuts (1). Fig 2.
3. L i i offthe casing. Ensure that the fan casing is secured by means of wooden blocks, for
example, Wore the bolts are loosened.
4. Loosen the bolt (2) of the end washer. Fig. 2.
5. Remove the impeller by means of a puller. Fig. 7.
6. If the motor is t o t e replaced, mark out the location of the motor feet to facilitate
installation of the new motor.
Radial fan HCBB. HCBT. -
NO. 9 5 0 3 H C an1 1:2
I IIT HCRB. HCSB Page 7
Figure 7
I
Impeller
1
Impeller
Installation
42
1. Fit the motor with ihe 4 bolts (4). Fig. 2.
I 1 2. Use the puller and fit the impeller as shown in Fig. 8. The impeller must not be knocked into
position by blows to the hub. This will damage the motor bearings which could lead to
extensive damage to the fan -1
3. Fit washer and bolt (2.3). Fig. 2. Tightening torque as specified in table 1.
4. Fit the casing. Replace the garket as required. Tighten the nuts (1). Fig. 2.
5. Chedc the gap. Fig. 3.
6. Change the gap by loosening and adjusting the motor. Then tighten the motor bolts according
to Table I.
Figure 8
Maintenance
1- Ensure thal the safelyisolahg M c h is open. If an isolating switch has not been installed, the
power supply must be disconnected by an authorised electrician before work on the fan
()
Commences.
Impeller
1 Im~oflmt! I Corrosion of dust deposits on the impellers will cause imbalance and consequent damage to the
bearings. It is important, therefore, to chedr the level of vibrations at regular interrals.
Max. permissible level at the centre of the bearing is 7.1 mmls RMS.To minimise the risk of
damage, clean and re-balance the impellers as required.
Motor
For lubrication and maintenance, see instructions provided by the supplier.
Instruction
Radial fan HCBB. HCBT. No. 9543-HC an1 1 2 -
HCRB, HCSB Page 8 /%
Hoisting instructions
- Assembled fan should be Iifled as shown in Fig. 9.
- The motor is to be lift& in the lifting eye in accordance with the instructions issued
by the motor manufachtrer.
Figure 9
1L-1
Oikosulkumoottori I i.13
Kortsluten motor
Squirrel cage motor *W
Drehstrom-Kafiglaufermotor
. Moteur triphase a cage
Motore a Gabbia di Scoiattolo
Asennus- ja hoito-ohje
; Installation och skotsel
Installation and Maintenance
Aufstellung und Wartung
Installation et Maintenance
lnstallazione e Manutenzione
A 6 6 Motors
1. GENERAL
The safety equipment required to prevent accidents at the mounting and

operating site shall be in accordance with the regulations prevailing in the
country conserned.
1.1 Reception
Check all the data on the rating plate to see that they correspond to your
order. Make a special point of checking the voltage, and the connection
method. (i.e. star or delta).
Inspect the motor to see that it has not been damaged in transit.
'Turn the shaft by hand to check it turns freely.
\' -1 1.2. Storing
If the motor is not taken into use directly it must be stored in a dry storeroom.
To prevent bearing damage the storeroom must be free of vibration. It is
-
recommended that the shaft be rotated by hand perjodically to prevent
I 1 ; grease migration.
If anti-condensation heaters are fitted, energize them if possible.
2. INSTALLATION
To avoid vibration and resonance the motor must be placed on a sturdy and
even foundation.
Check that the drain holes face downwards when the mounting designation
differs from standard. In a very dusty environments the drain hole plug should
be knocked in. See picture no. 8 .
2.1 Foundation studs

Ci )
Bolt the foundation studs to the feet of the motor and place a 1...2 mm plate
between the stud and the feet. Align the motor direct by means of steel
shims or adjusting bobs. After alignment cast concrete and drill holes for
locating pins. See picture no. 1.
2.2 Belt drive
Fasten the motor to the slide rails as shown in picture no. 2. Place the slide rails
horizontally on the same level. Check that the motor shaft is parallel with the
driven shaft.
Tension the belts according to given instructions.

Note: An excessive belt tension will damage the bearings. Do not exceed
the max. belt forces in our brochures FIMOTlM2BA 1 GB and
HXV 1 GB.
4. CONNECTION
4.1 Termination of the motor
The terminal box can be turned 180', thus allowing cable entry from the left or
right side of the motor. Unused cable entries must be closed.
4.2 Connection; single-speed motors
The motor terminal box has six main terminals and two earthing terminals.
Direct starting:
In direct starting the motor can be used in two different connections. The
voltage and connection, e.g. 660 VY. 380 VD, is stamped on motor rating
plate. This means that the motor must be in Y-connection for 660 V and in
0-connection for 380 V.
star-delta starting:
In star-delta starting the line voltage must be equal to the motor rated voltage
in D-connection. Remove all the connection links from the terminal block.
See picture no. 5.
4.3 Connection; two-speed and special motors
Connect the motor according to the directions on the inside of the terminal
box cover.
4.4 Direction of rotation
Direction of rotation is clockwise viewed from the drive end when the phase
(:.
sequence is as shown in picture no. 6. To alter the direction interchange the
connection of any two phase terminals.
Note: Check that the earthing is done according to local regulations.

(3
5. MAINTENANCE AND LUBRlCATlON
5.1. Instructions for maintenance
Inspect the motor at regular intervals. Keep the motor clean and make sure
there is free ventilation air flow. Check the condition of the seals (e.g. V-ring)
and replace i f necessary.
Check the bearing condition by listening for any unusual noise, by measuring
the vibration or the temperature of the bearings and by inspecting spent
grease. When changes of condition occur open the motor and check the parts
and replace if necessary.
The motor bearing temperature can be obtained roughly by measuring
the hottest place of the bearing cover at the D-end and adding to that
figure 5 - 1 0 ' ~ . See picture no. 7. /lo
5.2.2 Lubricants
Use greases specially made for ball bearings, e.g.
Esso Beagon 2 or 3
Shell Alvania G2 or G3
Mobil . Mobilux 2
6P Energrease LS2 or LS3
Texaco Regal Premium 3
or other similar lubricants
For highly loaded and/or slowly rotating bearings EP-greases must b e

used (e.g. Esso Beacon EP 2).
In the case of lubrication intervals being very short because of bearing

temperature being 80'C or above, use high-temperature greases. With
'
the following greases 15'C higher bearing temperatures can be allowed:
Esso Unirex N2 or N3
SKF LGHT 3
Shell Dolium Grease R2
Mobil Mobiltemp SHC 100
Texaco Ultra temp grease 2
Kluber Staburags NBU 8 EP
or other similar lubricants
. . I
If the make of grease is changed and miscibility is not certain, lubricatb

the bearings initially several times at short intervals in order to displace
the old grease from the bearings.
'( > If the ambient temperature is below -25'C use low temperature greases,
e.g. Esso Beacon 325 or similar.
6.SPARE PARTS
When ordering spare parts for a motor state the type designation of the
motor and the manufacturing serial number stamped on the rating plate.
. .. ..
.
.....
..*.. MOUNTING AND ASSEMBLY INSTRUCTIONS
Doc No
Page 1
Rev.No.
AALBORG SUNROD Date 18.08.93
BURNER MOUNTING AND ASSEMBLY INSTRUCTIONS
The following notes have been compiled as a guide to the installation and erection of
the D F ~ L Uregister, They are intended only as a broad outline of the procedure to be
adopted. since the precise procedures dictated by practicality will vary from
installation to installation.
Before commencing installation, it is advisable to remove the gaslelectric igniter, the

flame monitoring photocells, and the centre fuel sprayer. On most sizes of DFlLU
register these items may be removed as a single assembly by disconnection of a sub-
mounted frontplate from the main frontplate unit.
The register should then be lifted into position and the furnace wall and front plate
flanges carefully positioned and aligned before finally bolting into position. Correct
alignment of the register is essential, reference should be made to the general
arrangement drawing.
The %urner air inlet damper assembly complete with characterising cam is mounted
directly onto the burner windbox. Care should be taken not to damage the linkage
arrangement during ligtinglinstallation of burner. When burner is in position ensure
damper blades operate without obstruction and that limit switches are mounted to prove
open and closed positions.
The register should now be re-assembled and the setting dimensions for the sprayer. gas
spuds and gaslelectric igniter should be checked. These dimensions together with the
centralising of the entire assembly within the primary refractory annulus are normally
set during initial manufacture, but should in any case be confirmed at this stage of
the erection.
The importance of these setting dimensions cannot be too highly stressed and tolerances
of the order of *1 mm (0.039 in) should be achieved, particularly where maximum
combustion efficiency is essential. Variation of these dimensions will disturb the
primary to secondary air flow relationship, the register air pressure loss, flame
stability and combustion efficiency.
I Doc No
COMMISSIONING
The following MUST be read in conjunctionwith the instructions givenby manufacturers

of any associated plant.
It is a representative list, meant as a guide for operators prior to lighting the

burner.
It is not stated as being complete. nor in any sequential or preferential order.
1) Operation of this eqiupment should only be carried out by personnel having a

clear understanding of the functioning of the equipment and its associated
controls.
Read this manual, and if any doubt, please contact Hamworthy Engineering Limited.
2) Any combustion process requires adequate ventilation.
Ensure that sufficient ventilation is available to the area of the fan intake.
Check the induced draught fan for direction of rotation.
Check the forced draught fan for direction of rotation.
It is essential that all air and gas ducts in a boiler should be thoroughly
purged with air before introducing fuel to any burner. to ensure that no pockets
of potentially explosive gas are present in the system. In the absence of any
firm instructions of the quantity of air to be passed through the duct system.
a quantity equivalent to five complete air changes is normally accepted as
sufficient.
If an induced draught fan is installed. it is normal to start it with any

suction dampers closed, in order to keep starting torque to a minimum. If
the drive is a steam turbine warm through slowly when first starting.
If a forced draught fan is installed and there is a suction damper or inlet

vane control, this should be started in a similar manner to the induced
fan.
Open, and where applicable lock, all isolating dampers in the air supply
and gas discharge ducts.
Open all burner register air sleeves, if fitted.
Check that there is a positive air flow throughout the duct system.
Allow an appropriate furnace purge period. preferably with maximum air

flow.
Close all burner register air sleeves with the exception of the first
burner (or burners) to be fired.
Reduce the air flow until it matches the pre-determined lighting up fuel
pressure.
On an automatically controlled system the preceding progranrme will be timed out

by the control equipment.
.- -.
...-
.....
.....
-
COMMISSIONING
I Doc No
Chpt 5 Page 2
JUUII,
AALBORG SUNROD
Rev.No. A
Date 18.08.93
3) Check that the power supply to the control equipment is on. and that compressed
air for actuators is available at the correct pressure, and adequately filtered.
4) Check that the igniter is connected to the gas supply, and its transformer. and
that gas is available at the required pressure.
Check igniter is available at the correct pressure (if applicable)

) -J>
..
....
.....
..... TECHNICAL DATA
Doc No
chpt 6 Page 1
(JiUii,
AALBORG SUNROD
Rev.No.
Date
A
08.08.95
BURNER SPECIFICATION (2 off)
GENERAL CONDITIONS
Ambient Air Temperature 15-45OC

Atmospheric Pressure 1.013 Bar a
Furnace Pressure 18.6 mBar
Preheat Temperature 15-45OC
FURNACE REOUIREMENTS
Heat Input per Burner 14.03975 Million kCalIhr

Number of Burners per Boiler 1
Furnace Length 2.54 metres
Furnace Volume 19 m3
Actual Heat Release Rate 738939 k~allhrlm'
Maximum allowed HRR 966287 k~allhrlm'
Turndow Ratio 7 to 1
OIL DATA
Oil Name HE0

Oil CV 10278 kcallkg
Oil SG 0.97 (Water =1)
Oil Stoic Air 10.57 Nm3/kg
FUEL AND AIR REQUIREMENTS
OIL
Oil Name
Oil Flow @ MCR
Air Required (Oil)
Excess Air (Oil)
Design F.No. Actual F.No.

The RDL for firing HFO 21.51 mBar 31480 30349
FLAME LENGTH 1.93 metres
OIL ATOMISER SPECIFICATION
Available Oil Pressure 22 bar g

Oil Flow @ MCR 1366 kglhr
Oil Pressure @ MCR 13.09 bar g
Turndown 7 to 1
Oil Flow at Turndown 195 kglhr
Oil Pressure at Turndown 3.07 bar g
Available Steam Pressure 5.5 bar g
Calibration Steam Pressure 5.5 bar g
Steam Flow at MCR 43.69 kg/hr
Steam Flow at Turndown 67.16 kg/hr
.. ....
..... Doc No
Chpt 6 Page i
(IUUIII
AALBORG SUNROD
CHARACTERISTIC CURVES
Rev.No. A
Date 25-AUG-95
I)!
...
...
..... Doc No
.me..
Chpt 6 1 Page 2
(iUiiii,
AALBORG SUNROD
Rev.No. A
Date 25-AUG-95
......
.....
.em*.
Doc No
Chpt 6
JUiUi
MLBORG SUNROD
Rev.No.
Date
A
18-AUG-93
cj
.. .. ..
.....
...a.
Doc No
TROUBLESHOOTING Chpt 7 Page 1
,JuuII
AALBORG SUNROD
Rev.No.
Date
A
18.08.93
BASIC FAULT FINDING
BURNER WILL NOT LIGHT
Ignition failure. i) Ignition gas turned off or pressure too

low.
ii) Ignition gas solenoid valve failure.
iii) Ignition transformer failure.
iv) Ignition electrode damaged, worn, or dirty.
V) Airlignition gas ratio incorrect.
vi) HT lead damaged or disconnected.
Flame monitoring cell dirty or faulty.
Fuellair ratio incorrect.
Fuel isolating valves closed.

Automatic fuel shut off valves not operating.
No fuel available, or incorrect fuel pressure.
Draught too high.
Blocked fuel filter.
BURNER STARTS BUT FAILS TO ESTABLISH

a) Flame monitor not supplying amplifier with signal to operate relay.
i) Monitor obscured by dirt or moisture.
ii) Monitor worn or damaged.
iii) Polarity of electrical connections
reversed.
iv) Open circuit or ground between monitor and
amplifier.
v) Alignment of monitor and flame incorrect.
vi) Flame too small or too dark to be viewed,
i.e. fuellair ratio incorrect.
b) Fuel Starvation. i) Manual or auto valves notopen fully.

ii) Filter normally blocked.
iii) Fuel control valve set too low.
iv) Low fuel pressure.
v) Any other restriction in fuel line.
vi) Atomiser blocked (oil).
vii) Fuel pressure regulator fault.
c) Excessive Forced Draught Air Pressure.

160
... I Doc No
TROUBLESHOOTING Page 2
Rev.No.
AALBORG SUNROD 18.08.93
LOCKOUT DURING NORMAL FIRING
a) As section 2a above.
b) As section 2b above.
c) Water in fuel (oil only).
d) Failure of a running interlock.
BURNER WILL NOT SHUT OFF
a) Auto valves sticking in open position.

BURNER LIGHTS SEMI-EXPLOSIVELY
a) Delayed ignition. i) Ignition flame too small.

ii) Igniter wrongly positioned.
iii) Forced draught pressure too high.
b) FuellAir Ratio incorrect.

C) Water in fuel oil.
INCORRECT COMBUSTION
a) Incorrect fuellair ratio.

b) Inconsistent fuel or air pressure.
c) Damaged, blocked or incorrectly sealed atomiser.
d) Incorrect fuel oil temperature.
e) Impurities in fuel.
f) Burner geometry incorrect.
BURNER FAILS TO MEET LOAD
a) As section 6.
b) Incorrect full fire setting.
C) Excess induced draught.
d) Faulty coupling.
e) Load demand higher than plant capability.
Any of the faults referred to could be caused by electrical or control faults and
failures. The comments given are meant as a guide to the sort of immediate failures
to look for.
..a*.
...
... Doc No 1L
PARTS LIST Chpt 8 Page I
RevNo. A
AALBORG SUNROD
Date 25-AUG-95
-
1 UST OF PIRTS
SERUL NO. CONT. OTY. DESCRIPTION ISSUE CONTRACT DATE DUE L0.P. JATE
NO. SHER I
OF 2
SEE BELOW OF545 OIL BURNEX A 3707547 X 07 95 21 CI 95
ITEM PAR: NO. OW DESCRIPTION TAG NO.

NO. PER
L 212.i0,:W 2 STEAM PRESS. GAUGE (0.16 KOCM'I TAG F12
M %I IDITGIOM1 2 S T E M PRESS. SWrrCH TAG F13

N D306017EIE 2 STOP VALVE FOR PRESS SWlTCH TAG FIS
loim
-
P 2 STOP VmM FOR OIL GAUGE TAG F15
0 74724'025 4 PHOTOCEU (PAW TAG FIB

R GS300984 2 JUNCTION EQX TAG F19
S 37075471108 2 BURNER GUN TAG F21

-
T 2 FLEXBLE HOSE (Oh) TAG F2lC
U 2 FEUBLEL(0SEIW TAG F2 ID
V 370754705608 2 COMBUSTION U R DAMPER TAG F22
W W W 2 PNEUI3ATIC rUR DPIMF€R TAG F22A
X 33202!i06 2 SOWDEN CABLE 11.5 MI TAG F22K
LOOSE nEMS
'I H2HC ;5;1 2 BURNERNOmE TAG F21A
Z 331ZUU31 2 PACKS CERAMIC RBRE ROPE T A G F25

2
PA
I
7171L6566
I
2
I
COMBUSTION AIR PRESS SWITCH
I
TAG F!6
I
.... ..
.....
..... PARTS LIST
Doc No
Chpt 8 Page 2
jiiiUI,
AALBORG SUNROD
RevNo. A
Date 25-AUG-95
DESCRIPTION
. .. ..
.
.....
..... MAINTENANCE
Doc No
Chpt 9
1 l?
Page 1
Rev.No. A
GENERAL CARE AND MAINTENANCE
Registers
It is important that registers, if they are to perform to their specification.

are kept clean and in good condition.
Inspection should be carried out at regular intervals, preferably on a planned
maintenance basis.
Large quantities of dust laden air pass through the register, particularly on
some industrial sites. and inevitably this tends to build up deposits. These
deposits should be brushed off using a soft brush, or washed with paraffin.
Care should be taken not to damage the surfaces exposed to direct flame
radiation, as this may cause a reduction in their resistance to heat erosion.
Fuel Carriers
a) Oil Sprayers. These should be cleaned frequently, together with the

atomisers. Details of care and maintenance are covered under a separate
heading.
It is suggested that a complete spare sprayer and atomiser be held. This

enables one to be used for firing. whilst the other is cleaned, then held
as spare, in this way down time is kept to a minimum.
Other Equipment
In general. on a plant in constant use. care of other equipment is necessary.

other than cleanliness, and repair of damaged or worn parts. Any special
requirements will be covered in the literature supplied by the manufacturer, in
which case reference should be made to the appropriate section of this manual.
PERIODICAL MAINTENANCE
Regular inspection and maintenance of the equipment pays dividends. Potentially

hazardous situations may be avoided. and cost delays in production minimised.
The following check list is put forward as a suggestion to be carried out at fortnightly
intervals. However, depending on the installations. some items may need more frequent
attention.
1) Primary and secondary swirlers, and all other surfaces exposed to radiated heat
should be checked to be free of carbon, or heat erosion.
2) The refractory should be inspected for general condition, and exmained to be free
of carbon deposit, or any other form of deterioration.
Doc No
.**..
119
MAINTENANCE Chpt 9 Page 2
Rev.No. A
Control panels. and other electrical equipment should be kept clean and dry.
Check that no foreign matter accumulates in, on, or around them.'
Replace lamps, contacts and other components when they cease to function or shon
signs of deterioration. A part replaced before it actually fails could save a
costly delay. Check all connections are secure and that all wiring is in good
condition.
Check that fan inlets are kept clear of unintended obstructions.
Check pipework for leaks. particularly on flanges, joints and connections.

Attend to any leaks as necessary, for reasons of cleanliness and safety.
Check the general condition of pipework, lagging and tracing.
Check that the glands of manual valves are tight enough to prevent easy operatior
of the valve.
Oil and atomising steam filters should be inspected and cleaned.
Air filter/regulators should be checked to be operating and in good order.
Manually operated valves should be periodically operated where possible to ensure

free movement. Normally open valves should be one quarter turn from fully open.
The ancillary equipment should be inspected and serviced in accordance with the
respective manufacturer's instructions.
Pressure gauges should be checked to be operative and if necessary.

re-calibrated.
It is recornended on plant in continuous operation. (i.e.. longer than one week)

that periodically, as plant conditions permit, each burner in turn should be
shut down and then re-established.
This practice ensures that all the interlocks and their associated supplies are
working correctly, as well as proving controls, ignition equipment, etc. Where
possible this should be done once a week.
Apart from proving components. we consider that wear or other deviations fron
optimum efficiency can be detected and therefore rectified in a planned manner.
resulting in savings in both operating and production costs.
.. .. ..
.....
.*a*.
Doc No
JUUII,
AALBORG SUNROD
Rev.No.
Date
A
18.08.93
STEAM ATOMISERS
GENERAL NOTES ON FITTING AND MAINTENANCE
INTRODUCTION
The design of steam atomiser employed by Hamworthy Combustion Systems for l a m

installations is shown in figure number 1. The atomiser can be seen to consist of i
one piece nozzle plate located and sealed against the sprayer and by means of a cap nut.
The principle is one whereby an oil nozzle intersects with the counter bore of a stean
nozzle. The steam and oil mix in this chamber at pressure. The ex?ansion of thc
mixture as it discharges to low pressure. results in the fuel oil breaking up into i
finely atomised spray.
The atomiser design utilising this principle consists of a multiplicity of steamloi]

nozzles. arranged on a pitch circle. The spray angle of the atomiser is determined b]
the angle at which the nozzles are drilled.
In order to produce optimum atomisation of the fuel oil, much research has gone intc
perfecting the geometry of the atomiser. For example, the various nozzle diameter anc
lengths ratios have to be correct.
For correct operation, it is important that the steam and oil do not meet before thf
prescribed point in the counter bore. It is therefore. critical that no leakage shoulc
occur across the joint face formed by the atomiser and the sprayer end; the joint is
metal to metal and depends on both faces being flat, clean and satisfactorily clampec
together.
The following notes describe the reasons for maintenance with causes and affects. This
is followed by the maintenance procedure which must be adopted.
REASONS FOR ATOMISER MAINTENANCE
1. Atomiser nozzles blocked internally (1)
Cause:
Pipe scale. welding slag, etc. Usually only occurs during commissioning and
affects both steam and oil nozzles.
Effects:
A blockage of a steam nozzle will result in an increased oil flow with a marked
deterioration in atomisation. A blockage of an oil nozzle will result in a
reduced oil flow and corresponding flame distortion.
Fuellair ratio will also be affected.
Doc No . .Ll

-~
2. Atomiser nozzles blocked internally (2)
Cause :
Carbonised fuel oil. This is a result of incomplete purging coupled with

inadequate steam cooling. Any fuel oil left in the atomiser of a shut down
burner, if inadequately cooled. will carbonise. due to overheating of furnace
radiation.
Effects:
Will normally only affect the oil nozzles as in (1)
3. Carbon growths on atomiser face and cap nut
Cause:
Any factor affecting the correct operation of the atomiser can result in carbon
growths. These factors include:
(a) Nozzle blockages as described in 1 and 2.

(b) Badly worn atomiser.
(c) Incorrect steam pressure or wet steam.
(d) Incorrect oil temperature (viscosity).
(e) Oil leakage from cap nut due to:
i) damaged atomiserjcap nutjsprayer and

ii) dirt between seal faces.
iii) cap nut not tightened.
Deterioration of combustion due to the primary cause above, and secondly to the
carbon growth itself. If the carbon is allowed to grow atomised oil spray will
impinge upon it, resulting in large oil droplets or streams of oil.
4. Variation in design calibration
This can be a deficiency or an excess of flow.
1. Flow Defficiency
Cause: (a) Fuel oil or steam pressure measured incorrectly.

(b) Fuel oil or stream pressures incorrect.
(c) Fuel meter incorrect.
(d) Nozzle blockages, see 1 and 2.
(e) Atomiser not sealing satisfactorily against sprayer and.
allowing steam cross flow to restrict fuel oil flow.
Effects:
Reduced oil flow on individual burners upsets fuellair ratio on a

burner basis (unless fuel and air is metered per burner). Combustion
performance in terms of flame length and unburnts will deteriorate.
DOC NO ! G7-
. m i * .
MAINTENANCE Page 5
Rev.No.
2. Excess Flow
Cause: (a) Fuel oil or steam pressures measured incorrectly.

(b) Fuel oil or steam pressure incorrect.
(c) Fuel meter incorrect.
(d) Steam nozzle blocked, see 1.
(e) Oil nozzles worn oversize.
(f) Cap nut not tightened adequately.
Effects:
Excess oil flow on individual burner upsets fuellair ratio on burner basis
(unless fuel and air is metered per burner). A worn atomiser will result
in poor atomisation and subsequent combustion deterioration.
NOTE: Causes (a), (b) and (c) indicate apparent calibration errors not
real ones.
COMPONENT HANDLING
The major reasons demanding atomiser attention have been detailed. it is, however.
unfortunate that in practice'the very action of atomiser removal can. itself. produce
hazards requiring maintenance. These can come under the general heading of
"Manhandling" and usually constitute the following:-
Atomiser
(a) Damaged whilst 'hammering' out of cap nut.

(b) Dropped onto floor. producing burrs on sealing face.
(c) Damaged whilst cleaning with unsatisfactory tools.
(d) Sealing face 'lapped' on a convex or concave lapping plate.
(e) Atomiser worn by cleaning on unapproved blast cleaning equipment.
(f) Surface hardness affected by use of muffle furnace to clean off surface
carbon.
Sprayer End
(a) Sealing face left exposed to damage.

(b) Lapped concave or convex by inexperienced fitter.
Cap Nut
(a) Damaged whilst removing 'janrmed' atomiser.

(b) Cleaning with unsatisfactory tools.
General
In view of the above hazards and loss of availability, it is obvious that sprayer
and atomiser removal should only be considered if positive indications for
maintenance arise.
.. .. ..
.....
..om.
Doc No
\ LQ
(IUUII,
AALBORG SUNROD
Rev.No.
Date
A
18.08.93
MAINTENANCE
Atomiser Removal
In most cases little difficulty is experienced in removing the atomiser from the
cap nut.
However. in some instances the atomiser can become wedged in the cap nut. This
is not due to inadequate clearance but is a result of the atomiser tilting as it
is pushed out. this is a function of the atomiser being a relatively thin disc.
When this occurs, the atomiser is usually removed for 'force' resulting in
damaged atomisers and cap nuts.
The real solution is relatively easy. The following procedure should be adopted.
(a) The sprayer must be held rigidly on a bench, locating on the sprayer hexagon
adjacent to the cap nut. Loosen the cap nut and undo approximately 1 to 2
turns. Using a piece of wood or soft metal, tap the atomiser back into the
nut until it contacts the sprayer end. Hold it in this position and screw
off the cap nut. Figure number 2. This procedure keeps the atomiser square
with the cap nut and prevents wedging. Care must be taken not to drop the
atomiser when the cap nut finally clears the sprayer.
(b) If an atomiser has become wedged in a cap nut this can usually be squared
up again by simply screwing back onto the sprayer. The procedure above can
then be employed.
In the case of a severely wedged atomiser. it may be necessary to use a soft

metal drift in order to square up then tap out. Under these circumstances
both the atomiser and the cap nut should be closely examined and rejected
if damaged.
Atomiser Maintenance
Before any examination can be made, the atomiser must be cleaned. This is
normally done by soaking in a paraffin bath to wash any heavy oil films, this
also has the action of loosening carbon deposits. it may also be necessary to use
a soft metal scraper to lift away any heavy carbon deposits. A hardened scraper
could possibly damage the atomiser.
The use of abrasive blast equipment or muffle furnaces should not be used without
consultation. Incorrect use of these methods can reduce component life
seriously.
The cleaned atomiser should then be examined for damage. The nozzle sizes should
be checked using 'go and no go' pin gauges. This action will also determine if
any nozzles are blocked and should. in fact, clear them. Compressed air will
normally clear any debris left in the nozzles after cleaning. The sealing face
of the atomiser is checked by rubbing on a surface plate with marking blue. If
the face is not square and flat it is necessary to correct this by lapping with
a fine carborundum paste.
DOC NO !6 9
.iii.
MAINTENANCE Page 7
Rev.No.
-
If a surface plate and marking blue are not available a light rub.on the lapping
plate with fine paste will also indicate the condition of the sealing face. The
atomiser should only be lapped if the sealing face is found to be unsatisfactory.
Do not carry out unnecessary lapping.
It is important to inspect the lapping plate at regular intervals. This plate

must be maintained flat if it is to be of any use. The atomiser should be lapped
by using the figure eight pattern. Figure number 3, employing the maximum surface
area of the plate to prevent local wear.
Finally the atomiser must be washed to remove all lapping paste. If the atomiser
is not to be used immediately. it must be kept in a plastic or similar container
to prevent damage or scratching of the sealing face.
It is false economy not, to reject an atomiser if it is found to be

unsatisfactory, i.e.
(a) Not possible to produce a complete sealing face across atomiser.

(b) Nozzles excessively worn (see note).
(c) Nozzles damaged by hammering etc.
It is possible that satisfactory atomisation could be achieved with a larger

oversize tolerance. However. on a multi-burner application the overall minimum
excess air level is greatly influenced by the individual burner fuellair ratios.
It is, therefore, vital that the fuel flow to individual burners is controlled
as closely as possible. In this context by not allowing atomiser wear to effect
unacceptable flow variations.
Sprayer End Maintenance
The sprayer end must be washed clean with paraffin or similar before examination.
A hand held surface plate with marking blue can be used to determine the
condition of two sealing faces. As with the atomiser, this could also be
determined by a light rub directly with the lapping plate. If a complete lapped
face is not immediately produced. further action is necessary.
The action of lapping a sprayer end calls for considerable care and attention.
The lapping plate which must be hand held, must be regularly maintained for
flatness. Again the figure of eight pattern is employed and much care must be
taken to ensure that the plate does not rock, creating a convex end, Figure no.4.
If a sprayer end has been severely damaged. it will not be possible to produce
a satisfactory finish by hand. in this case it will be necessary to have the
sprayer machine faced and ground and finally lapped.
When a sprayer is not in use a protective cap or cover must always be fitted to
protect the sealing face and threads. The sealing face and threads are not
hardened and particular care must be taken.
. ....
.
.....
..... Doc No
Chpt 9 Page
\ ;i?
8
JUUIii
MAINTENANCE
Rev.No. A
4. Cap Nut Maintenance
Provided the atomiser removal procedure (2) is adopted and the correct sizr
spanner (not Stilsons) used to remove the cap nut, little maintenance other that
cleaning will be required.
Cleaning will be achieved by soaking in paraffin or similar. Stubborn carbor

deposits should be lifted out with a soft metal scraper. Care must be taken not
to damage the threads, these should be chased out if any damage is evident.
FITTING ATOMISER ASSEHBLY ONTO THE SPRAYER
Before locating the atomiser into the cap nut. check that no inclusions are trappet
between the atomiser shoulder and cap nut. Care must be taken to keep the atomisel
square with the cap nut as it is located. otherwise wedging may occur.
The threaded portion of the sprayer should be covered with a non-hardening higl
temperature lubricating compound. This facilitates subsequent removal. Particular cart
must, however, be taken to ensure that no compound is trapped between the sealing faces
The cap nut is run up until the atomiser comes into contact with the sprayer, a fina:
tightening torque of 150 to 200 ft. lbs. shoull then be applied. Provided due attentio~
has been paid to all the aforementioned points, no difficulty should be experienced i~
achieving a satisfactory seal between atomiser and sprayer. If doubt exists remove tht
atomiser immediately and examine the witness marks on the atomiser face, these shoul~
be two complete rings corresponding to the sprayer and seal face.
GENERAL NOTES
When a clean sprayer is fitted into a burner. it is imperative that the cooling stear
isolating valve is opened hediately. otherwise overheating may occur.
By the same token. when a sprayer is removed for maintenance, the cooling steam shoull:
not be isolated until the moment of removal.
Regular checks must be made to ensure that blockages of the cooling steam valve haw
not occurred.
The design and assembly of the steam atomiser described is very simple. The maintenanc~
and fitting procedure is not particularly demanding when considering the function tha!
this camponent plays in the overall plant performance.
It can. therefore, not be overstressed the importance of rigidly following these rule!
if efficient operation is to be achieved and maintained.
...
.....
.-
.-*a.
- - -
m
M A I N T E N A N C E
Doc No
AALBORG SUNROD
I Date 18.08.93
STEAM ATOMISER
.-
' 2 .<,
.
; \.
,
!
.
L.rouorro
OIL
I*P..
- -.
ATOWSCrn
....
..
..... , 'J .-L-
..... M A I N T E N A N C E
Doc No
Chpt 9 page 10
Jliiiiii
AALBORG SUNROD
Rev.No.
Date 18.08.93
.. ....
..... I Doc No i , ?
a .--a.
AALBORG SUNROD
Instructions to Open Up the Burner
-
and - -
also --
Primary --Replacement
Swirler --- . Chpt g
Rev.No.
.
Date
Page
General : The entry into the furnace is to be made through the burner
opening, this is achieved by opening up the burner front plate
and carrier tube. (the flange bolted to the front of the
windbox). This also gives access to all burner components such
as the primary swirler throat etc (see the burner GA drawing).
To Open the burner: 1. Check that the burner control is off.

2.1 Remove the quick release couplings on the sprayer to the
flexible hoses.
Remove the burner sprayer.
Remove the photocells from their holders and locate them
so that they will not be damaged during disassembly of
the burner.
Remove the limit 'switch sprayer not in position'.
Unplug the electric connection to the igniter.
Release the flexible hose from the igniter both for oil
and air.
Remove the igniter.
Remove the nuts holding the front plate and carrier tube.
Pull the front plate backwards, the secondary swirler.
primary swirler and carrier tube is attached to the front
plate and will follow as a unit.
If there is a narrow space around the burner the removal of

the front plate can be done as below.
6.1 Remove the 4 inner screws holding the secondary swirler

and dividing ring.
6.2 Remove the nuts holding the front plate and carrier tube.
6 . 3 Pull the front plate backwards, the carrier tube and
primary swirler is attached to the front plate.
6.4 Pull out the secondary and dividing ring.
The burner is now open for either swirler entry into the
furnace. burner inspection or maintenance.
Primary Swirler The primary swirler consists of a swirl plate fitted on a

Replacement : hub piece which is an extension of the carrier tube. The
primary swirler is attached to the carrier tube with 3
brackets and bolted together.
1. Remove the screws holding the primary swirler.

2. Attach the new primary swirler.
3. Adjust the swirl plate so the dimension is the same as on
the drawing of the quick release sprayer. (carrier tube
+ primary swirler hub).
4. Check at this time also the checking length, (swirler
face to seat of burner nozzle).
I DRAUING PART LlST
I
I Aalborg Sunrod AB Telephone r46-8580-24300
1 Box 907 Telefax +46-8580-27801
I Sueden
Project: 11-417 Name: HALLA LAURIN Revision:

Product: 00018 FO PUMP UNIT Drawing: GS-301366A

Data
'3 OGO0 OOSTAL

1 FUEL
~ C S OIL Pump STATION 3-5518675 0.00 GS-201431A
2 pcs IGNITER OIL PUMP UNIT 3-4714887 0.00 GS-300153A
2 pcs STRAINER OVENTROP R8 PN 1 BSP1/4" 2.00 GS-300153A
I n c l u d i n g bracket 110369
and o i l h o s e 400xBSP1/4 u i t h 90 deg.BSP114 con.
S t r a i n e r basket Siku 50-75 my
2 pcs BRACKET FOR STRAINER

110369
4 pcs STOP VALVE INLET/ WTLET I C N . OIL PUMP OV 10-PL PN16 lOMH 0.80
Length bod~75mn. Length handle=74mn

Material body Brass.
Temp 100 deg C
Tube connection 10 mn diam.
2 pcs NOH RETURN VALVE IGN. OIL PUMP OUTLET RHV 10-PLR-ED PNlOO BSP114" 0.20
Length b o d ~ 5 3 m n
Flw d i r e c t i o n from screu thread
Temp 100 deg C
Tube connection 10 mn diam.
2 pcs PIPE CWPLING
S t r a i g h t male stud f i t t i n g
Pi~e diam.=lDmn
2 pcs PIPE CWPLING
2 pcs FLEXIBLE HOSE
R114"
Length 0.4m
DRAWING PART LIST
Project: 11-417 Name: HALLA LAURIN Revision: . - -

P r o d u c t : 00018 FO PUMP UNIT Orauing: GS-301366A ( continued )
Pos. A r t i c l e aty Function Type P r e s s Dim Weight Drauing

Data
F160 7100002 2 p c s DIESEL OIL Pump BFP2OL3 1.00 GS-300153A
Speed 1400-3600 rpn

Pressure range 7-15 b a r
V i s c o s i t y 1.8-12 C s t
Capacity 10 kg/h
2 p c s MOTOR
220V/50-60Hz
l20U
2 p c s PRESSURE GAUGE
Range 0-25 b a r
Oiam. 40mn
Connect i o n BSP1/8"
2 p c s VALVE FOR PRESSURE GAUGE
2 p c s SHAFT COUPLING ON MOTOR
2 p c s SHAFT COUPLING ON PUMP
2 m SHAFT COUPLING L=45MM
1 pcs DUPLEX STRAINER
Mesh s i z e 0 , 3 m
2 p c s VENT VALVE STRAINER

MATERIAL BRASS
2 p c s REDUCER
P a r a l l e l thread
M a l e l f e m a l e 1/2" - 3/8"
2 p c s PIPE CWPLING ELBOY WHO 10-PSR PN400 BSP3/8" 0.60
DRAUING PART LIST

H u l l no.: S-226 System name: 2 X CPH-18 T / H Ctass: ONV
Product: 00018 FO PUMP UNIT Orauing: GS-301366A ( continued
Pos. A r t i c l e aty Function Press Dim Ueight Drauing

Rape diam. lOmn
F72B 7000000 2 pcs DRAIN VALVE STRAINER 0.00

MATERIAL BRASS
F72B. 1 7590095 2 pcs REDUCER R I 1/2X3/8 PN630 BSP1/2" 0.20
Hale/female 1/2" - 3/8"
2 pcs PlPE COUPLING
S t r a i g h t male s t u d f i t t i n g
Pipe diam.=lOmn
1 pcs BYPASS VALVE

PN25.5 KGFlCM2
1 pcs DIFF. PRESS INDICATOR SMFlOO77
Range 0-5 kgflcn?

Diameter l O O m n
2 pcs MANMETER COUPLING GAI10-PSR
S t r a i g h t female s t u d f i t t i n g
Pipe diam.=lOmn
2 pcs PIPE COUPLING GAI10-PSR
Pipe diam.=lOmn
LEFT HAND THREAD
1 pcs DUPLEX FUEL OIL PUMP
1 pcs PRESSURE INDICATOR
TO BE FITTED ON OGOO PUMPSTATION BY YARD

Range 0-40 kgflcm2
Diameter 1OOmn
ORAUING PART LIST
Project: 11-417 Name: HALLA LAURIN Revision: - -

Product: 00018 FO PUMP UNIT Drawing: GS-301366A ( continued )
Pos. A r t i c l e Qty Function Type Press Dim Ueight Drauing

Data
GO8 7000128 1 pcs FUEL OIL HEATER 8100/80K15-9V PN40 100.00
2 pcs STOP VALVE OIL TO HEATER AJ3540 PN40 ON32
1 w s STOP VALVE OIL FROn HEATER AJ3540 PN40 DN40
1 pcs SAFETY VALVE TODD134 3/4

PE.25 KGFlCI42
Pressure s e t t i n g : PE = 26.5 kgf/cm2
2 pcs TEMP INDICATOR SIKA 2718 BSP1/2"

Range 0-160 deg C
I n s e r t length 100 mn
GlOA 7401105 2 pcs POCKET FOR TEMP. INDICATOR POCKET 2718 BSP1/2"
Material' stainless steel

For i n s e r t length=lOOmn
1 pcs FUEL OIL PRESSURE CONTROL VALVE 5911N0-200/20 PN40 ON15

FLOU 1900KG/H, P1=18KG/CM2, PZ=lKG/CMZ, KV4.5, MICROFLUTE
Actuator u i t h t o p mounted hand uhee1,Air t o close.
S t e l l i t e d plugg and seat, Teflon s t u f f i n g box.
A l S l 316 STST P h g and i n t e r n a l t r i m
C h a r a c t e r i s t i c MFS (EQP M i c r o f l u t e ) Plugg
D i f f press max. 25 bar. Tenp max 165 Deg C
3 pcs STOP VALVE AJ3540 PN40 ON25
1 pcs FUEL OIL TEMP CONTROL VALVE 591-22-200/20 PN16 ON15

FLOU 115 KG/H. P1=7KG/CM2, P2-6.2 KG/CM2, KV=4,5
U i t h hand uheel
Reverse a c t i n g (close a t a i r f a i l u r e )
EQP PLUGG and i n t e r n a l t r i m
Teflon ppacked s t u f f i n g box
20-100 kPa signal
1 pcs TEMPEATURE CONTROLLER 663-TllU30S
P c o n t r o l l e r u i t h c a p i l l a r y b u l b i n c l pocket U30S
AlSl 3 1 6 s LISP 112 inch,uith 2 meter tube.
DRAWING PART LIST

H u l l no.: S-226 System name: 2 X CPH-18 T/H CLass: ONV
Product: 00018 FO PUMP UNIT Drawing: GS-301366A ( continued
Pos. A r t i c l e aty Function Type Press Dim Weight Drawing

Banae 50-150 deg C 1 20-100 kPa
6238 OOJUCK 1 pcs POCKET FOR TEMPERATURE CONTROLLER 2-0003426 0.00 1
1 pcs A I R FILTER REGULATOR FR2O/M 1.00 1

, jC23C
7601001
U i t h output pressure gauge 20-200 kPa
Output pressure range: 20-200 kPa
G230 OOJUCK 1 pcs PRESSURE INDICATOR FOR A I R FILTER REGUL. 2-0003426

( i
1 pcs STOP VALVE FOR CONTROL A I R AJ1891 PN400 BSP3/BD1 0.45 1
2 pcs PlPE CWPLINC
Pipe O.D.= 10 mn
5 pcs PlPE COUPLING
Pipe diam.=lOmn
1 pcs STRAINER FOR TEMP. CONTROL VALVE F I G 33 PN16 ON15 5.00 1
3 pcs STOP VALVE TEMP CONTROL AJ3540 PN40 DN25 3.75
2 pcs PRESSURE INDICATOR STEAM TO HEATER SMFlOO2O BSP3/8" 1.20

Range 0-10 kgflcrn2
Diameter l O O m
7 pcs STOP VALVE FOR PRESS INDICATOR AJ1892 PN400 BSP3/8 2.45
3 pcs UNION NUT BSP318"

FOR G25.GO7
1 pcs STOP VALVE AJ1892 PN400 BSP3/8 0.35

DRAWING PART LIST

P r o d u c t : 00018 FO PUMP UNIT Orauing: GS-301366A ( continued )
Pos. R r t i c l e Qty Function Type Press Dim Weight Orauing

Data
G29 7302203 1 p c s STEAM TRAP MK35111-F PN25 ON15 3.50
3 p c s STOP VALVE STEAM TRAP AJ3540 PN40 ON25 3.75
2 p c s PRESS. SUITCH FO PUMP STAND BY START KPS37 6-18 BSP3/8" 2.00
Range 6 - 1 8 bar
2 pcs TEST VALVE AJ1844 PNlOO ESP318 0.82
2 p c s PIPE COUPLING MAVIO-SR318" ESP3/8" 0.20
P i p e O.D.= 1 0 mn
1 p c s T-PIECE
P i p e diam.=lOmn
1 p c s PIPE COUPLING GAI10-PSR PN630 BSP318" 0.10
P i p e diam.=lOmn
LEFT HAND THREAD '
I ORAUING PART LIST
I
1 Aalborg Sunrod AB Telephone +46-8580-24300 96-09-24
1 Box 907 Telefax +46-8580-27801
1 175 29 J a r f = l l a Telex 19268 SUNROD S
1 Sueden
I

Product: 00019 OIL SUPPLY EQUIPMENT LWSE SUPPLIED Drawing: GS-301366A

Data
,GO1 7500372 1 pcs HFOl DO CHANGE OVER VALVE AJ3771-2L2V50 PNl6 DN50 14.00
I TO BE MOUNTED SEPARATE FRCU THE PUMP UNIT
I
GOlA 7400814 1 pcs LIMIT SUITCH HFO/ DO CHANGE OVER VALVE AJ3835-914CE1-1
MOUNTED ON GO1
110-22OV/50-60Hz
1 pcs HRNDLE FOR HFOl DO CHANGE OVER VALVE AJ3410NV-50 1.50
Length 28Omn
1 pcs FUEL OIL PRESSURE CONTROLLER 623 PN40 ON50 3.50 1
PI c o n t r o l l e r w i t h diaphragm separator 1 AISl

3 1 6 s 2 meter 1ength.FLange connection.
Flexible capillary (sylicon o i l f i l l e d ) .
Range 0-2.5 MPa.Control signal 3-15 PSI=10-150 kPa
PI c m t r o l
G2lB OOJUCK 1 pCS DIAPHRAGM SEPARATOR FOR CONTROLLER 2-0003426
1 pcs A I R FILTER REGULATOR FR2O/M

, .1 G21C 7601001
With output pressure gauge 20-200 kPa
Output pressure range: 20-200 kPa
1 pcs PRESSURE INOICATOR AIR FILTER REGULATOR 2-0003426 0.00 1
1 pcs STOP VALVE CONTROL A I R AJ1891 PN400 BSP3/8" 0.45 1
2 pCS PIPE COUPLING MAV10-SR3/8" BSP3/8" 0.20
5 pcs PIPE CWPLING GE IO-PLl114NPT PN250 NPT114" 0.50
Pipe diam.=lOmn
-
11-4161417 I HALLA S 225 / 226
---------_
0.0 TO IGNITION OIL P U N
COMPRESSED- - - G23E
AIR
PIPE DIMENSION RETURN

OIL FLOW 0,02-0,05 M/S
/BASED ON PUMP CAPACITY ;
I
I
HFO
iERVlCE
TANK
A PIPE AND PUMPS BELOW

I THE BOTTOM OF THE TANK
L---------,---,,,J,,,---------------------------------------------,-4--
HFO FROM BURNERS
Article No Drawing No :.VI Material
Remarks Weighl
PIPING 5x1s Int volume Webkt
r-i CAPILLARY TUBE
I
'SUNROO OELIVERY
I mYAW] SUPPLY
011 SUPPLY FOR BURNERS
Replaces Wgn 0
lf8.l-Z
C k k d
w
oats
PMUMAM FlFM
' i YAW3 SUPPLY DDItinotion
\ I I G70 and G70A deleted 1 950720 1

do Plac Change I Date I Sian. ICheCkl Rev. No
e
l Cmclim
A STEAM IN
B COMENSATE OUT 25
0l011 OUT
E I WL RETURN
16
1 40 1 40
1 25 1 40
K%NPES%Zbar
SEPARATE ITEM LIST
FUEL OIL PUMP STATION

'$ 33I I
I P a nr Anlal Benamnlnp
Ko~pos-nr Rltning
-* Vlkl
~rnh a, o~e~.llon 8 2 , , ,o Material
I W H O Oc L wwn
For 81Io~emnsaattomdn palm fokmnser suv-m I ~ ~ I n r b w w av w e w
som ar anghna 1 Slandard SMS 715 medel i';2
anrnmpl-"urn EDI~IRYVL~S Gnn.IuFM ?'
j
5
GodW@mv
Pumphg Unt2 """armW n r l M M a r a n D.wND.a
89-?if-h-
JW ~IIVSrQnrrrp
I
Doc No.
DIESEL OIL IGNITER Ch0t 17 Paae I
,,,,, BFP Service pump Rev. NO.
Date
ECKERLE ECKERLE SUMEC

I)UNI I I R I R M UNI 2.1171 (R+S)I4 AN 47A73
I.lRlLM 21RI f L + M I I I 47 B 73
1.lLlLM 47C73
l.lL1RM 47073
UNI 2.1R51RtS) I4
Z.IRSIL+M) I4
Z.ILS(L+M) I4
2.lLSIR+SI I4
2) UNI I.ZR1RM 1) UNI 2.2R1 (R+S) 14 M S l l R301l8
1.2RlLM 2.2RI ( L + M ) l I R30118
l.2Lll.M 2.2LI ( L + M ) I I UOll7
1.2L1RM 2.2LI lR+SJ I 4 UOIl7
UNI 2.2R51RIS) 14 M S I I R50126
2.2R5IL+M) I 4 R5 0126
2.2L5IL+M) I 4 L5 0127
2.2LSIR+S) I 4 L50127
MS11 L30162 B F P I I L30141

RJOl18 R30155
M S l l L30117
Oil pump type BFP d l.~ u .r n ~..e T v~

BFP
BFP 20
T~hdcalaala TechnlLShe Dalen
Virsor~tyrange: 1.842.0mm2;r ViSk0lllll5be~1ch: 1.8.12.0mm'ls
Speed: Tvm5 14w.3mmin-' Dlehzahl: TypS 14W46Wmin-'
~&24W.i6W min-. Typ324W.3600min.'
Pressurerange: Dru~kbeleich
BFPII. 21 and 4,: 7.15 bar[kPa !O,i BFP 11.21 und 41 745bar(kpa101
BFP31: 7.20 bar (kPalO') BFP3I: 7-20bar (*Pa 1 0 1
Fastoryrell~ng: 10 bar(kPa10') Werkrelnrlellung: I 0 bsrWPa 103
Coilvollage: 22OR40V. 50!W Hz SpvlLnspannung: 220RlOV. SO?M)Hz
Temperalure range: -1010 7 0 T Temperaturbere~ch, -10 bir 70.c
A I I C m h s e l (Abb. 6)
F i ~ e m n r a u b eim Oeckel mnu eincm 4 mm sch!ur-
-N.B.4\11 pumps iniondcd lor I-pipe operation are

S~DPli(ldw t h a ~ I ~ l i ~ . r r a p p~ e0d ~ ~s1w0w 1
,
- T h e BFP I 1 L 3 m o 4 1 anlyhav~nozrlesannac.
!hongon the 1ell.Tha bleeder is lilted on meright
[only BFPII).
- ThmBFP 11 R3only haranozzlaconnesl~onon
- Olv~kCnfnahme
OleEnllullung won BFP4I arfolglrorn ander
und bci gercnlosrenam Magnet.
wen,,,
DIESEL OIL IGNITER Doc No.
[hot I 7- Paue 2-
,,,,, BFP Service pump Rev. NO.
Date
28Wmin.'
BFP3 BFPS
H 06 08 010 06
m 08 010
mm mm mm mm mm mm
4.0 33 IW 1W 21 67 I W
3.5 31 98 20
3.0 29 63 100
91 IW 19 59 100
2.5 27 05 IM) 17
2.0 25 55 100
79 16 51 IW
1.5 23 72 1W I5 46 I W
1.0 21 66 1W I3 42 100
0.5 19 60 IW 12 30 94
0 I7 53 100 II 34 04
-0.5 IS 47 100
-1.0 13 10 30 74
41 99 6 26 64
-1.5 I8 34 61 7
-1.0 22 54
9 20 68 6 18 44
-2.5 7 22 53 4 I4 34
-3.0 5 15 37
-3.5 3 9 3 10 24
22 2 6 I4
4,o 3 6 I 2 4
2
,
....~!
..
-
DIESEL OIL IGNITER Doc No.
C h ~ t17 Paoe .?
BFp20 BFP Service pump Rev. NO.
Date
INSTRUCTIONS I
BFP Service pump
BFP 11 L3 BFP 11 R3 BFP 201.21
.-
Ch~t 17 Paoe 4
STRAINER SIKU Rev. No.
late
Choice of filter element.

All filter inserts have a "bayonet" type connection and are fully interchangeable.
The SlKlJ element consists of a mass ()f minute bronze balls. :jtrUCtU-
rally similar to sinter bronze. This element offers the highestguaran-
tee for the safe and long lasting life of the whole burner installation.
where the "back-flow" method of element cleaning is contemplated.
His advantages:
0 Approx. 70% larger filter area, when compared with other tradi-
tional filter elements.
Prevents accumulation of air or gas in the filter cup.
0 No erosion by fibre particles or similar solid matter hence reduc-
tion of possible burner malfunction.
The sintered bronze insert consists of a mass of miniature bronze

balls, it possesses excellent filtering characteristics but is difficult to
clean.
The nickel mesh insert provides good quality of filtering. It is not af-
fected by asphalt or paraffin. It is a typically long lasting filter material
and easy to clean.
The felt insert made of man -made fabric, offers a complete protec-
tion to the system, as many ageing byproducts of heating oil are filte-
red out. When contaminated it cannot be cleaned and must be
replaced.
Type No.
PRESSURE GAUGE 111021
Range 0 - 2 5 bar
Diam. 40mn
Connect ion BSP1/8"
VALVE FOR PRESSURE GAUGE

DOC NO. -,
Screw Pump Twin Aggregates Got \+ Paoe Y.
Series SPZ Rev. No.
Date
I SPZ with filter

SPZ without filter
Abbreviation system -.
5b
SPZ 10
T. T
R
-7-
38
-T
I
'
Series A I I I
= theoretic delivery per
pump with 1450 llmin and
46 d e g r e e s pitch angle
Direction of screw pitch
R = right
Angle of screw pitch (degrees)
Type of bearing
G=internal slide bearing
U= internal groove ball bearing
Shaft sealing by unheated,
uncooled mechanical seal
Design with filter O I
Design with electric heating
of t h e filter casing O
Material design
O a t extra charge
1 ,'>
Doc No.
Screw Pump Twin Aggregates ChOtI7-
Series SPZ Rev. Na
Date
Aggregate dlmenslons and swltchlng diagram

SPZ with filter
1 OuarallnQ ana stand-by Dump

2 Thml-pham motor
3 stop 1.l".
L Flit.,
>
I - : ,,: ,
p o t No
Screw Pump Twin Aggregates.. mot 9. . ~
Series SPZ Aw. NU
Date
Sectional drawlng
SPZ with f i l t e r
S e ~ t l o nE-F 1 2 161 1K
SleUon C-D
2i3
k1
Pump size 10 and 20
Pump size 40
Omomlnatlon Pan NO. Dmomlnatlon Pan No. Osnomlnallon Pan NO.

~ -
Jolnt rlnp I43 Screw plug 222 Slop valve 383
Qa~kat 145 Vmtlnp screw 223
Qalkal l48 Connactor 3e4
SC1aw plug 227 Connector 370
Jol.1 rlnp 147 Hexagon nut 231
Carlnp e w e r 7 Casing 372
Sedlnp warher 148 Screw plug 235
Filtar caalnp 8 Seallnp r a t h e r 151 Hollow .craw 373
Eaarlnp rlng 10 Hexwon nut 238 Manometer
Jdnt dnp I52 Herapon nut 238
Drirlng a e r w 12 Joint r h o connastlnp branch 374
158 Clfcllp 250 Blank flange 440
Wmklnp m a w 13 Qk.l.1 157 Clrellp 251
Olalmee bush 20 Jolnt ring Blank Ilanpa 441
I59 Su~ponlnawa9h.r 283 Pump bnckat 480
Soekat.haad cap a c r w 24 Jolnl plup 180 RIve1 280
PIP. 28 Jolnt plug Foot angle 471
PIP.
I81 Key 290 011l r o ~ p h 475
30 Jolnt tape 185 Q100~eball b m b g 292
Gasket 100 n1t.r 481
MechanlcaI~eu 188 Raranlnp valve sarlnp 301
Jdnt rlnp 107 5Ockebhe.d UP 8 e r w 2PO Clam~lng~ l a s r a 485
Jolnl rlnp Valve cone 330 Coupling hall
108 SOCk*I.hm¶ cap #craw 201 V a h l rpdng plate 231
O4ng 1I 8 H a w o n screw 204 pump ilda 800
O4np Adlurtlnp asrsw 333 drlm aide 801
120 Haxagon m a w 205 Valve lprlnp 340
0.ring I22 Socket.haaa cap screw Dllrlnp motor 910
(3asket 208 stop ".I". 355 Heating shall 982a
123 Heragon n o w 207 Lockabla now
(3l)st.t 124 Sockat-head eap screw 208 Nama plate 878
Gasket 125 return valve 358
SOCke1.head cap screw 215
Gasket 128 Hexagon screw 218
Manometar 380 m A heatlnp ahall for each pump
J o l n l rlnp Manomater 351 Ir ruppllwJ on requasi only
I42 Hexagon scram 217 Check valve 382 (at extra charpa).
11
Doc No.
Screw Pump Twin Aggregates C h ~ t IF P a m 16
Series SPZ Rev. No.
Date
Use
For handling light or heavy fuel oil.
Maln field of application

Compact aggregate with operating and stand-by pump for
transfer or burner operation plants in fuel oil engineering.
Type of construction
Twin aggregate of the compact type of construction in which
two screw pumps are interconnected by way of a reversing
valve casing.
..
Structural design
Pump:
Internal self-priming three-screw type of pump. The hardened
and ground spindles run in an exchangeable pump casing
insert.
The driving spindle is hydraulically balanced. The axial thrust of
the idler spindles is absorbed by the pump cover, non-drive
side. Their drive is hydraulic, the thread flanks merely transmit
the torque resulting from the liquid friction. Thus, the thread
flanks are practically stress-free and not subject to any wear.
All sliding partsare lubricated by the fluid pumped, being within
the range of full liquid friction.
The radial and axial bearing of the driving screw with pump size
10 and 20 is by the balancing piston guided in the bearing ring.
with pump size 40 by a groove ball bearing.
A maintenance-free mechanical seal is provided as the shaft
seal.
Sealing chamber and suction chamber are interconnected by
way of a return gallery. Thus, irrespective of the delivery pres-
sure. only the suction pressure becomes effective at the shaft
seal.
The connection of pump and driving motor is by a pump lantern
with foot angle.
Compact aggregate:
Two of the described pumps are attached to a common re-
versing valve casing.
Arranged in the reversing valve casing are two stop valves and
two lockable non-return valves.
Data on the design with filter, on the possible filter heating and
on the manometers included in the scope of supply can be
taken from the separate items of description.
Ooc No.
Screw Pump Twin Aggregates Chat 17 Paoe I L
Series SPZ Rev. No.
Date
Operation
Pump:
Owing to a special profiling of the thread flanks, the three
spindles form sealed chambers, the contents of which are axi-
ally and completely continuously shifted from thesuction to the
pressure side of the pump as the spindles rotate. There is no
turbulence in spite of the spindle rotation. The constant cham-
ber volume excludes squeezing.
Compact aggregate:
The operating pump primes the fluid to be pumped through the
suction chamber of the reversing valve casing and, in case of
the design with filter, through the filter. During this procedure.
the filter is passed through from the outside to the inside. The
operating pressure building up in the pressure chamber opens
the non-return valve of the operating pump closing that of the
inoperative pump. This prevents the stand-by pump from turn-
ing in reverse motion.
Both pumps can alternately be operated by hand or automati-
cally (for automatic control, please refer to Operating controll
Reversing device).
Noise/pulsation
The structural design and operation of the screw-pump twin
aggregates ensure a very low noise level and an almost pulsa-
tion-free delivery.
-
Doc No.
Screw Pump Twin Aggregates [hot 17 Paue I<
Series SPZ Rev. No.
Date
Filter
As a protection against contaminations, the pumps can be
supplied with a filter casing with incorporated filter (extra
price). Filter mesh size 0.4 mm.
Shaft seal
Each pump by a maintenance-free mechanical seal of the
unbalanced type.
Material design of the mechanical seal:
Denomination
Rotating seal ring Tungsten carbide
Stationary seal ring Tungsten carbide
Seal ring Viton
Spring Stainless steel
Metal arts Stainless steel
Performance data
Delivery Q up to 112 Ilmin O and/or 6.7 m3/h O
Temperature of the fluid pumped t up to 150°C O
Inlet pressure ps up to 10 bar
Pump outlet pressure p d up to 40 bar Q
Viscosity range v = 3 to 750 mm%
Pressure flange DNd = 20 to 40 mm
O With n = 2 9 0 0 l l m i n and v = 750 mm2/s
O With higher temperatures, please inquire.
O For the attainable delivery pressure as a function o f viscosity and speed.
please reler to the individual characteristics. The pressure data onlv
apply to nearly static pressure load. With dynamic pressure change load.
please inquire.
Pressure-relief valves
Asan overload protection, installed in each pump is a pressure-
relief valve which, for all designs, is set at a response pressure
approx. 10% above the operating pressure.
In case different response pressures are requested, same must
be indicated in the order.
Doc No.
Screw Pump Twin Aggregates Chut 17P a u e / ~
Series SPZ Rev. No.
Date
with filter, heating shell may
,
Connection for , d a t i n g capacity
SPZ 10 165 W
SPZ 20 205 W
SPZ 40 265 W
Drive/coupling
For the supply of complete aggregates, motors of the following
type are normally provided:
Surface-cooled three-phase squirrel-cage induction motors.
l M V l type of construction; enclosure IP54 according to IEC
Standard, class 6 insulation, performances and main dimensi-
ons according to DIN 42677.
Motors which are rated for 50 Hz can, without change, be oper-
ated also in 60 Hz mains, speed and performance are changed
as follows:
Motor Connection Conversion factor for

wound for to 60 Hz operation at 60 Hz
50 Hz
...V ...V Speed I performance
Power transmission is effected via a flexible coupling. Addition-

al radial forces must not act on the driving spindle.
-
Doc No.
Screw Pump Twin Aggregates Chot I7 Paae ,q,
Series SPZ Rev. No.
Date
The mano-vacuummeters show the pressure behind the filters.

Thus, the pressure loss in the filter can be determined and an
inadmissible contamination realized.
Reversing device:
Against extra charge, a reversing device is supplied for opera-
ting control purposes, which, regarding its circuitry, is designed
so that in case of failure of the operating pump, the stand-by
pump is automatically put into operation. Signal lamps indicate
the respective operating conditions.
Scope of supply:
Reversing device U1 for motors up to 3 kW (380 V operating
voltage) for across-the-line starting, consisting of:
1 steel plate casing, enclosure IP54, dimensions:
width 320 mm, height 320 mrn, depth 160 mm
2 three-phase air-break contactors with overload relay
1 selector switch (pump 1, pump 2 and Off)
2 green signal lamps ,.Operationu
1 red signal lamp ,,Faultu
1 control fuse
Connecting terminals for all incoming and outgoing lines
2 control line terminals for connection of additional control
stations, if any.
Reversing device U3for motors with4.0 and 5.5 kW drive power
(380 V operating voltage) suitable for star-delta starting, con-
sisting of:
1 steel plate casing, enclosure IP54, dimensions:
width 520 mm. height 520 mm, depth 210 mm.
1 selector switch (pump 1, pump 2 and Off).
2 green signal lamps ,,OperationM
1 red signal lamp ,,Faultu
2 circuit fuses
1 control fuse
Connecting terminals as U1.
Installation
SPZ compact aggregates are provided for horizontal installa-
tion or wall mounting. For safety purposes, arrangement with
,,motor downwards" is not admissible.
Oil trough
A separate oil trough is supplied for each SPZ compact aggre-
gate.
, ,
Doc No.
Screw Pump Twin Aggregates Chd 17 P a ~ /A
e
Series SPZ Rev. No.
Date
Flanges/connections
SPZ aggregates have flange connections on the suction and
pressure sides. Blank counterflanges PN 16, DIN 2633 (suction
side) and PN 40, DIN 2635 (pressure side) as well as screws and
gaskets are included in the scope of supply.
Moreover, the following connections are provided:
SPZ without filter: MI, M2 Manometer
SPZ with filter: 87 Draining filter casing
E7 Venting filter casing
MI, M2, M3 Manometer
Denomination Part No. Material desians

W8
Pump casing 1 GG-25 GG-25 GGG-40
Pump casing insert 2 Grinatal GGK-F Grinatal
Pump cover,
drive side 3 GG-25 GG-25 GGG-40
non-drive side 4 GG-25 GG-25 GGG-40
Casing cover 70 GG-25 GG-25 GGG-40
Filter casing 9 0 GG-25 GG-25 GGG-40
Bearing ring 10 Silafont GG-25 Silafont
Driving screw 12 Nitrided st. Nitrided st. Nitrided st.
Working screw 13 Nitrided st. Nitrided st. Nitrided st.
Reversing valve
casing 301 GG-25 GG-25 GG-25
Wire mesh at filter 481 0 Steelgalvan Steel galvan Steelgalvan.
O f o r design with filter only.
Operating control
Manometers:
SPZ without filter
Outlet side: amanometer (included in thescope of supply). A
mano-vacuummeter being requested on the
suction side, same would have to be provided at
the site. Measuring point M I is provided for con-
nection.
SPZ with filter
Suction side: two mano-vacuummeters
Outlet side: a manometer
(each of which included in the scope of supply)
IPSH req. (m)
'he values as indicated apply to pumps without filter for air-free fluids pumped. A safety allowance is not required. When using
lumps with filter, the shown NPSH values are increased by 0.5 m.
ump size
95011140 I 145011740
Speed l l m i n
I 2900
Kinematic viscosity mm21s (E)
I G3 I
3-40 75 150 380 750 3-40 75 150 380 750 3-40 75 150 380 750 3-40 75 150 380 750
1.2-5) (10) (20) (50) (100) (1,2-5) (10) (20) (50) (100) (1,2-5) (10) (20) (50) (100) (1,2-5) (10) (20) (50) (100)
NPSH req. m
Doc No.
Screw Pump Twin Aggregates Oat 17 Paoe li
Series SPZ Rev. No.
Date
Pedormance table Data for 3400 llmin
-
Pump
size
-
10-28
-
10-38
-
10-46
0
10-56
-
20-36
-
20-46
-
20-56
-
40-38
40-46
w=-
Operating and -Maintenance Doc NO.
lnstnrctions with is mounting mot 17 Paue :/A
and Mounting Instructions Rev. No.
Date
Screw Pumps
Series SPZ
1. General
1 Abbreviation
The abbreviation of the screw pump twin aggregates is
set up according to the following scheme.
Example:
Size
= theoretic delivery in
[Ilmin] with 1450 11min
and 46 degrees pitch
angle
Direction of screw pitch
R= right
Angle
-
Kind of bearing
-A
of screw pitch (degrees) -
internally supported slide bearing

Shaft sealing by mechanical seal
Design with filter
Design with electric heating
of the filter casing
Material design
1.2 Warranty
Our liability for shortcomings in the supply is laid down
in our delivery conditions. No liability will be undertaken
for any damages caused by non-compliance with the
operating instructions and service conditions. If at any
later date the operating conditions happen to change
(e.g. different fluid conveyed, speed, viscosity, temper-
ature or supply conditions), it must be checked by us
from case to case and confirmed, if necessary, whether
the pumps are suited for these purposes. In case no
special agreements were made, the pumps supplied by
us may, during the warranty period, only be opened or
varied by us or our authorized contractual service sta-
tions; otherwise, our liability for any defects will expire.
Q2:3
Operating and-Maintenance Doc No.
Instructions with is mounting . +
Rev. No.
Pa J4 ,-., ' ,+
and Mounting Instructions
Date
Screw Pumps
Series SPZ
Testing
Prior to leaving our factory, allaggregatesaresubjected
to a thorough test run and performance test on the test
stand. Only properly operating pumps leave the factory
achieving the performances assured by us.
Thus, compliance with the following operating instruc-
tions ensures proper operation and full delivery.
Performance data
Delivery Q up to 56 llmin O andlor 3.36 m3/h O
Temperature of the fluid pumped t up to 150°C @
Inlet pressure p, up to 10 bar
Pump outlet pressure pd up to 40 bar O
Viscosity range v = 3 to 750 mm2/s
Pressure flange DNd = 20 to 25 mm
O With n = 2900 llmin and v = 750 rnrn2/s

Q With higher temperatures, please inquire.
O For the attainable delivery pressure as a function of
viscosity and speed, please refer to the individual
characteristics. The pressure data only apply to nearly
static pressure load. With dynamic pressure change load,
please inquire.
The exact performance data applicable to the pump can

be taken from the lay-out andlor acceptance certificate,
and are engraved on the rating plate. Please also refer to
the performance tables in our leaflet VM 533 E l...
Application and lnstallatlon

The screw pump twin aggregates of series SPZ for a
pump outlet pressure up to 40 bar are three-screw, self-
priming, rotary positive displacement pumps for hand-
ling lubricating fluids. The fluids must not contain any
abrasive particles nor chemically attack the pump
materials.
Both pumps of the aggregate are designed as flange-
mounted pumps and via a pump bracket each connect-
ed with the driving motor.
Attentlonl The aggregates are provided for horizontal
installation or wall mounting. For safety purposes, the
arrangement with .motor downwards" is not admissible.
- ,.& 4
Operating and-Maintenance Doc NO.
Instructions with Dismounting C h ~ t n Pape 20
and Mounting Instructions Rev. No.
Date
Screw Pumps
Series SPZ
Structural design
The screw pump twin aggregates of series SPZ consist
of two screw pumps. Via a reversing valve casing (301),
the two pumps are connected with each other.
The screw pumps are of the three-screw type. Adouble-
threaded driving spindle (12) and two double-threaded
idler spindles (13) are enclosed by the bores in the
pump casing insert (2) with a narrow running clearance.
The pump casing (1) accommodates the pump casing
insert (2) and is closed by the pump cover, drive side (3)
and by the pump cover, non drive side (4) andlor the fil-
ter casing (9).
Shaft seal
For each pump, by a maintenance-free mechanical seal
of the unbalanced type.
Material design of the mechanical seal:

Denomination
Rotating seal ring Tungsten carbide
Stationary seal ring Tungsten carbide
Joint ring Viton
Spring Stainless steel
Metal parts Stainless steel
Bearing and lubrlcatlon

The radial and axial bearing of the driving spindle of a
screw pump is effected by the bearing ring. At the same
time, the delivery chamber is separated from thesealing
chamber by the gap between the compensating piston
and bearing ring. The bearing is lubricated by the fluid
pumped.
Flanges/Connections
Blank flanges with screw and gaskets
Suction side: PN 16, DIN 2633
Outlet side: PN40, DIN 2635
Connections
SPZ without filter: MI. M2 Manometer
SPZ with filter: 87 Draining filter casing
E7 Venting filter casing
MI. M2, M3 Manometer
(refer to our leaflet VM 533 E l...)
ABB Electrical Motor dimension
Motor type MBT 90 L
Power 2,5 kW
Speed 3460 rpm
Efficiency 80 %
Cos cp 0,87
Nominal current 4,7 Amp
Start current 32 Amp
Start time 0,5 sec
Insolation class F
'3 Protection grade IP55
- Type Poole A" AA AB AC B1' BA BE AQ C" CA CB D" DA" DB DC Eq

..-
Nn
90 L 2 140 27 170 178 125 30 150 97 56 94 - 24 14 M8 M5 50
EA EG EH F" FA" G GA GB GC H" HA HC HD K L LC
I)Deviation Bearing size: D-end 6205-UC3

A. B ISOjsl4 N-end 6204-UC3
C, CA +0,8 -0,s
D I S 0 j6 Electric connection Cable size rnax 2.5rnrn2 4 x Pr 223 (PR2,5 = Pg16)
DA I S 0 i6
Marked according to IEC 34-8
HEAT EXCHANGER
w~~RMEAUSTAUSCHER
ECHANGEUR DE CHALEUR,
VARMFVAXI ARF
BENDEK
SOUPAPE OE SURE1 P U R M 0'4\11)

SAKERHEISVEIIIIL
Fl."..h.
Blid"
FIB..,
D I N 2635 DIN2635
G 08
Weight
Gswlcht m 1~81..NW. Toilla Ansl.
Type Typ Vlkt
P.O~~Skg
I
CI I b I c d e I f I q I
8 100/&0x 15
B 100160x 15 80
Doc No.
[hot I8 Paoe /
HEAT EXCHANGER -Rev. No.
Date
Description
and instructions
Shell
The shell is made of seamless hot-rolled pressure vessel tube,
conforming in dimensions to IS0 recommendations. One end
of the shell is provided with a flange to which the tube plate is
bolted and the other end is sealed by means of a domed end
cap. A flanged oil inlet pipe is welded to the front end of the
shell and an outlet pipe is provided at the rear end. A branch is
provided for safety valve.
Tube stack
The heat transfer surface consists of cold-drawn, seamless, precision
steel tubes, in crosswound layers. The cold drawn seamless Nbes
have no welded joints in the tube stack. The tubes are welded into
tube plates at the collecting - and distribution headers. The tubes are
arranged ata normal pitch of 15 mrn and the number of tubes ranges
between 5 and 144, in order to provide optimum heat exchange for
any capacity. The tube stack is wound into a center tube which also
acts as inlet pipe for the heating medium.
The tube plate is drilled to suit the flange of the shell and is bolted to
the shell. An oil-resistant gasket is fitted between the tube plate and
the shell flange. The tube stack is entirely free to expand, and can
easily be disassembled for inspection and cleaning.
Method of operation
The heating medium flows through the center tube to the distri-
bution header from which it enters to the spirally wound heat
transfer tubes. While flowing through the tubes, the heating
medium dissipates heat and is then discharged by the collecting
header to the outlet.
Doc No.
HEAT EXCHANGER Chot 18 P a o e Z
Rev. No.
Date
During heating, the oil flows through the area between the spi-
rally wound layers of tubes. Due to the spiraE shape of the tube
coils and the crosswound spirals, a high degree of turbulence is
induced, providing a high coefficient of heat transfer at a low
pressure drop. In addition, due to counterflow of the media,
the mean temperature difference between the media is the high-
est possible, providing maximum heat transfer.
The Bendek heat exchanger can be used with steam, hot water
or thermal oil as heating medium.
Due to the spirally wound shape and the small hydraulic diame-
ter, the heat transfer coefficient is very high. In addition, when
steam is used as heating medium, the condensate may be sub-
cooled below the saturation temperature, reducing the neces-
sary steam consumption for heating.
If a specific degree of subcooling of the condensate is required,
the temperature should be specified when submitting the in-
quiry.
Lagging
The heat exchanger is provided as standard with 30-50 mm
mineral wool lagging med painted sheet steel cleading.
Mounting brackets
The order should specify whether the heat exchanger is to be
provided with brackets for horizontal or vertical installation.
The brackets are provided with holes for bolting to the founda-
tion.
In case of horizontal installation, the bracket at the flange end
of the shell should be tightened firmly and the opposite bracket
should be tightened lightly, in order to allow unrestrained
thermal expansion of the shell.
Doc No.
HEAT EXCHANGER Chot I Paoe3
Rev. No.
Date
Materials
In its standard version, the Bendek heat exchanger is made o f
the following materials:
Tubes: DIN grade St 35.811 carbon steel, cold-drawn, se-
amless precision steel tubes to the tolerances speci-
fied in DIN 2391 alt. stainless steel.
Shell: Seamelss pressure vessel tube of DIN grade St
35.811.
Tubeplates: HI1 pressure vessel steel or steel to Swedish
Standard Specification SS 1430.
Domed end HI1 pressure vessel steel or steel to Swedish
caps: Standard Specification SS 1430.
Flanges: T o Swedish Standard Specification SS 1430 or
DIN grade C22.8.
Branches and Seamless pressure vessel steel tubes of DIN grade
steam pipes: St 35.811.
Gaskets: Klingeroilit - PN 40
Spiral-wound gaskets PN 64 and PN 100.
Classification
The Bendek heat exchanger is delivered with material and test
certificates to meet the requirements of the classification socie-
ties.
Design pressure and temperatures

Standard heaters are designed with the following data:
Flanges Max working pressure bar(e)/ternperature OC
Pressure class Shell side Tube side
PN 16/16 15/150 16/204
PN 40/40 32/ 150 25/226
P N 64/40 55/150 25/226
PN 100/40 92/ 150 25/226
Special designs of the Bendek heat exchanger are available for
higher pressures, temperatures and other materials.
7
Doc No.
HEAT EXCHANGER Chot I$ Paae 51
Rev. No.
Date
Installation
The Bendek heat exchanger is suitable for both horizontal and
vertical installation. In case of vertical installation, which is re-
commended when steam is used as heating medium, the heat ex-
changer should be arranged with the main flange pointing
downwards.
When the heat exchanger is installed vertically, with the shell
flange upwards, and using steam as heating medium, the direc-
tion of the flow must be reversed.
When installing the heat exchanger, free space should be left to
allow disassemble and withdrawal of the tube stack at horizon-
tal installation, and to lift the shell at vertical installation (for
further particulars, see under the headline "Mounting
brackets").
Pipework
The size of the pipework should be selected to suit the permissible
pressure drop in the whole of the pipe system. Pipes should be instal-
led so that the thermal expansion can be carried out without resulting
in excessive forces to the branches of the heat exchanger. The pipes
should be provided with supports and fixed points wherever ne-
cessary.
The condensate pipe should be below the water level of the conden-
sate tank, to avoid air to enter into the steam system when the unit is
shut down.
Doc No.
Ch~t 18 P a o e X
HEAT EXCHANGER Rev. No.
Date
Venting and draining

The branches for oil and heating medium are located so that the
Bendek heat exchanger is self-venting. Heat exchangers de-
signed for vertical installation are provided with drain pipes for
the oil side. The oil side needs only to be drained if the tube
bundle is to be diassembled (see "Shutting down").
' ' Safety valve

The heat exchanger shell must be provided with a safety valve in
accordance with the classification societies' regulations. The
discharge pipe from the safety valve should be run to the drip tray.
Steam trap
When steam is used as heating medium, the condensate branch
should be provided with a steam trap and preferably also a by-
pass valve. The heat exchanger is normally designed for 15OC
subcooling of the condensate. It is essential to ensure that the
steam trap is designed for the maximum condensate flow at the
available pressure differential. If the subcooling of the con-
densate is higher, a special steam trap should be used.
Service
Due to the design and.the high oil velocity, the Bendek heat ex-
changer is almost self-cleaning and need not to be cleaned when
used with oils containing normal amounts of impurities.
Following cleaning methods are recommended for:
I) light impurities: spray kerozene and blow with compressed
air
2) heavy impurities: steam cleaning by use of a steam lance
3) carbonizing: fill the heat exchanger with carbon remo-
val for approximately 24 hours and then
wash with water.
/ HEAT EXCHANGER
Starting up and shutting down

Start the oil circulation before the steam valve is opened.
When shutting down, the steam valve should be closed before
the oil circulation is stopped.
In event of an extended shut-down, the heat transfer surface
should be protected from corrosion on the steam side, and the
following procedure is recommended for this purpose:
a) When installed vertically with the main flange pointing
downwards, shut off the steam and condensate valves and
drain the condensate from the tube stack. Shut the drain val-
ve and the heater will then be protected from corrosion when
out of service.
b) When installed horizontally and vertically with the main
flange at the top, the tube stack is not self-draining and the
remaining condensate can therefore cause corrosion when
out of service if it contains oxygen. Therefore blow the tubes
free from condensate by compressed air or nitrogen.
Fault tracing
If the capacity of the heater should decrease, check:
1) that the pressure, flow and temperature of the heating medium are
correct
2) that the capacity of the steam trap is sufficient
3) that the steam trap is not choked and that satisfactory circulation
is maintained on the side of the heating medium
4) that the heat transfer surface is clean.
I DRAUING PART LIST
I
1 Box 907 Tekefax +46-8580-27801
I 175 29 J a r f a l l a Telex 192MI SUNROD S
I Sweden

H u l l no.: 9226 System n m : 2 X CPH-18 T/H Class: DNV
Product: 00005 FEED WATER TREATMENT SALINCUETER Drauing: GS-20143%
Pos. A r t i c l e ~ t y Fulction Type Press Dim weight Drawing

Data
,r-, HI0 7700101 1 pcs SALINOIIETER MALL KUYTED SL3005/50045-10 12.00 1
U a l l momting
S a l i n i t y range 0-2010-200 ppn selectable
1 pcs SALINCUETER SENSOR 2-0003129 0.00 1
HI2 7000019 1 pcs SALINCUETER SENSOR TIPIECE (FITTING) 2-0003129 0.00 1

Ch19 0
instruction manual
Salinometer
ppm seasalt
mains
a
alarm
fuse O.4A
b 0 - m ~ m
I 0- z o o m
range
meter alarm
.
1. SPECIFICATION.
Function: The salinometer measures and supervises the sali-

nity (salt content) of fresh water produced by
destillation of sea water.
Mains Supply: 90-130 or 180-250 V, 50-60 Hz.
Power: 2-880 W dependent on the consumption of the ex-

ternally connected divices.
Range of Salinity: 0.0-19.9 or 0-199 ppm of sea-salt.

'3
!- Alarm Level: Adjustable 0.7-19.9 or 7-199 ppm
Test: By means of two button switches the salino-

meter can be checked.
E. - -1 Cable Connections: Terminals 1-2: Mains.

Terminals 3-4: Buzzer or bell.
Terminals 5-6: Normally de-energized solenoid
valve.
Terminals 6-7: Normally energized solenoid
valve.
Terminals 8-9: Connection for external alarm
system requiring normally closed
contacts.
Terminals 9-10: Connection for external alarm
system requiring normally open
contacts.
Alarms to devices connected to any of terminals
8-10 can be cancelled by means of a push button
switch "ALARM" on the front panel.
Devices connected to the terminals 3-7 shall be

designed to operate from the same mains voltage as
the salinometer.
Controls: "MAINS" : Toggle switch for the supply

voltage. The fuse for the
salinometer is below the
mains switch.
"ALARM" Toggle switch by which.
the alarm signals to the
externally connected devices
can be cancelled.
The fuse for the externally
connected devices is below
the alarm switch.
"TEST/ADJUST METER": Push button switch of the
momentary type. When pushed the
display shall read 10 or 10.0.
IF the meter is out of adjust-
ment a trimming potentiometer
is accessible for adjustment
by a small screwdriver through
the hole above the switch.
"TEST/ADJUST ALARM": Push button &itch of the

momentary type. When pushed
the display reads the level
at which the salinometer is
set to give alarm. The alarm
level can be changed by ad-
justing a trimning potentio-
meter accessible by a small
screwdriver through the hole
above the switch.
"RANGE" : A push/release type o f switch

by which one of the ranges
0.0-19.9 or 0-199 is selected.
The presence of a decimal
point between 2nd and 3rd di-
git in the display window in-
dicates that the lower range
is selected.
The display reads the salinity
in ppm's of sea-salt. I F sa-
linitv exceeds the upper limit
of thk selected. range the
1-1 or I 1 1 1 l i s dis-
.
olaved
, in the low and hiah -
range respectively. The alarm
lamp right to the display
window is blinking on alarm.
11. ELECTRICAL DESIGN.

The mains transformer T1 supplies power to the rectifier, CR1, and associated
filter capacitors, C1 and C2. The DC outputs +/- 6V DC drive the electronic
components.
An auxiliary winding deliver the necessary signals to the electrode unit

(terminals 11 and 14 on the terminal board). The current is converted to voltage
in U1A the ratio of conversion being dependent on whether R3 or R4 is selected by
the range switch 55.
The signal is then rectified in UlC. A DC voltage equal to the peak value of the
alternating input signal is derived from U1C #= 9 and connected to the signal
input of a digital voltmeter (DVM) U3. A DC signal the-level of which is depen-
dent on the setting of potentiometer R7, "Alarm/adjust", is connected to the
non-inverting input of the comparator U2.
A current proportional t o the conductance of the electrode u n i t a t constant
s a l i n i t y (varying w i t h varying temperature) enters a t terminal 13. The current
i s again converted t o voltage i n U1B and r e c t i f i e d i n UlD. The r e c t i f i e d s i g n a l
i s applied t o the reference input o f the DVM c i r c u i t U3. The r a t i o o f the two
signals applied t o the DVH i s simply the s a l i n i t y which i s displayedmn the
three 7-segment displays.W, US and U6 driven by the DVM c i r c u i t .
Normally (i.e. a t low s a l i n i t i e s ) Q1i s on and the r e l a y K 1 i s excited. When

the DC voltage on the non-inverting i n p u t o f the comparator U2 exceeds t h e
reference voltage (proportional t o the temperature c o r r e c t i o n s i g n a l derived
from U1B and U2D) U2's output c u t s o f f the t r a n s i s t o r Q1.Relay K 1 changes
s t a t e and the external alarm devices connected t o the relay contacts operate.
i) The toggle switch S2, t1ALAR14n, can be switched o f f t o cancel the e x t e r n a l
alarms. O n alarm CR7 (the LED t o the r i g h t o f the display) i s b l i n k i n g .
The meter reading i s tested by pushing the switch S4 ("TEST/ADJUST METER") by

which the electrodes and the temperature correction c i r c u i t i n the electrode
u n i t are replaced by f i x e d r e s i s t o r s R 1 and R2. The meter reading should be 10
or 10;D.
By pushing the switch S3 ("TEST/ADJUST ALARM") the electrodes are again removed
from the c i r c u i t and a p o s i t i v e feedback i s established from the r e l a y c o i l t o
the i n p u t o f the comparator U2, making U2 o s c i l l a t e . The averaged output from
U l C # 9 i s s t i l l connected t o the DVM s i g n a l input g i v i n g a d i r e c t read-out o f
the l e v e l t o which the salinometer i s set t o give alarm.
111. MECHANICAL DESIGN.
The salinometer i s housed i n a p l a s t i c box. The PC board w i t h a l l e l e c t r o n i c

c i r c u i t s i s mounted on stay nuts i n the bottom o f the box. By means o f wires the
salinometer i s connected t o the terminal s t r i p placed i n the bottom o f the l e f t
side of the box.
&) The electrode u n i t consists o f a bronce T-piece w i t h 1 1/4", 1" or 1/2" thread.
Two rhodanized electrodes and the two temperature compensating elements are
placed whithin the T-piece i n such a way that they are e a s i l y removed f o r
inspection.
IV. INSTRUCTION FOR USE.
1. Switch "MAINS" (1) on. Switch "ALARM" (3) on. The salinity is shown in the
display window (12). If the salinity exceeds the present alarm level the
red alarm lamp (11) is blinking.
2. Test the instrument. This test should be made with the range switch (9) in
the lowest range (a decimal point (10) is shown in the display window (12)).
6
a) Push the test meter button ( 5 ) . 10.0 ppm should be displayed. If not,
adjust the trimpot (7) by means of a small screwdriver.
b) Push the test alarm button ( 6 ) . The alarm level is displayed. The alarm
level can be adjusted to any value 0.7-19.9 or 7-199 ppm by adjusting
the trimpot (8).
C) 3. Select the required range on the range switch (9). The decimal point (10) is
lit in the range 0-19.9 ppm. It is lit in the range 0-199 ppm. Note
that the alarm level is changed by a factor 10 when the range switch (9) is
operated. E.g. if the alarm level is set to 5 ppm in the range 0-19.9 ppm
the alarm level will be 50 ppm in the range 0-199 ppm.
4. The salinometer .is now ready for use. Point 2. should be repeated from time
to time during operation. If the salinity exceeds the alarm level, the in-
strument signals alarm:
a) The alarm lamp (11) is blinking.
b) The externally connected alarm devices (solenoid valve(s), buzzer, external
alarm systeds) etc.) are functioning. :The externally alarms can be
cancelled by switching off the "ALARM" button (3). but not the solenoid
valve.
If the range limits (19.9 or 199) are exceeded the first digit shows 1, the
second and third digits are blanked ( l r l o r fm. )
V. ADJUSTMENT OF THE SALINOMETER.
1. Switch "MAINS" (1) on and "ALARM" (3) on.
2. Push "ADJUST METER" (5) and adjust the trimpot (7) u n t i l t h e 10.0 is
displayed (range 0-19.9).
3. Push "ADJUST ALARML' (6) and adjust the trimpot (8) u n t i l the desired a l a n
l e v e l i s displayed.
4. A c t i v a t e the e x t e r n a l alarm c i r c u i t s by switching the "ALARM" b u t t o n (3)

on.
V I . MAINTENANCE.
Always keep the salinometer dry and clean. Ifa fuse burns over f i n d the cause
before i n s e r t i n g a ne* one. The "MAINS" Fuse (21, 0.4A protects the salinometer
i t s e r f . The "ALARM" fuse (4) 4A, protects the e x t e r n a l l y connected alarm devices.
The electrodes should be taken out once a month and wiped w i t h a s o f t rag. Avoid
damaging the rhodium p l a t i n g .
VII. INSTALLATION.
-1. The salinometer i s adopted t o operate from 200 t o 250 V AC, 50-60 Hz. I f
the l o c a l mains voltage i s 100 t o 130V AC, 50-60 Hz adaption should be made
by 56 under the frontplate.
2. The necessary fastening holes are d r i l l e d according t o f i g . 1.
\
3. Unscrew the two screws t h a t fasten the cover for the terminals.
& I 4. Lay the necessary cables ( f i g . 2) and connect them t o the terminal board i n
the bottom-part o f the salinometer box.
5. Put on the cover f o r terminals again and fasten the f i x i n g screws.

6.J
\
6. Apply the mains voltage and t e s t the instrument as described overleaf.
WARNING! Never remove the f r o n t p l a t e without f i r s t being sure t h a t the mains

supply voltage i s removed from the salinometer and remains so as l o n g
as you work w i t h the salinometer.
'9,
1'-
.. m. ,
.-. -
.r
,.
~)
.. . . .. . .
'w b d- d
PARTS LIST l:'R1.NTET. 90/1:10/ 1'3
0
E
P
cP
TITLE: DOCUMENT NO.: REV: SHEET NO.:
M(.2(130 laaww.
SnL I I'dCji'IETEH S L 3 0 0 5 60 - H R 4 8 9 0 5 0 nc
Dansk Radio AS . ..
~ ~ r m l h
lw,,.,.
TW111 4 5 42 52 23 80
(48'3050 )
OF 1 p
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.:n
El I 2 F3 EL I 5 I 6 F l E8 I 9 I I O E l l El2 El3 ClL El5 E l l
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0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
FIGI
INSTALLATION OF SALIOMETER
TYPE SL3005
WEIGHT : 1050g.
F IG. 2
Salinometer
S L 3005 To obtain maximal distance from salinometer to
EXTERNAL ALARM SYSTEM:
Contact o p e n Contact c l o s e d
in the non-alarm in the non-alarm
condition condition
CABLES: A = 4~0.75'
' -
B I
PIPE SIZE ~ O X Ells?
A
I L O ~ ~ ~ ~ P V ~ WRCEVIND
NDE
M I S PACKING NUT SHOULD BE UNSCREMD I 7 FILllAGE AU SPIRALE ocL
WHEN C L U N I N G THE ELECTROOE UNIT PAS DU CAl U
lO
,
EsTA TUERCA DE UNION SE DESATOR-

NILLIRA AL LIMPIAR L A UNIDAD DE
ELECTROWS
DENNE O M L O B E R M ~ T R I K AFSKRUES
VCD RENSNINC AF ELEKTRODEENHEOEN
QUEST4 VOTE Dl POTAZIONE SI STACCA

PER L A PULITURA DELL' E L E M E N T O
ELECTRODE
ELECTRODE UNIT
OUTLINE
r
I DRAWING PART LIST
I
I Aalborg Sunrod AB Telephone +46-8580-24300 96-09-24
I Box 907 Telefax +46-8580-27801
I 175 29 Jarf=LLa Telex 19268 SUNROO 5
I Sweden
I
Project: 11-417 Name: HALLA LAURlN Revision: - - -

H u l l no.: 9 2 2 6 System name: 2 X CPH-18 T/H Class: DNV
Product: 00006 FEED UATER TREAT. CHEMIC. DOSING PUMP Drawing: GS-201432A
~ - -

Data
1 pcs CHEM1CAL DOSING TANK, MIXING HANDLE DOSING PUMPUNIT 17.3
,-I
"01 7700030 LEVEL SWITCH
Cmfattning:
1 pc 1001 Tank OK 100 art.nr.00681-DK100
1 pc Levelswitch LSF art.nr.00681-LSF
1 pc Hard mixer art.nr 2-11 1 pc Nozzle 2-13 SS
1 1 pc Dosingpunp 2,2l/h.Press:~x 17.3 bar PWF
HOlA OOPRSTR 1 pcs DOSING PUMP W I T H MOTOR 3-3818325
HOlB OOPRSTR 4 pcs TUBING STRAIGHTNER 3-3818325
HOlC OOPRSTR 1 pcs INLET STRAINER 3-3818325
HOlD OOPRSTR 1 DCS ELECTRIC CABLE FOR OPTIONAL REMOTE CONT. 3-3818325
HO2 OOPRSTR 1 pcs FLEXIBLE HOSE 5 METER 3-3818325
( . ) H03 OOPRSTR 1 pcs INJECTION NOZZLE

STAINLESS STEEL
H03A OOPRSTR 1 DCS INJECTION NOZZLE 3-3818325

-A[ 3
.t
C No.
DOSING UNIT [hot 19

,ev.No.
Date
P a ~ e\ 4
ELECTRONIC
METERING PUMPS
1,NSTALLATlON
MAINTENANCE
TROUBLESHOOTING
?'>" d e?
--
Doc No.
-
DOSING UNIT : ,
Date
Pauet5
CONTENTS
1 .O INTRODUCTION...............................3
2.0 UNPACKING CHECKLIST... ....... . .... ..5
3.0 PRE- INSTALLATION INSTRUCTIONS.. ......7
4.0 INSTALLATION.................................9
5.0 METHODS OF EXTERNAL TRIGGERING.... I 9-
6.0 START-UP & ADJUSTMENT ..........20
7.0 CALIBRATION ................................. 23
8 . 0 SPARE PARTS REPLACEMENT
& ROUTINE MAINTENANCE........... 26
9,O PROPER ZEROING/
KNOB REPLACEMENT .,.................32
1 0.0 TROUBLESHOOTING.. . . . . . . . . . . . . . . . . ...34
1 1.0 EPU RESISTANCE CHART ............ 56
SUPPLEMENT, ASSY. PA[?-lS LIST,

SPECIFICATIONS, AND TANK ..........37-4-8
-7-
-iS ]
%
Ooc No.
DOSIN-G UNIT sto.

Date
EXAMPLE:
Your pump consists of two parts:

The Drive Assembly and
The Liquid Handling Assembly.
192s
Drive Liquid Handling
1.0 INTRODUCTION
LMI is the world's most versatile manufacturer of
economicalandefficientmeteringpumps. This manual
addresses the installation. maintenance and
mubleshootingproceduresformanuallyandexternally
controlled pumps. LMI has a worldwide network of
stocking representatives and authorized repair centers
to give you prompt and efficient senice.
Please review this manual carefully. Pay partidar
attention to warnings and precautions. Always follow
good safety procedures, including the use of proper
clothing, eye and face protection.
This manual is for A, B, C, J, P, Z Series pumps.
--- . .>d
Doc No.
DOSING UNIT Ch~t@

,.NO
Date
Paoe 18
2.0 UNPACKING
Your carton will contain the following items. Please
n o w the carrier immediately i f there are any signs of
damage to the pump or its parts. Nohfy your pump
supplier if any of the following parts are missing.
Please refer to the enclosed Drive Assembly Parts
List Sheet for an illustration of your complete
pump, electrical diagram and a parts list.
u
Metering Pump
I
Foot Valve
Tubing
Depending on the model. your carton

may containo. 1.2 or 3 rolls of tubing.
Yo? carton may contain an additional \
roll of clear vinyl tubing. this is for
connection to the SUCTIONSIDE OF Suction Tubing
THE PUMP HEAD ONLY. Straightener
- ? :, :$
Doc No. __Z
1 DOSING UNIT Date

, pu
Liquid Handling Drive Assembly Parts List

Assembly Sheet & Exploded View Drawing
I FOUR FUNCTION Valve I

I (4-FV) and Tubing I
I I
I Yourcartonmayormaynotcontain 1
Injection Check 1 a 4-FV, an accessory for pump I
Valve 1 models ending in "M" or "S". I
---
DOSING UNIT 2;:.
Doc No.
Date
3.0 PRE-INSTALLATION INSTRUCTIONS

The following precautions should be taken when
working with LMI metering pumps. Please read this
section carefully prior to installation.
3.1 Precautions
A Protective Clothing
ALWAYS wearprotectiveclothing, face shield, safety
-
glasses and gloves when working on or near your

meteringpump. Additional precautions should be taken
depending on the solution being pumped. Refer to
MSDS precautions from your solution supplier.
A Water re-prime
AULMI pumps are pre-primed with water when shipped
from the factory. Lf your solution is not compatible
with water, disassemble the Pump Head Assembly.
Thoroughly dry the pump head, valves, seal rings,
balls and Liqw£im@(diaphragm). Re-assemble head
assembly tightening screws in a crisscross pattern.
Refill the pump head with the solution to be pumped
before priming the pump. (This will aid in priming).
A Solution Compatibility
Your Liquid Handling Assembly Sheet lists the
materials of constructionincludedin the liquid handling
portion of your pump. Should you have any further
compatibility questions on your LMI Metering Pump.
review theLMIPumpSelection Guide and Chemical
Resistance Chart for compatibility. Ifthis sheetis not
available to you, call yourlocal LMI distributor, or the
LMI Customer Service Department for further
information.
A Tubing Connections
Inlet and outlet tubing or pipe sizes must not be
reduced. Make certain that all tubing is SECURELY
ATTACHED to fittings prior to start-up. (See Section
4.3.Tubing Connections). ALWAYS useLMI supplied
tubing with your pump,'& the tubing is spedically
designed for maximum compatibility with the pump
operation. It is recommended that all tubing be shielded
to preventpossibleinjuryincase of ~ p t U R 0accidental
r
damage.
A itt All
tin&fittings
And Machine Threads
should be hand tightened to a maximum of
118- 114 turn after the fitting contacts the seal ring. DO
NOT OVERTIGHTENFITITNGS. Overtighteningor
use of a pipe wrench can cause damage to the fittings,
seal rings, or pump head, causing the pump to LOSE
PRIME OR NOT FUNCTION.
All LMI pumps have straight 3/4"-16 o r
1"-12 machine threads on the head and fittings and are
sealed by the seal rings. DO NOT use Teflon tape or
pipe dope to seal threads. Teflon Taw mav onlv be
usedonthe 112"NPTthreadsideofthe Iniection Check
Valve before installing in a pipe line or tee.
A Plumbing
Always adhere to your iocal plumbing codes and
requirements. Be sure installation does not constitute
a cross connection. Check local plumbing codes for
guidelines. LMI is not responsible for improper
installations.
--
Doc No.
DOSING UNIT EL, Paqe 21
Date
A Electrical Connections
Allwiring- must conform to local electrical codes. The
metering pump should be plugged into a grounded
outlet with ratings conforming to the data on the pump
control panel. The pump must be connected to a good
ground DO NOT USE ADAPTERS!
4.1 Pump Location and Installation

Locate pump in an area convenient to solution tank and
electrical supply.
The pumpshouldbe accessibleformtine maintenance.
and should not be subjected to ambient temperams
above 122°F (50°C). If the pump will be exposed to
direct sunlight, LMI black, UV resistant tubing should
be installed.
4.2 Pump Mounting

The pump can be mounted in one of two ways:
A. FLOODED SUCTION (ideal installation) or
-
B. SUCTION LIFT when suction Lift is less than 5
feet (1.5 m) for solutions having a specific gravity
of water. For denser solutions, consult the factory.
YourLMI metering pumpmust bemountedsothat
the suction and discharge valves are vertical.
NEVER position pump head and fittings
horizontally.
-
4.2A Flooded Suction

7 DOSING UNIT %rxexl
The pump is mounted at the base of the storage
tank. Thisinstallationisthemosttrouble-free, and
is recommended for very low outputs, solutions
that gasify, and high viscosity solutions. Since the
suction tubing is filled with solution, priming is
accomplished quickly and the chance of losing
prime is reduced
--
Ooc No.
DOSING UNIT ' 3 ~ f l Paoe

Rev. No.
Date
~ a
4.2B2 Suction Lift - Tank Mount

The pump may be mounted on a molded tank
provided there is a recess to keep pump stationary.
LMI logallon tanks @artno.27421) and50gallon
tanks @artno. 26350) have molded recesses for
pump mounting.
F'Esute
I 1 Une
"It-
\
LMI
50 Gallon
Sollfion
Tank
I, -,
Doc No.
DOSING UNIT [hot19

RevNo,
Date
P a ~ e2s
C. Before installation, all tubing must be cut with a

clean square end.
D. Valve and head connections from the factory are
capped or plugged to retain pre-prime water.
Remove and discard these caps or plugs before
connecting tubing.
DO NOT USE PLIERS OR PIPE WRENCH
ON COUPLING NUTS OR FI'ITINGS.
Tubing Connection Tubing Connection

114" O.D. (.250")Tubing 318" O.D. (.375") Tubing
& Coupling Nul
Tubing Connection 114" or 112" NPT

112" O.D. (3)
Tubing Pipe Thread '
Connection
1R' ODTublrg
W l r g Not
NOTE: See Melric Liquid Handling Sheet for metric tubing connections
d : 1
Doc No.
DOSING UNIT Ch~tl9
Rev. No,
Date
Paoe 26
The suction tubing straightener, when assembled,

positions the foot valve and suction tubing in a vertical
position.
1. Attach the foot valve to one end of the suction
tubing (see Tubing Connections, section 4.3).
Assemble the suction tubing suaightener by
pushing together alternating yellow and black
tubes. Adjust the length of the tubing straightener
by pushing tubes further together so when placed
over the suction tubing and sitting on the foot
valve, approximately 3 inches (75 mm) of tubing
exits the tubing straightener on the side to be
connected to the pump.
3. Place foot valve, tubing and suction tubing
straightener into the solution tank. Check that the
foot valve is vertical and approximately 2 inches
(50 rnm) from the bottom of the tank or drum (see
illustration). Connect the other end of the tubing to
the suction side of the pump head (bottom side).
Proper Foot Valve Position
INCOfUiEGT CORRECT
--
Ooc No.
DOSING UNIT Date
4.7 Injection Check Valve Installation

The Injection Check Valve prevents backnow from a
treatedline. ConnecttheInjection Checkvalveto your
"DISCHARGE"(outlet) line. Any sizeNPTFfittingor
pipe tee with a reducing bushing to 112" NPTF wiU
accept the injection check valve. Use Teflon tape or
pipe dope to seal the pipe threads only.
When installing the Injection Check Valve, be sure to
position it so that the valve enters the bottom of your
pipe in a vertical position. Variations left and right
within 80' are acceptable. (See illustration below)
After cutting an appropriate length of tubing, connect
tubing to the injection check valve then back to the
discharge side of the pump head (top side), making
sure it does not crimp or come into contact with hot or
sha~psurfaces.
Typical Injection Check Valve Installations

/ ~ R X OF E
E5.0 METHODS
I
--07 P l J
Methods of Triggering
Metering (Dosing) Pumps
2. NPN Trmhtor
saY) gDes hlgh
lo Mggor pump
MlchoruanrlsmnmurtbeapableolsrrlWlnglSVDC
a12 rnilliampersr. Mnlrnurn Ume In lmlrnpdanma8ts
(on) b 5Jrnllliremnbs. MlnlrnurnUrne In hlghlmpedana,
sta10 (om k 100rnlnkccondr.
Ooc No.
DOSING UNIT Chat

Aev.Na
Date
19 Pape 29
6.0 START-UP and ADJUSTMENT

NOTE: m e pump is normally self-primingifsuction
lift is 5 !t (1.5m) or less and the steps below are
followed.
NOTE: Pumps are shipped from the factory with
water in the pump head to aid in priming.
6.1 Output Adjustment Controls

Note: Manual series pumps controls are not equipped
with pressure control.
hmostextemalcontro~edpumpsthe uppermost setof
knobs on the control panel serve a dual puIpose. The
smallest of these knobs (inner knob of this concentric
knob) is Pressure Control. The larger h o b directly
underneathis Speed Control. Graduation makings for
the small Pressure Control Knob are etched in yellow
on the Speed Knob itself. Graduations for the Speed
Knob appear directly on the face of the control panel.
The largest knob below is Stroke Control.
Pressure Control Adjustment: Pressure control
provides the adjustment of the pump's pressure
capabiity and power consumption, reducing heat,
pipe shock and pulsation while increasing pump
life. 'See Section 7.0 after priming for proper
adjustment settings.
Speed Adjustment: Speed control provides
adjustment of the percent of maximum strokes per
minute. Turning thish o b clockwise 0increases
stroke frequency.
Note A7 Series Only: When operating pump
in externalmode,the speed control knob should
be turned fully counter clockwise 0. A click
indicates pump is in external mode.
Note A34 and A37 Series Only: Pump
comes equipped with a range selector switch
-
Doc No.
DOSING UNIT E ;
Date
:
which provides high or low speed adjustment.
The high setting provides speed adjustments
betwe& 8-100 strokes per minute. The low
setting provides accurate speed adjustments
between 1-12.5 strokes per minute for
applications requiring W q u e n t stroking.
Sgoke Adjustment: Stroke control provides
adjustment of percent of maximum ~ i ~ u i f r a m @
(diaphragm)travel. Tumhgthis knob clockwise0
increases percent output per stroke.
6.2 StartUpIPriming for Pumpsupplied with 4-FV
A CAUTION: Read this entire section completely

before proceeding.
When all precautionary steps have been taken, the
pump is mounted, and the tubing is securely attached,
you may now start priming the pump.
1. Plug in or switch the pump on.
2. While the pump is running,set the speed knob at
80% and the stroke knob at 100%.
Note: If the pump is equipped with a pressure
control knob, tum knob fully clockwise.0
3. If your pump is equipped with a 4-FV, grip both
the yellow and black knobs, 114 turn or pull and
hold open.
4. The suctiontubiigshould begin tofill withsolution
from the tank.
5. A small amount of solution will begin to discharge
out the return line of the 4-FV. Once this happens,
114 tum or release the h o b s and SHUT THE
PUMP OFF.(If pump is not equipped with an on/
off switch, disconnect the power cord.)
DOSING UNIT
6. The pump is now primed.
7. Proceed to output adjustment, Section 6.4.
NOTE: If the pump does not self-prime, remove
the 4-FV on the discharge side of the pump head
Removethe ball andpour water or solutionintothe
port until the head is filled. Replace valve, then
follow start up/priming steps.
6.3 Start-UpIPriming without 4 - N
A CAUTION: Read this entire section completely

before proceeding.
When all precautionary steps have been taken, the
pump is mounted, and the tubing is securely attached,
you may now prime the pump.
Plug in or switch the pump on.
While the pump is running, set the speed knob at
80% and the stroke knob at 100%.
Note: If the pump is equipped with a pressure
control knob, turn h o b fully clockwise. 0
The suctiontubingshould begin t0jiJ.I with solution
from the tank.
Once the solution begins to exit the pump head on
the discharge side, SHUT THE PUMP OFF. (If
pump is not equipped with an on/off switch,
disconnect the power cord).
The pump is now primed.
Proceed to output adjustment, Section 6.4.
NOTE: If the pump does not self-prime, remove
the fitting on the discharge side of the pump head.
Remove theball and pour water or solutionintothe
port until the head is filled. Replace valve, then
follow start uplpriming steps.
..
Ooc No.
DOSING UNIT !Date paQe32
6.4 Output Adjustment

Once the pump has been primed, an appropriate output
adjustment MUST be made, M p output should be
calculated and adjustments made accordingly.
TOTAL PUMP OUTPUT
Calculate the total output of the pump as follows:
PUMPOUTPUT = MAX PUMPOUTPUT x %SPEED x OBTROKE
Example: Al51-192s
Use MAX Output (From dataplate on bottom center of
pump control panel) = 24 GPD (24 gallons per day).
If the pump is set at 60%speed and 70%stroke length.
the approximate pump output is:
24.0 x 0.60 x 0.70 = 10.08 GPD (gallons per day)
Divide by 24 (hours in one day) to calculate in gallons
per hour
Note: If pump is not equipped with speed adjustment,
calculate by Max Pump Output x % Stroke only.
7.0 CALIBRATION
Once installation is complete and the approximate
output has been determined, the pump should be
calibrated to adjust speed and stroke for your actual
desired output.
1. If equipped, make certain Pressure Control Knob
is turned fully clockwise 0
2. Be sure the pump is primed, and discharge tubing
'
and Injection Check Valve are installed as they

would bein normal service (i.e., including factors
such as injection pressure, fluid viscosity, and
suction lift).
-
/ ,
:v~
Doc No.
[--DOSING UNIT
!
&~aoe
.v.N,
Date
33
Place the Foot Valve in a graduated container with

a volume of 1000 ml or more.
Plug in and switch pump to InternalMode. Pump
until a l l the air is exhausted fromthe suction line
and head
Turn the pump off. Refill graduated container to a
level starting point.
NOTE: If pumpis equipped with pressure control,
see Section 7.1 before proceeding.
Using a stopwatch or timer, turn the pump on for
a measured amount of time (50 pump strokes
minimum). The longer the time period, the more
confidentyoucanbe of the results. Be sure to count
the number of strokesduringthe calibrationperiod
when making comparisons.
Turn the pump off. Note the time elapsed in
relationto volume displaced in the graduate. Now,
calculate the output in the time unit you choose
(minutes, hours. days, etc.).
If the output is too low or too p a t , a m s t speed
and or stroke, estimating required correction and
repeat steps 1-7.
-
Ooc No.
DOSING UNIT 2; Paoe34

Date
7.1 Pressure Control

Adjust Pressure Control: While unit is running, turn
Pressure Control Knob slowly counterclockwise C)
until unit just begins to stall. From this stallpoint, now
turn Pressure Control Knob clockwise (3.from 1 to
1 I12 graduation marks. 'Ihis is the optimum pressure
control setting for your application.
NOTE: Increase settingifback pressure is increased.
Bar P ~ ~ s sControl
u~ psi
Adjust pressure wnkol to reduce heat,

shock, pulsations and prolong pump lie.
7.2 Calibration Procedure On-Site -

Volumetric Calibration in External Mode
1. Since pump output is governed by an external
device such as Flowmeter-Pulser, LiquitronTM
Current-to-Frequency Converter or 4-20 mA DC
signal from an instrument with an LMI Analog-to
Digital Converter, only the output per stroke
may be calibrated.
2. With pump primed anddischargetubing connected
to the injection point as it would be in normal
service, place Foot Valve and Strainer Assembly
in a graduated container with a volume of 500 ml
or more.
3. Switch pump to Internal mode with Speed Knob
set at 100 until air is exhausted from suction line
and pump head.
s:
.-
Doc No.
DOSING UNIT Date

paue35
Adjust Pressure Control - See Section 7.1.

Switch pump OFF 'and note solution level in
graduated container. Relill graduate to a starting
pint.
Switch pump ON and count the number of
strokes forexactlyone minute. 'Ihen switchpump
OFF.
Notevolumepumpedduring the calibrationperiod
of one minute. Divide into this the number of
strokesto determine thevolume of solutionpumped
per stroke.
Ewmple: 500mlin 100strokes=5.0mlperstroke.
Multiply this by your expected m k e rate per
minute, per hour or per day and compare with
desired output requirements.
Adjust Stroke Length Knob (lower knob) to your
best estimate of requixed correction and repeat
calibration procedure.
8.0 SPARE PARTS REPLACEMENTS

ROUTINE MAINTENANCE
8.1 Depressurizing the Discharge Line
(For Pumps Equipped with a 4-RI only).
A WARNING: ALWAYS wear protective clothing,

face shield, safety glasses and gloves when performing
any maintenance or replacement on your pump.
A WARNING: Read steps 1 and 2 below before

proceeding.
1. Be sure the Injection Check Valve is properly
installed and is operating. If a shut off valve has
been installed downstream of the Injection Valve,
it should be closed to off.
A WARNING: Be swe your relief tubing is connected

to your4-FV and runs back to your solution dnun or
tank.
2. 114lumor pull on both the yellow and blackknobs
on the 4-FV. The discharge line is now
depressurized Keep valve open until solution
drainsbackdown the dischargetubinginto solution
drum or tank. Then release or 114 turn knobs to
normal position.
8.2 ~iquifram
(~iaphragm)
~ Replacement
A WARNING ALWAYS wearprotective c10thing. face

shield, safety glasses and gloves when working near or
performing any maintenance or replacement on your
pump. See MSDS Sheet from solution supplier for
additional precautions.
LMI metering pumps are designed for muble-fm
operation,yet routinemaintenanceofelastomericparts
is essential for optimum performance. This involves
replacing the ~ i q u i f r a mseal
~ rings, valve balls, and
the Injection Check Valve spring. LMI recommends
replacing these parts at least once a year, however,
frequency will depend on your particular application.
When replacing the ~i~uifram@, the valve balls, seal
rings and the injection check valve spring should also
be replaced. See next section (8.3). A Spare Parts Kit
(SP-#) containing these parts may be obtained from
your local distributor. (See the Liquid Handling
Assembly Sheet for Spare Parts Kit Part Number).
?
Doc No.
DOSING UNIT mot19

RW.NO.
Date
Paoe 37
Carefully depressurize, drain, and disconnect the

discharge Line (See Section 8.1 in this manual).
Place the Foot Valve into a container of water or
other neutralizing solution. Turn the pump on to
flush the head assembly. Once the pump head has
been flushed,liftthe Foot Valve out of the solution
and continue to pump air into the pump head until
the pump head i s purged of water or neunalizing
solution.
Note: If the liquid cannot be pumped due to
~i~uifram@rupture, using protective gloves,
carefully disconnect the suction and discharge
tubing. Remove the four screws to the head and
immerse the head in water or other neutralizing
solution.
Startthe pump. While running, set the stroke knob
to zero and turn the pump off.
NOTE: See Section 9.0 for proper zeroing.
With the unit off, unscrew the ~iquifram@by
carefully graspingthe outeredge of theLiquiframG9
and turning it counter clockwise 0. Discard old
Liquifram@.Remove the ~ i q u & m @disk if so
equipped (located behind the ~i~uifram@) and
check that the size code matches the size code on
the replacement ~iquifrarn@ (see illustration).
Reinstall the disk so the alignment pin on the disk
(if present) seats in the recessed hole in the EPU.
A ' WARNING: Take care not to scratch the Teflon face

of the new Liquifram?
i
Ooc No.
DOSING UNIT .
Date
PaPe 3g
For Series
B&C
be rkferencid,,& -a --,
5.0 Bladt Adapter not the 3.0 Spacer
5. Start the pump and turn the smke knob to the

setting indicated below on Stroke Setting Chart
whichmatches the pump model numberlocated on
the pump dataplate. With the pump stroking
( m g ) , screw on thenew Liquifram@c1ockwise
until the center begins to buckle inwards. Stop the
Pap.
~iquifrarn~stroke
Setting Chart
Pump Series Stroke Knob Setting
All A, J. P. Z Series
811.871,812.872,813,B73
Dl 1. D71. D12, D72, D10. D70 90"h
C11. C71. C12, C72, C10, C70
€50, E51. €52
All L Series 85%
814,874
D13, D73 70%
cis, ~ 7 3cn,, cn
€53
D14, D74
C14. C74. C78 50%
€54
All U and M Series 1WAbvt~iquiham@must bebottomed
ampleteiy. DoNolUseSlrelgMMge.
Doc No.
DOSING UNIT Rev. NO.
""19
Date
6. Grasp the outer edge of the Liquifram@andadjust by

screwingit in or out so that the centerof the LiquiframB
is flush with the outside of ihe spacer edge (see
illustration). ,LMI upumam'=
7. Once the L.iquifram@is properly positioned, remount

the pump head to the spacer using the four (4) screws.
Tighten in a crisscross pattern. After one week of
operation,recheck the screws and tighten if necessary.
8.3 Seal Ring, Ball and Injection Check Valve

Spring ~eplacement
A WARNING: ALWAYS wear protective clothing, face
shield, safety glasses and gloves when working on or
performing any maintenanceorreplacementon yourpump.
See MSDS Sheet from solution supplier for additional
precautions.
1. Refertothe LiquidHandlingAssembly Sheetincluded
with your pump for the proper Spare Parts Kit number.
(SF'-#)
2. Carefully depressurize and disconnect the discharge
line (See Section 8.1 in this msnual). Place the Foot
Valve into a container of water or other neutralizing
solution.Turn the pump on to flush the head assembly.
-- Doc do.
' L dJ
DOSING U-NIT 19
Rev. No.
Date
paw 4a
Once the pump has been flushed, lift the Foot Valve out
and continue to pump tolet airinto the pump head until
pump is purged of water or neutralizing solution.
If the liquid cannot be pumped due to L i p f r m @
rupture, with protective gloves, carefully disconnect
thetubing and fourscrewstoremove the head Immerse
the head in water or other neutralizing solution.
IMPORTANT: Before disassembling valves, note
the orientation of seal ring and ball. (See illustration)
Carefully disconnectone tubing connectionand fitting
at a time and remove the worn seal ring and ball.
Carefully loosen sealing by prying side to side using a
small screw driver through the center hole of the seal
ring.
Install new seal ring and ball in each location.
IMPORTANT: Note correct orientation
Install the new spring in the Injection Check Valve.
WARNING: Depressurize anddrainpipeline(orisolate

I.C.V. point using valves) so that I.C.V. can safely be
disassembled.
(Refer to Liquid Handling End Sheet for proper
assembly orientation.)
Order of Installation
Note: Order of assembly changes depending on vabe location
Doc No.
DOSING UNIT L.
Ql~t19
Date
No.
Paoe 4 1
9.0 CHECKING PUMP FOR PROPER

ZEROING (STROKE KNOB)
1. Withpump~unning, wnstrokeknob counterclockwise
toward zero or end of black or red band.
2. LISTEN to the clicking as the pump is running. The
pump should operate quietly at the zero position (no
clicking).
3. Ifthe pump continues to click at zero or stops clicking
before zero is reached, the pump zero must be reset.
(See Section 9.1 or 9.2)
9.1 -
Type A Push on Knob
Rezeroing and Stroke Knob
Disassembly and Assembly
Remove stroke knob from the pump by grasping the
knob M y and pulling it toward you.
Pry off the yellow cap.
Place the knob on a flat surface.
Using needle nose pliers, squeeze the inner section
together while lifting the outer section up.
Push the inner section back onto the "D" shaped stroke
shaft.
With the pump running, zero the pump by turning the
inner section of the knob counter clockwise until the
pump stops clicking.
Position the outersectionof the knob so that the pointer
aligns with zero on the nameplate or end of the black
or red band.
Push down on the outer section (a snap sound indicates
parts are locked together).
Replace the yellow cap over the outer section of the
knob, aligning the tabs on the cap with the slots inside
the knob.
- -
DOSlNG UNIT se
Doc No.
Pape42
Date
Stroke Knob Assembly (Type A)
Type B Collet Knob

Rezeroing and Stroke Knob
Disassembly and Assembly
1. Remove Yellow Cap.
2. Hold knob with soft jaw pliers.
3. Disconnectknob by loosening5/16" (8 rnm) colletnut.
There is no need to remove nut.
4. Remove knob by pulling towards you.
5. With pump running, zero the pump using a screw
driver to turn the stroke shaft counter-clockwise 0
until the pump just stops clicking.
6. Pump is now zeroed.
7. Positionknob at zero, or the end of the low range band,
and tighten 5/16" (8 mrn) collet nut).
8. Replace yellow cap.
I
10.0 TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE

!
( SOLllTlON
I I
Pump Will Not Prime I. Pump not turned on or plugged in. i I. ~ u on
m pump~p~ug
In pump.
2. Output dlals not set properly. 2. Always prime pump wllh speed at Bm and slroke at 100%.
Foot valve must be vertlcal (See Foot Valve Installatlon.
3. Foot Valve not In VertlCal pOShlOn on
bottom of tank. I 3.
Sectlon 4.61.
4. Pump sucllon llh too hlgh. 4. Maxlmumsucllonlinls5ft. 1 sm) ~umpswnh ~ i g h w x o squid
~~
5. Sucllon tublng Is curved or colled In

I
I 5.
HandllngAssemblies r e q k flooded sudlon.
Sucllon tublng must be vertical. Use LMl tublng straightener
tank supplied with pump. (See Sectlon 4.6)
6. Filngs are over tightened. 6. Do not overtightenfmlngs. Thls causes seal rlngstodlslort and not
Seal properly whlch causes pump to leak back or lose prlme.
I
7. Alr trap in suction valve tublng. ! 7. Suction tublng should be as vertical as posible. AVOID FALSE
I FLOODED SUCTIONI (.See Section 4 . 2 ~ )
8. Too much pressure at dlscharge,
(Pumps wnhout 4FV) 11 8. Shul on valves In pressurized llne. Disconnect tubing at inJecllon
reconnect discharge tublng.

. . .
check valve (See prlmlng Section 6.0). m e n pump 1s primed.
~ --
Pump Loses Prlme 1. Solullon contalner ran dry 1. Rellll contalner wllh solution and reprlme (See Section 6.0)
2. FootVaivelsnotlnavenlcalposiilonon I 2. Foot Valve must be venlcal (See Foot Valve Instaliatlon.
the bonom ol the lank. Secllon 4.61.
3. Pump sucllon llh Is too hlgh. I 3. Maxlmumsudion lln Is Sft. (Ism). Purrpswiih HQhVolume Llquld
Handling Assemblies requlm llooded sudlon.
!
4. Sucllon lublng Is curved or colled In 4. Sucllon tublng must be Vertical. Use LMl tublng slralghtener
tank. I supplied with pump. (See Sedlon4.6)
5. Fmlngs are overtlghlened. 5. Do not overtlghtenfmlngs. Thlscausesseal rlngslodlstort and not
! ' seat properly whlch caused pumplo leak back or lose prlme.
6. Alr trap In sunlon valve tublng. 1 6. Sunlon tublng should be as vertical as possible. AVOID FALSE
! FLOODED SUCTlONl (See Sectlon 4.2A)
7. Alr leak on sucllon slde. 7. Check for plnholes, cracks. Replace li necessaiy.
TROUBLESHOOTING (continued)
PROBLEM POSSIBLECAUSE I
I
1 SOLLITION
Leakage at tublng 1. Wom tublng ends. 1. Cuttublngaboutllnch(25mm)offtublngandthenmplaceasbefore.
I
I
2.
3.
Loose or cracked fmlng.
Worn seal rlngs.

'. I
2. Replacaflttlngifcracked.Caretull handtlghtenliltlngs. Do not use
plpe wrench. Once Mllng comes i t o contad whh seal rlng. tighten
an addltlonal 118 or 114tum.
3. Replace balls and seal rlngs. (See Sectlon 8.3) Spare Parts (SP-#)
4. Solutlon attacking Llquld Handllng 4. Gonsun LMI or your local dlstrlbutor for anemate materials.
Assembly material.
Low Output or Failure 1. Pump's maxlmum pressure ratlng 1. lnlectlon pressure cannot exceed pump's maxlmumpressure. See
to Pump Against Is exceeded by lnjectlon pressure. pump data plate.
Pressure
2. Wom Seal Rlngs. 2. Worn Seal rlngs may need replacement. (See Sectlon 8.3) Spare
Parts l S P~4. ,
~ ~
.-
3. Ruptured UquiIraM. 3. Replace LlquilrarmB. (See Sectlon 82)
4. Incorrect stroke length. 4. Check zem on pumpme-zem pump. (See Sectlon 9.0)
5. Tublng run on dlscharge may be loo 5. Longer tublng runs may create frlctlonal losses sufllclent to reduce
long. pump's pressure ratlng. Consultlactoryfor mom Informallon.
Fallure to Run 1. Pump not turned on or plugged In. 1. Turn on or plug In pump.
2. EPU fallum. 2. Disassemble pump and measure the resistance ofthe EPU across
the EPU wlres. Reslstanca readlng should be In accordance to the
table (See Sectlon 11.0). Also check EPU leadsto ground. Consult
suppller or faclory.
3. Pulser fallure. 3. The ulser should be replaced It EPU checks out OK. Consun
- 1 f'
supp Ier or factory.
Excessive Pump Output 1. S honlng (Pumplng downhlll wlthout 1. Move lnjectlon palnt to a pressurized locatlon or install an LMI 4-FV.
a%). ' (See Sectlon 4.4)
2. LHlle or no pressure at lnlealon polnl. 2. n pressure at lnjenlon polnt Is less lhan 25 psl, an LMI 4-FV should
be lnslalled. (See Sectlon 4.4)
3. Ex~855lvestrokes per mlnule. 3. Replace pulser or reslstor. Consult factory.
7
Doc No.
DOSIN-G UNIT' Ch~t19

Rev. NO.
Date
Paoe $t
11.0 EPU RESISTANCE CHART
Voltsge Coll Resistance (Ohms

@ 200~(68*F)
115 VAC -
63 73
230 VAC 260-300
115 VAC -
124 143
230 VAC -
481 554
12 VDC 1.0-1.2
115 VAC 25.7- 29.6

230 VAC 97- 112
115 VAC 43-49

230 VAC 167- 193
115 VAC -
22.8 26.2
230 VAC 91 - 105
115 VAC -
14.4 16.6
230 VAC -
57.7 66.3
EPU checked within 10hoursof operation

can increase coil resistance reading as
moth as 20%
Doc No.
DOSING UNIT mot l9

Re,
Date
NO.
Paae );b
Series A7 Instruction Supplement

Metering Pump Component Dlagram
Drive Assembly Exploded Vlew Dlagram
Drive Assembly Parts Ust
Control Panel Oetall
Wiring Dlagrain
Metering Pump Component Diagram
DISCHARGE TUBING
COUPUNG NU
-- Doc No.
DOSING UNIT 2;;.
Date
SUCTION TUBING STRAIGHTENER

Model No. 32293
Aids in maintaining optimum pump perfor- Helps prevent loss of prime
mance by keeping the suction tubing and
foot valve straight. Makes priming easy
For use with all LMI suction tubing sizes

(114" 318" and 112" and recommended
.a
Constructed of polyethylene. Resistant to
wide variety of solutions.
metric tubing sizes).
- Four piece modular construction for ad-
Simplicity of design for easy assembly and justable length.
installation.
INSTALLATION 5. A minimum of 6" (152 mm) of suction tubing
should exit the tubing suaightener at the top so the
1. Install foot valve on the end of the suction tubing connection can be made at the suction fitting on the
included with pump. S w Liquid Handling Assembly pump head Fig. 2) according to the insmctions on
shwt for complete insuuctions. the Liquid Handling Assembly sheet.
2. Determine and cut length of suction tubing 6. Install foot valve. tubing and tubing smightener
required for application (maximum suction lift must assembly into solution tank and attach tubing to
not exceed 5 feet [ISrn]). suction fitting on pump head (Fig. 2).
Note: The bottom of the foot valve should be at

least 2 inches (5Imrn) above the bonom of the
solution tank for sediment accumulation if tank or SUCTION
drum is MC changedregularly. TUBING-
6 152mn
MdIMuM
3. Assemble tubing smightener by interlocking
alternate black and yellow tubes (Fig. 1). Adjust
tubing smightener Length by equally forcing one
black tube inside one yellow tube. Twist the tubes in SUCTION
opposite directions to lock into place. (Maximum TUBING
tubing straightener height must not exceed 33 inches STRAIGHTENER
ASSEMBLY
(.8 m) fullv assembled.)
FOR
F TlON
V ANGLE CUT ALLOWS
4. Slide the tubing straightener over the suction SOLUTION TO DRAIN
tubing @lack tube first) so the black inner tube WHEN REMOVING
contacts the top of the foot valve coupling nut FOOT VALVE FROM
SOLUTION TANK
(Fig. 2).
Series A7 Drive Assembly Exploded View Diagram
Series A7 Drive Assemblv Parts List
Series A7 Control Panel Detail Series A7 Wiring Diagram
- STROKEUGtn
DATA RATE
-- Doc No.
/ L I-
DOSING UNIT Clot 19

No,,
Date
Paoe '57
Electromagnetic Dry Diaphragm

~djustableStroke Frequency
~djustableStroke Length
Max. Output to 7.57 'In
Max. Pressure to 17 Bar
Series A7 Proportional
(Instmment Responsive)
All A7 Series dosing pumps offer
the versatility of a selector switch Unique
for either automatic external Features
trigger control or manual control.
Clog resistant injection check
In external trigger mode, they may valves with flexible flapper nozzle
connect with LMI Micropace' Totally Enclosed
devices for 4-20 milliampere input are standard. CorrosionResistant 1 P 6 5
signal, pulse divide, pulse multiply LMl's unique 4-Function Valve or
or remote pulse frequency adjust- multi-functionAuto-Bleed Valve 0-Ring sealed corrosion resistant
are low cost options. enclosure of glass fiber reinforced
ment with digital display.
polypropylene protects the pump
An automatic low chemical level from harsh chemicals and tough
switch off and indicator light is environments.
standard. Complete
Electronic controls and circuitry
with Accessories are fully and permanently encap-
LMI A7 dosing pumps come sulated tor the utmost in corrosion
Wide Variety complete with Injection Check ~rotection.
of Applications Valve. Foot Valve and Suction
Pump head and valves in PVC. Tubing Straightener.
Polypropylene or PVDF plus Most models are also available Rugged
designs for high viscosity polymer with factory tubing. Construction
or abrasive slurries.
~ ~
Valve balls of ceramic seating On Thick wall glass fiber or cabon

Potyprelmor PTFE. fiber reinforced thermoolastic
~~ ~
construction plus integiated

Composite pump diaphragms of metal-plastic structural and
PTFE or the superior Fluorofitmm magnetic components result in
assure reliable and leak free vibration and shock resistance not
operation in a wide valiety of ordinarily found in competitive
chemicals. products.
Strong automotive type wire and
electrical connectors add to its
construction strength.
:. / .
- i . :.a
I
.
Doc No.
DOSING UNIT !Date paue52
Specifications
Dimensions
LlqUld EndlHead Model Numbers
4.Funaion Valve Option 161M. 162M- 168M

191M - I W M - l98M
Maximum pump pressure rating is reduced by 25 psi (1.7 bar) with
back pressure spring inslalled.
Do not remove back pressure spring I f pressure at injection point
i s less than 20 p s i (1.4 bar).
Threaded connections inlo pump head are V4"-16 straight threads.

Do not use Teflon tape. These joints are sealed by seal ring valve
seats (item 5 on exploded view).
r DOSING UNIT
.-
Ooc No.
.!9
2-c-
7
pa~e5J
Maxlmvm p ~ penure p raung k redwsd by 25 prl(1.7 bar) wih

bask perwm WE inr8lled.
Do no1remove back proarum apdnp If prerure at InjosUon p l n l
Is l a w lhrn 20 pd (1Abw).
'Optional extra
( )Quanlilies with Optional part no.'s 10634 8 26227
SPARE PARTS KITS
For LE-157, order SP-157 which includes:

4 ea. I0659 Ball. S.S.
4 ea. 10407 ~ e aRing.
i Tellon
1 ea. 26042 Liquilram
Doc No.
DOSING UNIT ,,
C b f l9
Date
Paoe 55
DOSING TANK
Volume Diameter Height

litre mm mm
DKl00 100 450 750

Material: Blue polythene
Bottom drainage: R 314" inner

LE-150 LE-151 LE-152
LIQUID HANDLING ASSEMBLIES
CAUTION
When pumplng chemkais make oertaln that all lublng is securely anached lo the linings. It Is recommended that tublng
or plpe lines be shlelded lo prevent posslble Injury$ case of rupture or aocldentat damage. Ahvays wear protecllve
cbthlng when wohlng on or near cherrlcal meterlng pump.
NOTE: See paas IIsf for rnalerlals of consirucllon
A. INSTALUNG INJECTION CHECK VALVE 7. Follow the same procedure lor connecting lubing
1. The injedion check valve should always be in- to injection valve.
stalled as close as mssible to the mint of chernical
iniection, at the very end of the tuding nm. C. CONNECTING SUCTION TUBING
2. Purpose of injection check valve is to prevent 1. Cut suction tubing to a length that the foot
backllow from treated line. vahe hangs just above the bottom of the chemical
3. A 1 l T NPT female fining with sufficient depth will container. Maximum recommended vertical suction
accept the injection check valve. lilt is 5 It. (1.5m).
, 4. To insure correct seating of the ball inside the 2. Follow same procedure (see B) in connecting
check valve. the injection check valve must be in- suction tubing to suction valve and loot valve.
stalled vertically upwards.
D. PRIMING
B. CONNECTlNG DISCHARGE TUBlNG 1. Temporarily remove tubing lrom injection check
NOTE: Cut tubing to length neededfor discharge valve and hold the end ol tubing so it is above the
line^ level of the pump.
1. Route tubing from injection check valve lo chemi- 2. Set pump at 80% speed and 100% stroke. Slart
cal metering pump making sure it does not touch hot pump.
surfaces, sharp surfaces, or is bent so sharply that it 3. As swn as chemical is visible through lranslucent
kinks. discharge tubing, just past lhe discharge valve, stop
2. Slide small end of coupling nut onlo tubing. pump.
3. SI de the long, straight end of the lermleinlo 4. Pump is now primed.
t ~ b ~ such
n g that tubina- exns at the coneshaoed end 5. Reconnm tubing to injection check valve.
of t h e f e r ~ l e .
4. Insert tubing into discharge valve housing so thal NOTE:
tubing butts up against valve housing and will rot go (a) Pump is normally self-primingif suction liH is no
any further. more than 5 H. (1.5m). valves in fhepump are wet
5. Slide fenule down so that cone shaped end fas with wafer (pomp is shipped lrom lacto~ywith water
snugly into discharge valve housing. in pump head) and the above sfeps (Dl thn, D5) are
6. Slide down the coupling nut until threads are lollowed.
engaged. lighten cwpling nut by hand, maintaining (b) I1the pump does no! sell-prime, remove dis-
pressure on tubing towards valve housing until charge valve housing and ball andpour water or
tubing is held securely in place. chem~cal slowly inlo dscharge pon unrd head SI
- ~p
!;/led. Follow sreps D 1 lhru 0 5 rhereater.
Excessive force will crack or dlstorl littlngs. DO
NOT USE PIPE WRENCH.
.
.i
, ..,Fb~
-
Doc No.
DOSIN-G UNIT !
Date
paue57
THIS SHEET USTS PARTS FOR THREE DIFFERENT LIQUID HANDLING ASSEM-
BLIES. BE SURE YOU ARE USING THE CORRECT PARTS LIST FOR YOUR
PUMP. THE uaum HANDLING ASSEMBLY NUMBER IS THE LAST THREE
DIGITS OF YOUR PUMP MODEL NUMBER.
-
Pans included in Spare Pads Kil SP-U8

., ,
i ;j
Ooc No.
DOSING UNIT [hot
.,NO
Oate
19 Paoe 58
4.5 4-FV Installation

To install the 4FV, remove the yellow screw cap on
the top of the pump head and screw in the 4-FV so that
the valve contacts the seal ring. An additional 118 -
114 turn may be necessary to prevent leakage. DO
NOT OVERTIGHTEN.Overtightening can cause
fittings and seal rings to distort, crack and function
improperly.
114" O.D. tubing connects to the side of the 4-FVand
acts as a retum line to the solution tank. This tubing
must NOT be submerged in the solution.
A WARNING: This return line tubing must be secured

to insure pumped solution will return to supply tank
4-FV Tubing Connection

114'Tubhg 7
V ~ottwn~ubinp TO
To In Rttlng Pump Head
Solution Tak Push and hold whik
uDNm tlgMenln0 .-
4.6 Foot Valve/Suction Tubing Straightener

Installation
The Foot Valve acts as a check valve to keep the pump
primed in suction lift applicaaons.
The valve js designed to be submersed in the solution
tank or drum and must sit in a vertical position at the
bottom. Position approximately 2 inches (50 mm) off
the bottom if the tank or drum contains sediment.
'L39
1- Doc No.
DOSING UNIT ,,
Ch~tl9
Date
Paoe
- -
4.4 Four Function Valve (4-FV)

Some pumpmodels come supplied with a 4-FV (pump
models which end in "Mor"S"). If your pump is not
equipped with this feature, and you feel it is needed in
your application, it can be purchased as an accessory.
Contactyourlocaldistributorfororderinginfomation
'Ihe functions of the 4-FV are:
1. Anti-Syphon (automatic).
Prevents syphoning when pumping downhill or
into a vacuum.
2. Back Pressure (automatic).
Supplies approximately 25 psi back pressure to
prevent over pumping when little or no system
back pressure is present.
3. Pressure Relief (automatic).
Lf discharge line is overpressurized,-the valve
opens sending the solution back to your supply
tank.
4. Line Depressurization (manual).
By pulling both knobs, the discharge line will
drain back to your supply tank.
Typical 4-FV Applications -, cG7-How

doc NO.
DOSING UNIT WDate
4283 Suction - Shelf Mount

The pump may be mounted on a shelf (customer
supplied) maintaining a suction lift of less than
5 feet (15 m). AnLMImountingkit @artnumber
10461) is available for securing the pump to a
shelf.
4.3 Tubing Connections
A A. Use only LMl tubing.

B. DO NOT USE CLEAR vmn T W ~ G ON
THE DISCHARGE SIDE OF THE PUMP.
The pressure created by the pump can rupture the
vinyl tubing.
- - Doc No.
2l'*
DOSING UNIT ZV=

Date
4.281 Suction Lift - Wall Bracket Mount

The pump may be mounted using an LMI Wall
Mount BracketAssembly @artno. 28272) cti~ctly
above the solution tank. A pump mounted in this
mannerallows for easy changing of solution tanks
or chums.
I DRAWING PART LIST
I
1 Aalborg Sunrod A0 Telephone +46-8580-24300
I Box 907 Telefax +46-8580-27801
I 175 29 J a r f a l l a Telex 19268 SUNRM) S
I Sweden

- - -
Product: 00021 SPARE PARTS FOR CPH BOILER Drauing:
Pos. A r t i c l e Qty Function Type Press Dim Weight Drawing

Data
7400750 1 pcs PRESSURE GAUGE SUFI6030 8SP318" 0.60 1
Range 0-16 kgf/crn2

Diameter 160m
7500969 1 pcs SPRING FOR SAFETY VALVE
Range 09.10-13.90 bar
SO3 7500226 1 pcs FEED UATER CHECK VALVE AJ1140 PN40 DN65 22.70 1
SO4 7400686 2 pcs WATER GAUGE GLASS 17/215LGLAS
Size 14
500*34*17mn
Gasket i n c l .
Reflexion type
SO5 0844397 1 pcs SWT LANCE
( :1
SO6 0845422 1 pcs FURNACE INSPECTION GLASS PYREX 83 X 6.0 0.07 1
SO7 0843938 2 pcs MANHOLE CASKET
SO8 0843948 8 pcs HANDHOLE GASKET DNR2448.15 P40 DNlOO 0.44 1
510 0844718 10 m HOSE FOR SWT LANCE 2102-0025 PNlO 1" 1.00 1
SlOA 0844717 2 ~ c CLAMP

s FOR HOSE
S11 0844787 4 pcs PLUGG FOR PINELEMENT

DRAWING PART LIST

Product: DO021 SPARE PARTS FOR CPH BOILER Drauing: ( continued )
Pas. A r t i c l e Qty Function Type Press Dim Ueight Drauing

Data
S99 0844415 1 pcs SPARE PART BOX 380 X 160 X 190 0.00 1
I DRAWING PART LIST
I
I Aalborg Sunrod AS Telephone +46-8580-24300
I Box 907 Telefax +46-8580-27801
I 175 29 J a r f i l l a Telex 19268 SUNROO S
I Sueden

H u l l no.: S-226 System name: 2 X CPH-18 T I H Class: ONV
Product: 00022 SPARE FOR STEAM. ATOM ERN Drawing:
Pos. A r t i c l e aty Function Type Press Dim Weight Drawing

Data
,<) S23 7000010 2 pcs PHOTOCELL 2-0001115 0.00 1
S38 7000010 2 pcs BURNER GUN 2-0001115 0.00 1
4
1 S39 7000010 2 pcs BURNER NOZZLE 2-0001115 0.00 1
S40 7000010 2 pcs SPANNER FOR CAP NUT 2-0001115 0.00 1

DRAUlNG PART LIST
Aalborg Sunrod AB Telephone +46-8580-24300

Box 907 Telefax +46-8580-27801
175 29 J l r f l l l a Telex 19268 SUNRW S
Sueden
Project: 11-417 Name: HALLA LAURIN Revision: .

H u l l no.: 5-226 System name: 2 X CPH-18 T I H Class: ONV
Product: 00023 SPARE FOR FD FAN STEM ATOM ERN Drawing: 1
Pos. A r t i c l e Oty Function Type Press Dim Ueight Drawing

Data
OOFLAKT 1 pcs BEARING FD FAN MOTOR D-END 3-9824954 0.00 1
S44A OOFLAKT 1 LKS BEARING FD FAN MOTOR N-END 3-9824954 0.00

I DRAUlNG PART LIST
I
I A a l b o r g Sunrod AB Telephone +46-8580-24300 96-09-24
I Box 907 Telefax +46-8580-27801
1 Sueden
I

Hull no.: S-226 System name: 2 X CPH-18 T I H Class: DNV
P r o d u c t : 00024 SPARE FOR OIL SUPPLY Drauing:

- - --
Pos. A r t i c l e aty Function Type P r e s s Dim ueight Drawing

Data
, ,S35 7200140 1 p c s STRAINER BASKET Strainer 4.00 1
I '
S36 7200139 1 p c s BEARING FOR FO PUMP MOTOR D-END Bearing
I
) S36A OOTOREL 1 pcs BEARING FOR FO PUMP MOTOR N-END 3-7004526
S37 0845663 1 p c s SPRING FOR SAFETY VALVE FO HEATER T000134/SPRlNG
Range 23.1-36.9 bar

I ORAUING PART LIST
I
1 Box 907 Telefax +46-8580-27801
I 175 29 JSrfSlLa Telex 19268 SUNROO s
I Sueden

H u l l no.: S-226 System name: 2 X CPH-18 T / H Class: DNV
Product: 00025 SPARE FOR CONTROL PANEL Drawing:
Pos. A r t i c l e Oty Function Type Press Dim Ueight Drauing

Data
1 pcs RELAY RELAY 0.30 1
S29A OOSES 1 pcs RELAY 3-5636709 0.00
) $298 OOSES 1 pcs RELAY 3-5636709 0.00

\
S29C OOSES 1 pcs AUX. CONTACT 3-5636709 0.00
S29D OOSES 1 pcs AUX. CONTACT 3-5636709 0.00
S29E OOSES 1 pcs AUX. CONTACT 3-5636709 0.00
1 pcs SEQUENSE PROGRAM RELAY LAE1/8865 2.00 1
S49A OOSES 1 pcs FLAME SCANNER 3-5636709 0.00
i,1
1 DRAWING PART LlST
I
I Aalborg Sunrod A6 Telephone +46-8580-24300 96-09-24
t Box 907 Telefax +46-8580-27801
I 175 29 JirfaLLa Telex 19268 SUNRW S
I Sweden
I

Hull no.: 5-226 System name: 2 X CPH-18 T/H CLass: DNV
- ~- - ~
Product: 00026 SPARE PART FOR IGNITER STEAM ATOM.BRN Drawing:
Pos. A r t i c l e Qty Function we Press D i m Weight Drawing

Data
(- 7 SlOO 7100033 1 pcs IGNITION TRANSFORMER 091315/52L0003 0.50 1
I
Power 22OV/10 OOOV
SlOl 7100009 1 pcs SOLENOID VALVE 091912 PN25 BSP1/4" 0.30 1
S102 7100032 1 pcs NOZZLE FOR IGNITER 094036 3.0-458 0.05 1
S103 7100025 2 pcs IGNITION ELECTRWES 091408 0.40 1
S104 7100026 2 m HIGH VOLTAGE CABLE

MWNTEO ON SlO3
S105 7100024 2 pcs RAJAH PLUGG

MWNTED ON S103

M48 Aux Boiler Burner Nut 2-2

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Book Chapter Description Page No. IDIW No.

1 I Boiler commissioning documents

2 Technical data for Boiler, Burner

3 List of equipment and drawings

4 Boiler description and instruction 1-33

1 5 Water level control instruction 1-6

1 6 Burner and oil supplly operation instruction 1-12

Book Chapter Description Page No. IDrw No.

Boiler main accessories

Book Chapter Description Page No. I Drw No.

Control panel instruments

Water level control system

Book Chapter Description Page No. IDtw No.

2 18 Heaters for pump units

CLIENT: AALBORG SUNROD AB, SWEDEN

SITE: HALLA HULL S226

CLIENTS ORDER NO: 911417-75500

CONTRACT NO: 3707548

DELIVERY DATE: NOVEMBER 1995

(,:1 drawn to the sections oovering safeh/:

CONTRACT NO. 3 7 0 7 5 4 8 DATE: NOVEMBER 1995

FUEL FIRING EQUIPMENT

WATER TUBE BOILER

HALLA HULL S 226

AAL.BORG SUNROD NO. 911417-75500

1.0 ATOMISING STEAM OIL VALVES AND FITTINGS

The principle components listed below have been supplied:

2 - Sets valves and instruments, each complete with:-

2.0 HAMWORTHY 6-VALVE PURGE UNIT

2 - Hamworthy 6-valve purge units, each supplied complete with:-

For further information on the purge unit operating principles, see

!,3 3.0 HAMWORTHY DF455 STEAM ATOMISED FUEL OIL BURNER

The principle components listed below have been supplied to be

3.1 2 - Hamorthy DF455 oil burners each supplied complete with:-

2 - Swivel mountings for flame detector heads.

Principle burner assembly dimensions can be seen on burner general

SPARE PARTS SCHEDULE

2 - Atomiser tip. Tag no. S39.

2 - Steam atomising sprayer. Tag no. 538.

2 - RARB photocell. Tag no. S23.

2 - Cap nut spanner. Tag no. S40.

HAMWORTHY COMBUSTION SYSTEMS

BURNER PRODUCTS SAFETY NOTE

General scope of amendment

It is essential to ensure. prior to commissioning. that all fuel control

The initial fuel flow adjustments necessary in order to provide light up

The relationship of fuel throughput and input

SDrav Characteristics (Spray A n ~ l eetc.1

Combustion Air Recister

a) Calibration The amount of air determined as that necessarj

Mixing Enerpy The register draught loss (R.D.L.) dete.rmines the

Flame Shaue The primary air therefore provides the major

1.3 DF Burner Desian

a) General Notes A practical burner design must therefore take

Environmental factors are mainly ones of furnace

The DF burner has been designed and developed

b) DF Burner Design Fia. No. 1

Combustion air enters the register from the

The swirl component of the secondary air can be

The internal division of the air flow enables

The flow dividing ring also has the effect of

THE COMBUSTION EQUIPMENT W O R T H Y DF REGISTER