CONTENTS

1. DESIGN DATA

2. DRWINGS

3. ACCESSORIES

4. CONTROL PANEL

5. SPARE PART

6. OPERATION MANUAL

7. PART DOCUMENTAIION

*NOTE
If we may be of further assistance, please do not hesitate to contact Mr. Ho Gon, Kim at 82-55-269-7739.

PLAN HISTORY

0 2022.11.07 FOR FINAL [Link] [Link] [Link]

REV. DATE DESCRIPTION PREPARED CHECKED APPROVED

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 DESIGN DATA

1. DESIGN DATA

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 DESIGN DATA

LIST OF DESIGN DATA

NO DRAWING NO. TITLE REV.

1 Technical data 0

2 Information table of instrument 0

3 General installation guide 0

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 DESIGN DATA

TECHNICAL DATA

1. Design data
Nominal capacity 3,000 Nm3/hr
Normal oxygen content 0.5~1.0 % by vol.
Gas composition by volume at O2 = 1.0 % by volume
SO2 Max. 10 ppm
CO Max. 1000 ppm
CO2 Approx. 15 % by vol.
N2 Balance
Soot Bacharach 0
Sea water Inlet temperature(for cargo cooling) Max 32 °C
Inert gas will be vented automatically and visual / audible alarm indicates each
equation locally and in the cargo control room.
It is possible to stop I.G.G from the cargo control room.
Fresh water flush to be provided for rinsing of the combustion chamber after use.
use

2. Refrigeration & cooling plant

A unit comprise a compressor with condenser including receiver, evaporator and
all accessories mounted on a common base frame into one unit including internal pipi
and wiring.
An inert gas cooler on a independent base frame shall be installed in separate.
After connection to inert gas duct, cooling water and power supply, and charging of oil
and refrigerant the unit is ready for commissioning.
Primary refrigerant R-407C
Secondary refrigerant 80% / 20%, Water/ Ethylene glycol

Gas outlet temperature 5 °C

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 DESIGN DATA
3. Inert gas/air dryer
The inert gas dryer is designed for continuous operation by means of one drying vessel
While one side rotor is in operation and dries incoming inert gas / air, the other side ro
is being regenerated.
Both rotor sides are filled with desiccant which has the physical property to absorb wat
vapour from inert gas/air.
The dryer unit is equipped with regenerative heaters.
Adsorption material Silica gel
Gas outlet dew point (At atmospheric) -40 ˚C

4. Consumption
1) Fuel oil (Inert gas at 0.5% by volume O2 by combustion of ambient air)
Capacity 272 kg/hr
Without preheating MGO&MDO use.
2) Sea water for scrubber
Capacity 255 m3/hr
Pressure at scrubber inlet 2 bar·G
3) Fresh water for condenser
Capacity 59 m3/hr
Pressure 1.5 bar·G
4) Fresh water for scrubber
Application Rinsing & Combusion air cooling

Consumption (For 15 minutes) 5 m3/hr

5) Fresh water for blower
Application Blower H2O injection

Consumption 0.06 Nm3/hr

6) Instrument air at 7 ~ 9 barㆍG
Control system (In balance) 5 Nm3/hr
Ignition burner 0.3 ~ 0.4 Nm3/hr

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 DESIGN DATA
7) El Power 3 Phase, 440V, 60Hz Rated power
EL motor, 100 % blower 63 x 2 kW
EL motor, F.O pump 1.7 x 2 kW
EL motor, R-407C compressor 123.1 kW
EL motor, Dryer fan 6.3 kW
EL motor, Dryer rotor 0.12 kW
EL motor, Chller water circulation pump 4.8 kW
EL Heater, Regeneration 50 kW

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 DESIGN DATA

Information table of instruments

Meas.
No. Item Unit Part No. SetPoint Location
Range

Pressure switch
1 bar 0~6 1810 (0.5) Scrubber
for cooling jacket sea water low
Pressure switch
2 bar 1~10 1830 (5) Scrubber
for instrument air low
Pressure switch
3 bar 0~6 1840 (0.7) Scrubber
for scrubber sea water low
Temperature transmitter for Inert
4 °C 0~100 1880 60 Scrubber
gas temperature high
Temperature switch for Inert gas
5 °C 0~100 1885 65 Scrubber
temperature high high
Pressure switch
6 bar 4~40 1850 10 Scrubber
for fuel oil press low
Temperature switch
7 °C 20~150 1910 55 Scrubber
for cooling jacket sea water high

8 High level switch for scrubber - - 1930 - Scrubber

Pressure switch
9 bar - 1960 0.1 Scrubber
for combustion air press low
Temperature transmitter for
10 °C 0~100 2020 80 Yard pipe
regeneration gas temperature high
Pressure transmitter
11 mmAq - 3120 5000 Cooler
for cooler inter gas pressrue high
Control panel inside temperature
12 °C 0~90 4001 50 Panel
high
Temperature transmitter for dryer H = 150
13 °C - 4120
HH = 165
Dryer
regeneration gas tamp. H / HH
Temperature switch for heating
H = 170
14 element temperature high / high °C - 4310/20
HH = 240
Dryer
high
H = 1.5
15 O2 Analyzer high/low % - 7000
L = 0.1
O2analyzer

16 O2 Analyzer high high % - 7000 2.5 O2analyzer

Dewpoint meter
17 °C - 8000 -35 Yard pipe
for Inert gas dryer dewpoint high

* NOTE : ( ) ~ PRESETTED. IT SHOULD BE ADJUSTED BY COMMISSIONING.

** NOTE : REGARDING THE ALARM & SAFETY TABLE, PLEASE SEE PART4-CONTROL PANEL.

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 INSTALLATION GUIDE

1. Storage
If the Scrubber, Dryer and Cooler etc. is to be stored for a period before it is
mounted in the ship, it is very important that the Scrubber, Dryer and Cooler etc.
is covered with a protection cover and stored in an indoor store room.
This is to protect the Scrubber, Dryer and Cooler etc. against corrosion caused by
rain/snow or pollution.

The following is recommended as storage condition.

- Store in a clean, dry place and in a storage room against direct sunlight.
- Store in a dust-free and moist less place.
- Keep away from shocking environment.

2. General
2.1 No welding to be permitted on the equipment as it might damage the interal coating.
2.2 All piping connected equipment should be tension free.
2.3 Seawater pipes must be protected against corrosion.
2.4 The seawater supply pressure should remain as contant as possible(±20%)
If seawater pressure varies with ship draft, the seawater pressure must be adjusted
by throttling the seawater discharge valve or other equipment.
2.5 In order to prevent clogging of the water spray nozzle of Scrubber, provide strainer
(filtered to 5 mm) on water supply line and any foreigh material and other dust in
seawater can damage interal coating of scrubber or corrde interal such as
demister etc.
2.6 Supply air for the pnematic control equipment to be dry and oil free otherwise the
oil mist seperator to be provided.
2.7 Before and after commissioning, Checks should be made for corrosion attacks,
fouling and damage to :
- Scrubber internal surface
- Cooling water pipe and spray nozzles (fouling)
- Other internals such as trays and demister filters

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 INSTALLATION GUIDE

2.8 Before initial operating, make sure the pipelines are clean. Any foreign material
such as pipe scale, metal chips, welding slag, welding rods, etc., can damage
internal coating of scrubber or corrode internals such as demister etc.
2.9 Inert gas system power should be on before operating the equipment connected or
related with inert gas system. Otherwise, it's vulnerable to accidents as safety device
to protect the equipment is not working. For example, Scrubber will be damaged
due to vacuum in case that the scrubber seawater pump is working while the inert
gas system power is off.
2.10 Main gas line should remain at same level, traps to be avoided. Branch from
topside of main gas line to avoid collection of condensate.
2.11 Do not use the gasket for butterfly valve connection point.

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 INSTALLATION GUIDE

3. Fuel oil pump

3.1 Fuel oil pump should be installed at bottom level of fuel oil tank
(Because max suction head of pump is -0.6bar)
3.2 Fuel used to be DMA, DMB or DMZ according ISO 8217.

4. Combustion air blower

4.1 The blowers should be arranged close to the generator in order to minimize the
pressure loss.
4.2 All bending(or elbow) and connections as smooth as possible should be installed.
4.3 Interconnection piping to the equipment supplied must be made tension free.
4.4 Fresh water injection nozzle unit for No.2 blower should be installed by shipyard.
4.5 The blowers should be mounted directly on a flat floor.
4.6 The suitable cable support to be installed for motor wiring.

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 INSTALLATION GUIDE

5. Seawater supply of inert gas generator

5.1 A filter with mesh size of 5mm has to present, general or especially for D-IGG
5.2 Additives are not allowed to be added to the seawater to prevent marine growth
/antifouling.
5.3 An alternatives supply of cooling water to the inert gas generator is to be provided
in accordance with IMO rule.
5.4 Seawater inlet valve(0050) should be throttled in case of use of non dedicated
seawater supply pump for the generator.
5.5 Required supply pressure has to be 1.5~2.5barg.

6. Water discharge of inert gas generator

6.1 The outlet flange of scrubber should be at least 4 meters above maximum load water
line.
6.2 Pressure transmitter (Part No. 2120) should be mounted minimum 7 meters below
seawater outlet flange of scrubber.
6.3 Boss of pressure transmitter (Part No. 2120) should be mounted maximum 1 meter
above level control valve (Part No. 0220).
6.4 Effluent control valve (Part No. 0220) to be mounted under same angle as effluent
water seal(minmum slope 15 degree)
6.5 Effluent control valve (Part No. 0220) should be at least 0.5 meters under light ship
water line.

____________________________________
6.6 The bilge drain line should be connected near effluent control valve (Part No. 0220).
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 INSTALLATION GUIDE

7. Condensate discharge piping

7.1 Traps to be avoided in all gas piping to avoid collection of condensate.
7.2 Install drain lines with drain valve on lowest point of gas piping were condensate may
be collected.
7.3 All drain lines should be installed under a minimum slope of 15 degree to discharge
fluids without resistance during all regular movements of the vessel.

8. Cooler condenste discharge

8.1 U-seal height has minimum 7 meter.

8.2 Height between vent and base of cooler has minimum 2 meters.
8.3 Height between U-seal top and base of cooler has minimum 1 meter.
8.4 U-seal top should be installed above maximum load water line 2 meters.
Cock valve to check the water filling condition of U-seal should be mounted 0.05~0.1
below position of U-seal top. If access to the cock valve is difficult, the valve should be
installed in an accessible location by extending the tubing line.
8.5 The drain valve must be installed to remove foreign substances in the U-seal.

____________________________________
8.6 Condensate water drain should be connected to bilge holding tank or sea.
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 INSTALLATION GUIDE

9. Inert Gas Dryer

9.1 The regeneration line and scrubber outlet line should be arranged with "Y" branch
connection as smooth as possible.
9.2 The dryer should be mounted directly on a flat floor.

10. Chiller unit

10.1 Use spread beams or similar to ensure a safe lifting operating.

10.2 Care must be taken to avoid inpurities to enter the pipe system prior to and during
installation.
10.3 Chilled water piping insulating is necessary when the ambient temperature is higher
than that of the chilled water.

11. Chilled water piping

11.1 The interconnecting piping between chiller unit and IG cooler should have vent valve
at highest point of piping for venting purposes.
11.2 The interconnecting piping between expansion tank should chiller unit should be as
vertical as possible, however if horizontal piping is necessary, it should have a slope
of at least 30°.
11.3 The expansion tank should be installed higher than the chilled water pump.

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 INSTALLATION GUIDE

12. Differential pressure transmitter

12.1 The straight pipe at minimum 2D should be maintained on the upstream of the flow
conditioner (Part No.2810).
12.2 The straight pipe at minimum 8D should be maintained between flow conditioner
and flow meter (Part No.2800).
12.3 The straight pipe at minimum 5D should be maintained on the downstream of the flow
meter (Part No.2800).
12.4 Do not install internally attachments that any affect gas flow in the straight pipe area.

13. Chilled water pump

13.1 Chilled water pump should be installed considering the NPSHr of 6.72mLC.

14. Non Return Valve

14.1 Non return valves used for IG will be of flap type and must be installed in piping
longitudinal to the ship.
14.2 Non return valve is stainless steel. Be careful do not expose carbon dust.
It should be installed immediately after open the packing.

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 DRAWINGS

2. DRAWINGS

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 DRAWING

LIST OF DRAWING

NO DRAWING NO. TITLE REV.

1 - Symbol Table 0

2 GG-PI-01 Flow Diagram for Inert Gas Generator 0

3 GG-SC-01 General Arrangement for Scrubber 0

4 GG-CD-01 General Arrangement for Cooler & Dryer 0

5 GU-PID-01 P&I Diagram for Chiller Unit 0

6 GG-CU-01 General Arrangement for Chiller Unit 0

7 GG-ET-01 Expansion Tank for Chilled Water 0

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 ACCESSORIES

3. ACCESSORIES

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 ACCESSORIES

PART LIST OF ACCESSORIES

PART NO. DRAWING NO. TITLE TYPE/SPEC. QT'y

<Mounting List >

[Link]

0050 GG-0050 Sea water inlet valve JIS 10K-200A 1

0230 GG-0230 F.O control valve 3/4" 1

0301 GG-0301 Rinsing valve JIS 5K-25A 1

0321/2 Valve for sight glass 1" 2

0350 Valve for sec. air to burner 1" 1

0430 Valve for instrument air inlet 1/2" 1

0450/60 Valve for sight glass air line 3/8" 2

0500 GG-0500 Valve for sea water to C.J JIS 10K-80A 1

0620 Valve for ignition burner air line 1/4" 1

0840 Flexible oil hose 3/8" 2

0850 Flexible oil hose 1/4" 1

0860 Oil nozzle main burner 500 Kg/h 1

0870 Ignition burner 1

0880 Oil nozzle ignition burner 9/16"

0890 Ignition glow plug M14 1

0900/10 Sight glass 2

1140 Sight glass for inspection 1

1170 Sea water spray nozzle 12

1300 Wet-filter section for scrubber 1

1310 Demister section for scrubber 1

1405 Pressure gauge 1/4" 1

1500 GG-1530 Valve for fresh water spray 1/2" 1

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 ACCESSORIES

PART LIST OF ACCESSORIES

PART NO. DRAWING NO. TITLE TYPE/SPEC. QT'y

<Mounting List >

1520 Solenoid valve for pilot air 1/4" 1

1530 GG-1530 Valve for fuel oil return 1/2" 1

1560 GG-1530 Ball valve for fuel oil to burner 1/2" 1

1570 Solenoid valve for main gun air 1/4" 1

1580/81 Solenoid valve for pilot oil 1/4" 2

1640 GG-PI-01 Pressure gauge 1/4" 1

1750 GG-TI-01 Thermometer 1/2" 1

1780 GG-TI-01 Thermometer 1/2" 1

1790 GG-TI-01 Thermometer 1/2" 1

1840 GG-PS-01 Pressure switch 3/8" 1

1880 GG-1880 Temp. transmitter 1/2" 1

1885 GG-1885 Temperature switch 1/2" 1

1910 GG-1885 Temperature switch 1/2" 1

1930 GG1930 Level switch 1

2000 Burner flame eye 1

2010 Burner flame eye 1

- GG-GA-01 Gauge board 1

2140 GG-PT01 Pressure transmitter 1/4" 1

2. Cooler

3110 GG-TT-01 Temperature transmiiter 1/2" 1

3120 GG-PT-01 Pressure transmitter 1/4" 1

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 ACCESSORIES

PART LIST OF ACCESSORIES

PART NO. DRAWING NO. TITLE TYPE/SPEC. QT'y

<Mounting List >

3130 GG-TT-01 Temperature transmiiter 1/2" 1

3210 Fin type cooler JIS 5K-100A 1

3220 Filter - 1

3230 Droplet separator - 1

3510 Sight glass JIS 5K-50A 1

3. Dryer

4010 Manual valve JIS 5K-50A 1

4020 Drain valve 1/2" 1

4110 GG-TT-01 Temperature transmiiter 1/2" 1

4120 GG-TT-01 Temperature transmiiter 1/2" 1

4210 Rotor 1

4220 Rotor motor 1

4230 Filter 1

4300 Electric heater 1

4310 Thermostat - 1

4320 Thermostat - 1

4420 Motor 1

4410 GG-DF-01 Regeneration fan JIS 5K-150A 1

4510 GG-1070 Flexible joint for fan JIS 5K-150A 1

4. Chiller

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 ACCESSORIES

PART LIST OF ACCESSORIES

PART NO. DRAWING NO. TITLE TYPE/SPEC. QT'y

<Loose supply List >

0010 GG-0010 I.G main valve JIS 5K-300A 1

0020 GG-0020 I.G Atmosphere valve JIS 5K-250A 1

0070 GG-0070 Combustion air control valve JIS 5K-300A 1

0100 GG-0100 I.G capacity valve JIS 5K-300A 1

0110 IG-0110 No.2 Blower outlet valve JIS 5K-300A 1

0120 IG-0110 No.2 Blower outlet valve JIS 5K-300A 1

0130 IG-0110 No.2 Blower inlet valve JIS 5K-300A 1

0140 IG-0110 No.1&No.2 Blower isolating valve JIS 5K-300A 1

0170 GG-0170 Valve for drain to bilge JIS 5K-50A 1

0220 GG-0220 Valve for SCR efflunet line JIS 5K-350A 1

20BAR-1/2",
0300 GG-0300 Ball v/v for fresh water injectio 2
A(SINGLE)+S
Globe v/v for fresh water
0301 GG-0300 JIS 5K 25A
injection
0350 GG-0350 Ball v/v for fresh water injectioFEMALE PT1/2" * PT1/2" 1

0640 GG-0640 Non return valve for I.G main JIS 300A 1

0940/90 GG-BS-01 Silencer JIS 5K-300A 2

1010/20 GG-BL-01/02 No.1/2 Blower - 2

1070/80/90 GG-1070 Flexible joint for blower RUBBER, 5K-250A 3

1100/10 GG-1070 Flexible joint for blower JIS 5K-300A 2

1401/02 GG-PI-01 Pressure gauge 1/4" 2

0~1 BAR /
1403 GG-PT-01 Pressure transmitter 1
8477.71.5917.0519
1404 GG-TT-01 Temperature transmitter 1/2" 1
B100Φ * 0~5000mmAq,
1680 GG-PG-01 Pressure gauge 1
PF3/8″
0~1 BAR /
1820 GG-PT-01 Pressure transmitter 1
8477.71.5917.0519
____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 ACCESSORIES

PART LIST OF ACCESSORIES

PART NO. DRAWING NO. TITLE TYPE/SPEC. QT'y

2020 GG-TT-01 Temperature transmitter 1/2" 1

2120 GG-PT-01 Pressure transmitter 1/4" 1

0~1 BAR /
2130 GG-PT-01 Pressure transmitter 1
8477.71.5917.0519
2180 GG-TT-01 Temperature transmitter 1/2" 1

2800 GG-2800 Differential press. transmitter - 1

2810 GG-2810 Orifice 5K-250A 1

3000 GG-DC-01 Cooler & Dryer unit - 1

3010 GG-2910 Chilled water cooler inlet valve JIS 10K-80A 1

3020 GG-2900 Chilled water cooler outlet valve JIS 10K-80A 1

4030 GG-4030 Wet gas manual valve 5K-150A 1

5000 GG-WC-01 Chiller - 1

5060/70 GG-AV-01 Auto venting valve 1/2" 2

5130/40 GG-TI-02 Chilled water temperature 1/2" 2

5200 CC-CP-01 Chiller pump unit JIS 5K-100A 1

5300 - Expansion tank - 1

6000 GG-FO-01 F.O Pump unit - 1

7000 GG-O2-01 O2 Analyzer panel - 1

8000 - Dew point transmitter - 1

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 CONTROL PANEL

4. CONTROL PANEL

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 SPARE PART

5. SPARE PART

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 23(5$7,210$18$/

23(5$7,210$18$/

BBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBB
KANGRIM HEAVY INDUSTRIES CO.,LTD.
 OPERATION MANUAL

Operation Manual

Dry Inert Gas Generator

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

1. General

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

TABLE OF CONTENTS

PAGE
1. GENERAL
1.1 General ----------------------- 7
1.2 Explosive Limits ----------------------- 8
1.3 Dry Inert Gas Generator ----------------------- 9
1.4 Safe Oxygen Levels ----------------------- 9
1.5 Health Hazard with Inert Gas ----------------------- 10
1) Oxygen Dificiency ----------------------- 10
2) Toxicity of Hydrocarbon Vapours ----------------------- 10
3) Inert Gas Toxicity ----------------------- 11
4) Entering a tank for inspection and Repair ----------------------- 11
5) Pump Room Work ----------------------- 12
6) Safety on deck ----------------------- 13
7) Source of Ignition ----------------------- 13
8) Tank Pressure ----------------------- 15
9) Electrostatic Hazards ----------------------- 16
10) Repair of Inert Gas Generating Plant ----------------------- 16

2. MAIN EQUIPMENT
2.1 Dry Inert Gas Generator ----------------------- 19
2.2 Inert Gas Cooler and Dryer System ----------------------- 19
2.3 Refrigeration Plant ----------------------- 19
2.4 Other ----------------------- 20

3. TECHNICAL DESCRIPTION
3.1 Dry Inert Gas Generator ----------------------- 22
3.2 Major Components ----------------------- 24
1) Combustion Air Blower ----------------------- 24
2) Oil Burner ----------------------- 24
3) Ignition Burner ----------------------- 26
4) Fresh Water Injection ----------------------- 27

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

5) Fuel Oil Systems ----------------------- 27

6) Cooling Water System ----------------------- 28
7) Drain System ----------------------- 28
8) Inert Gas Capacity Valve ----------------------- 28
9) Blow Off Valve ----------------------- 29
10) Delivery Valve ----------------------- 29
11) Oxygen Analyzer ----------------------- 29
12) Cooling Unit ----------------------- 29
13) Dryer Unit ----------------------- 30
14) Dryer Fan ----------------------- 30
15) Dew Point Transmitter ----------------------- 31
16) Pressure Transmitter ----------------------- 31
17) Non Retrun Valve ----------------------- 31

4. INSTRUMENTATION AND CONTROL SYSTEM

4.1 Indication Instruments ----------------------- 33
1) Thermometer ----------------------- 33
2) Temperature Indicator ----------------------- 33
3) Pressure Indicator ----------------------- 33
4) Flow Meter ----------------------- 33
5) Analyzer Indicator ----------------------- 34
4.2 Safety Interlocks ----------------------- 34
1) Set Points ----------------------- 34
2) Temperature Switch ----------------------- 34
3) Pressure Switch ----------------------- 34
4) Level Switch ----------------------- 34
5) Oxygen Switch ----------------------- 34
6) The Ignition Transformer ----------------------- 35
7) The Flame Control ----------------------- 35
4.3 Instrumentation and Control Panel ----------------------- 35
1) General ----------------------- 35
2) Main Control Panel ----------------------- 35
3) Oxygen Analyzer and Analyzing ----------------------- 36
4) The Instrument Air ----------------------- 36

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

5. INSTRUCTION FOR PLANT START, OPERATION AND STOP

5.1 HMI Description ----------------------- 38
1) System monitor ----------------------- 38
2) Alarm history ----------------------- 40
3) Commising data ----------------------- 41
4) Plc digital in/output and analog ----------------------- 42
in/output
5) Hour meter ----------------------- 44
6) Data trend ----------------------- 45
7) Parameter ----------------------- 46
8) Time setting ----------------------- 47
9) Engineer setting ----------------------- 48
5.2 Auto operation ----------------------- 50
5.3 Emergency operation ----------------------- 52
5.4 Trouble Shooting ----------------------- 54

6. ADJUSTMENT AND TOLERANCES

6.1 Ajustment and Tolerance ----------------------- 58
1) Oil Burner ----------------------- 58
2) The Combustion Air System ----------------------- 58
3) The Fuel Oil System ----------------------- 58
4) The Gas System ----------------------- 59
5) The Seawater System ----------------------- 59
6) Alignment Combustion Control ----------------------- 59

7. MAINTENANCE
7.1 General ----------------------- 61
7.2 Safety ----------------------- 61
7.3 Routine Manintenance ----------------------- 62
7.4 Inspection Schedules ----------------------- 62
7.5 Maintenance Schedules ----------------------- 65

8. SOM POSSIBLE CAUSES TO FAULTS DURING START AND OPERATION

8.1 If Control Current is not on ----------------------- 70

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

8.2 If ignition Does not Take Place ----------------------- 70

8.3 If Fuel Oil Pressure is too Low ----------------------- 70
8.4 If Sea Water Pressure is too Low ----------------------- 70
8.5 If Sea Water Level in Cooling Tower
----------------------- 70
is to High
8.6 If Inert Gas Temperature is Higher
than Approx. 5°C Above Sea Water ----------------------- 70
Inlet Temp.
8.7 If the Instrument Air Pressure is too
----------------------- 70
Low.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

1. GENERAL
1.1 General
The main reason for the installation of an Inert Gas Generator on board a tankship
is to minimize the danger of fire or explosion in cargo tanks. This danger always
exists, due to the fact that all three elements needed to start a fire or an explosion
will be present.
1) A combustible element, fuel, represented by hydrocarbon vapours from
the cargo.
2) Energy to start the combustion, represented by sparks from various sources.
3) Oxygen to support the combustion, represented by the oxygen in the air, which
contains roughly 21 % Oxygen and 79 % Nitrogen.
To set off a fire or explosion all three elements must be present simultaneously.
If any of the three elements can be eliminated, the danger of explosion is also
eliminated, and this is the philosophy behind the inert gas generator.

When looking for the simplest element to remove, one will find that:

(1) The fuel part can never be eliminated, due to the nature of the cargo, which in
itself is highly inflammable.
The cargo will always evaporate explosive hydrocarbon vapours, which will fill
any void spaces in the tanks, and mix with the air entering the tanks through
open hatches, etc. On ballast voyage the empty tank is also filled with a
mixture of air,drawn in when unloading and vapours from the cargo remain in
the tank.

(2) The energy spark to set off an explosion is also very difficult to eliminate
completely.
Exhaustive studies have been made by maritime bodies worldwide. No exact
conclusion has been drawn, but it is a recognized fact that the most dangerous
source of ignition is that of static electricity, which may be created in various
ways inside the tank. The nature of this static electricity is such that it is difficult
to recognize, and therefore almost impossible to eliminate.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

(3) The remaining element to support combustion oxygen, is always present, being
21% of the earth’s atmosphere.
The percentage of oxygen inside the cargo tanks can be controlled, by
replacing the air with an inert gas, namely, a gas with an oxygen content too
low to form an explosive mixture regardless of the amount of petroleum gas in
the atmosphere of the tank.

1.2 Explosive Limits

The chemical composition of air is basically:

Oxygen - O2 = 21 % volume
Nitrogen - N2 = 79 % volume

A mixture of hydrocarbon gas and air has two limits of explosivity.

The lower explosive limit (LEL), is 2 % of gas -(98 % of air)

The upper explosive limit (UEL), is 10 % of gas -(90 % of air)

Within these two limits, the mixture is inflammable. Below the lower explosive limit,
the mixture is too lean to burn. Above the upper explosive limit, the mixture is too rich
to burn.
Hydrocarbon gas in a hazardous mixture containing oxygen will only burn, if the
content of hydrocarbon gas in the mixture lies between the upper and lower limits of
inflammability. These limits which are respectively 10% and 2% in air, vary according
to the oxygen content of the mixture. The gap between them narrows progressively as
the oxygen content diminishes. (See diagram).

■ If the oxygen content of the gas mixture is below 11 %, the hydrocarbon gas
contained in the mixture CANNOT BURN WHATEVER ITS CONCENTRATION MAY
BE. An atmosphere containing less than 11 % of oxygen is considered to be
THEORETICALLY INERT.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

1.3 Dry Inert Gas Generator

The inert gas system must provide a dry inert gas atmosphere within the entire
cargo tanks. It shall prevent explosive gas mixtures, it must not contaminate the
cargo and it must be available in sufficient volume, dewpoint and pressure to suit
all operating conditions.
The inert gas used on this ship is produced by operating a controlled air blower
that sucks air from the engine room and feeds the air into the KANGRIM Inert Gas
Generator to burn fuel oil at a very low excess air value. The gas is then cooled and
cleaned by sea water in a scrubber unit, and subsequently distributed to the tanks
through a deck piping system. The produced gas consists mainly of Nitrogen N2
and Carbon Dioxide CO2.

The system has three basic groups of equipment:

1) A production plant to produce inert gas and deliver it to a dryer system under
pressure by mean of a blower.
2) A Dryer and cooling system.
3) A refrigeration system serving the dryer skied.

1.4 Safe Oxygen Levels

During inert gas plant operations, it is of utmost importance to keep the oxygen
level as low as possible, in order to have the greatest possible safety margin.

Oxygen levels :

____________________________________
2 % O2 : MAXIMUM OXYGEN LEVEL ALLOWED

KANGRIM HEAVY INDUSTRIES CO., LTD.

 OPERATION MANUAL

During inert gas plant operations. However, all necessary steps must be taken to
ensure oxygen level below 2 %.

1 % O2 : SATISFACTORY OXYGEN LEVEL

This is considered the normal maximum level that a good operating vessel shall
maintain, even with the worst IGG condition.

Less than BEST OXYGEN LEVEL for a good operating vessel.

The IGG operations in 0.5 % O2 : the following sections refer to this level.

1.5 Health Hazards with Inert Gas

NOTE !
ALL PERSONNEL MUST BE MADE AWARE OF THE HAZARDS AND PRECAUTIONS
LISTED IN THE FOLLOWING PARAGRAPHS.

1) Oxygen Deficiency
All inerted areas, are areas with an atmosphere containing very little oxygen.
Exposure to an atmosphere with a low concentration of oxygen does no
necessarily produce recognisable symptoms before unconsciousness occurs. The
onset of brain damage amd the risk of death can follow within a few minutes.
If the oxygen deficiency is not sufficient to cause unconsciousness, the mind is
liable to become apathetic and complacent and even if these symptoms are
noticed and escape is attempted physical exertion will aggravate the weakness
of both the mind and the body.
It is therefore necessary to ventilate thoroughly the space to be entered so
that no pockets of oxygen-deficient atmosphere oxygen remain. When testing
for entry a steady reading of 21% oxygen is required.

2) Toxicity of Hydrocarbon Vapours

The toxicity of hydrocarbon gas is not affected by pressure of inert gas.
Because of possible gas pockets, gas-freeing for entry into a space must
continue until a 1% lower flammable limit (LFL) reading is obtained for the
entire compartment, on the portable hydrocarbon gas analyser (explosimeter).

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

3) Inert Gas Toxicity

The pressence of toxic gases such as sulphur dioxide, carbon monoxide and
oxides of nitrogne can only be ascertained by measurement. However provided
that the hydrocarbon gas content of an inerted cargo tank exceeds
approximately 2% by volume before gas-freeing commences, the dilution if the
toxic components of the flue gas during the subsequent gas-freeing operation
can be correlated with the readings on the explosimeter. If by ventilating the
compartment, a reading of 1% LFL or less is obtained in conjunction with an
oxygen content reading of 21% by volume the toxic trace gases will be diluted
to concentrations at which the compartment will be safe for entry. Alternatively,
and irrespective of the initial hydrocarbon gas cotent, ventilation must be
continued until a steady oxygen content reading of 21% by volume is obtained.

4) Entering a Tank for Inspection and Repair

WARNING : THE FOLLOWING SAFETY PROCEDURES ARE COMPLEMENTARY TO
THE COMPANY'S SAFETY PROCDEURES, BUT IN THE CASE OF ANY
DISCREPANCY THE COMPANY'S SAFETY PROCEDURES MUST BE
COMPLIED WITH INERT GAS IS NON-POISONOUS, BUT IT IS
ASPHYXIATING IF INHALED IN LARGE QUANTITIES. INERT GAS CAN
ALSO CAUSE PERMANENT BRAIN DAMAGE IF INHALED IN LARGE
QUANTITIES FOR A PERIOD OF 8 SECONDS.

Reference must be made to the section on oxygen deficiency, and toxicity of

hydrocarbon vapours and flue gas.

* Before Entering a Tank

Before entering a tank, ensure the safety of personnel by carrying out the
following procedures :

(1) Check with the portable oxygen analyser that the cargo tank atmosphere
contains 21% oxygen. Check that the hydrocarbon content is zero as measured
on the explosimeter. These checks must be repeated at several openings in the
cargo tank at three different levels including the cargo tank bottom.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

NOTE : Both hydrocarbon gas and inert gas are heavier than air, therefore the
sampling line used must be of sufficient length to reach within 1.2m of the
cargo tank bottom from the deck. If it is necessary to join two lengths of
samplimg line to achieve this, the coupling should be taped or secured in some
way to prevent loss of the lower length of sampling line.
(2) The cargo tank atmosphere testing must be carried out by a responsible officer,
or under his direct supervision.
(3) The hydraulic cargo system power pack must be shut down. Power supply to
the cargo system control console is to be switched OFF and a warning notice
displayed on the console before any entry is made.
(4) A communication procedure must be established between the men entering
the cargo tank and a person to be stationed at the tank hatch.
(5) It must be clearly understood by all personnel that no person is allowed to
enter a cargo tank without direct permission from the Chief Officer.
(6) Self-contained breathing apparatus must be available at the tank hatch
together with a lifeline and rescue harness.
(7) The branch line isolating valve must be shut to isolate the cargo tank from the
inert gas deck main.

* During Tank Entry

The following precautions must be observed during the whole time in which
men are working in the cargo tank :
(1) A responsible person must be stationed at the tank hatch with clear
instructions not to leave that location.
(2) During the entire period that personnel are in a cargo tank, fresh air ventilation
must be provided.
(3) The bridge must be informed that men are working in a particular cargo tank.

5) Pump Room Work

Before undertaking any repairs or maintenance work on the pumproom cargo
system, the following procedure must be carried out :
(1) The Chief Officer must personally check that all bulkhead valves are shut.
(2) The hydraulic power pack unit and the supply to the pump and cargo control
room panel are switched off.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

(3) A warning notice must be displayed on the pump and cargo control room panel
(4) The pumproom vent. fans are to be running at all times when men are working
in the pump room.
(5) No personnel are to commence any work in the pumproom without first
obtaining permission directly from the Chief Officer.
(6) The pumproom lifeline and rescue harness must be ready for immediate use,
and an approved breathing apparatus must be in accessible position.

6) Safety on Deck
WARNING : IT IS IMPORTANT TO CHECK THAT THE CARGO TANK PRESSURE IS
ZERO BEFORE ATTEMPTING TO OPEN ANY CARGO TANK HATCH
COVER.
(1) When any cargo tank hatch cover is lifted, personnel must always stand
diametrically opposite the hinge and on no account lean over the opening.
(2) Whenever purging or gas-freeing is taking place, warning notices are to be
placed near tank hatches to warn of dangerous gases.
(3) It must be remembered that wind across the deck can cause the cargo tank
atmosphere to be drawn from an opening. Personnel should therefore be made
aware of the danger of standing downwind of any cargo tank hatch.
(4) Personnel must not stand beside a cargo tank opening at any time unless
absolutely necessary, and precautions must be observed.

7) Source of Ignition
* Smoking
Smoking must be permitted only under controlled conditions at time and in
place specified by the Masker. Matches, and especially lighters, must not be
carried by personnel while at work on board. Under no circumstances will no
smoking rule be lifted.

* Hot Work
No hot work to be carried out in any cargo tank or pumproom at any time
without prior permission from Head Office.

* Metals

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

(1) Aluminium equipment must not be dragged across steel as the resultant smear
may cause sparks if struck.
(2) No hammering of chipping must be carried out unless the area has been
declared gasfree by the Chief Officer.
(3) The use of non-sparking tools is not recommended, as tests have shown that
they do not effect a significant reduction in he risk of gas igniticn when
compared to the associated with ferrous tools : there are also certain risks

* Absorbent Material
Some materials, when damp or soaked in oil especially vegetable oil are liable
to ignite because of the build-up of heat during oxidation. For this reason,
absorbent material MUST NOT be stowed near oil or paint etc. If such materials
become damp, they must be dried stowage. If they become soaked with oil,
they must be cleaned or destroyed.

* Pyrophoric Oxidation
Inert gas provides a complete protection only if fully operational and property
operated. In case of inert gas system failure, this protection not only ceases, but
byproducts of the inert gas (such as pyrophorics and static electricity) may
increase the risk of explosion and fire if air is introduced in the tanks without
following the proper procedures. Measurements have revealed that cargoes of
normally sweet crude are occasionally sufficiently sour to give rise to several
percent of hydrogen sulphide gas in the vapour space. In a oxygenfree
atmosphere, where hydrogen sulphide is present, iron oxide (rust) is converted to
iron sulphide. When the iron sulphide is subsequently exposed to air, it is oxidized
back to iron oxide, free sulphur oxide gas.

This oxidation can be accompanied by the generation of considerable heat so that

individual particles may become incandescent. Rapid exothermic oxidation with
incandescence is termed pyrophoric oxidation.

Pyrophoric iron sulphide capable of pyrophoric oxidation in air - can ignite

flammable hydrocarbon-air mixture.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

In refinery operation pyrophoric iron sulphide is well recognized as a potential

source of ignition. Pyrohoric deposits are apt to accumulate in storage tanks in
sour crude service and in process equipment handling sour streams. When such
tanks or equipment are taken out of service, it is normal practice to keep all
internal surfaces thoroughly wet during ventilation so that there can be no
pyrophoric reaction before the equipment is made gasfree. Deposits and sluge
must be kept wet until removed to a safe area where subsequent ignition will
cause no damage. Numerous fires have occurred when deposits have dried out
prematurely.

While pyrophoric iron sulphide is a widely recognized ignition source in shore-

based operation, it has rarely been cited as the cause of a marine ignition.
Presumably marine operations have been free of this hazard because cargo tanks
(of non-inerted ships) normally contain some oxygen in the vapour space. The
presence of oxygen inhibits the conversion of iron oxide to iron sulphide by
hydrogen sulphide. Cargo tanks which are inerted may contain little or no oxygen.
Thus there is a possibility that pyrophoric deposits may be formed when sour
cargo is carried. In normal operation of inerted tankers the cargo tanks are not
allowed to become flammable at any time. Thus the pressence of any pyrophoric
deposits in the cargo tank or in the vent and inert gas piping would not result in an
ignition.

However, entering the cargo tanks could result in a flammable atmosphere with
the risk of ignition if pyrophoric deposits were present. Most foreseeable inert
gas system failures are can be avoided by timely maintenance. Furthermore,
most breakdowns can be repaired adequately in a few hours. Certain
components, notably the blowers, can fail totally without warning and all
vessels are advised to keep spares of these components which are a long
delivery item.

IN THE EVENT THAT THE INERT GAS GENERATOR BECOMES INOPERATIVE

BOTH AT SEA AND IN PORT, THE GROUP MANAGER MUST BE ADVISED
IMMEDIAT- ELY, NOTIFYING HIM POSSIBLY BY TELEPHONE, OF THE EXISTING
SITUATION AND OF MATERIALS / SPARES REQUIRED TO RESTORE THE SYSTEM
IN GOOD WORKING ORDER.

8) Tank Pressure
Personnel should be advised of the practical hazards when an inerted cargo
tank is maintained at a positive pressure. The pressure must be sufficiently

____________________________________
relieved before opening any tank lids, usage plugs or tank washing openings.

KANGRIM HEAVY INDUSTRIES CO., LTD.

 OPERATION MANUAL

9) Electrostatic Hazards
An electrostatic charge can occur in the small particulate matter carried in flue
gas. Although the charge is normally of a low level, much higher levels have
been observed with water mists created by tank washing.
Cargo tanks are usually in an inerted condition and electrostatic ignition is not
a consideration unless the oxygen content of the tank atmosphere is increased
by the entrance of air, or unless it is necessary to inert a tank already
containing a flammable atmosphere.

10) Repair of Inert Gas Generating Plant

Inert gas is asphyxiating and extreme caution must be exercised at all times
when working on the plant. Being in fresh air during the work is not a safety
guarantee, since inert gas possibly leaking from the plant can still cause
unconsciousness very quick. The plants should therefore be completely gas free
before any equipment is opened up.
An internal examination of any unit, such as the inert gas scrubber, must not
be performed without following the standard recommendations for entering
enclosed spaces. Blind flanges should be fitted where applicable or the plant
should be completely isolated.

* Safety Precautions
A. Operating the equipment in excess of the conditions set forth in the Sales
contract and the Technical specification, will subject it to stresses and strains
that it was not designed to withstand.
B. All electrical installation should be in accordance with the recognized electrical
codes.
Carefully read the cautions and instructions laid down in the manuals before
starting the equipment or doing any maintenance.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

(1) The gaseous product of this system contains nitrogen(N2) and carbon -dioxide
(CO2) ; also little or no oxygen(O2),carbon-monoxide(CO) and other toxic gases
are present. Exposure to or inhalation of the product gas should be avoided,
the more so as no oxygen is present. Leakage or venting of product gas into
closed of confined areas, or at places where personnel may be present, must be
strictly avoided. Any failure to heed these warnings may result in accidents
causing personal injuries.

(2) Before doing any maintenance to the electrical installation, be certain that the
electrical supply has been switched off by the main switch. Otherwise, severe
personal injuries may occur.
(3) Prior to doing any maintenance to the equipment, be sure that all pressures of
the entire system have been vented. Otherwise, severe personal injuries may
(4) When operating the equipment, do not exceed the rated capacities, speeds,
pressure, temperatures, or etc. Otherwise than laid down in these instructions
and the sub-contractors’ manuals. Failing to heed these warnings may result in
accidents causing personal injuries or property damages.
(5) Do not remove any covers from rotating units, such as the blower, while the
unit is in operation.
(6) Severe burns may result from touching hot piping, such as , the steam supply
pipe etc.
(7) At no time should the unit be energized and started in hazardous environments
Severe explosions may cause personal injuries and property damages.
(8) Spill of fuel oil may cause slipperiness of fire, which may result in severe
personalinjuries and property damages.
DON'T ENTER ANY CARGO SPACE AND/OR TANK BEFORE THE OXYGEN
CONTENT IN THESE SPACES IS MEASURED AND FOUND SUFFICIENT TO BE
SURE, THAT THESE PLACES ARE NOT INERTED!!

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

2. Main equipment

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

2. MAIN EQUIPMENT
2.1 Dry Inert Gas Generator
1off inert gas generator
- Main burner
- Pilot burner
- Combustion chamber with water jacket
- Cooling sea water spray nozzle and wet filter demister
- Demister
- Oxygen analyzer with sampling and calibration line
- Fuel oil pump unit with motor and starter panel
- Single stage combustion air blowers with motor and starter panel
- Necessary valves,instruments, flexible joints and hoses
- Main control panel for safe and automatic operation

2.2 Inert Gas Cooler and Dryer System

1 off Cooler and Dryer Skid consisting of Inert Gas Cooler and Dryer designed for
plant capacity with associated items installed and interconnected as marked on the
P&ID comprising:
- Inert gas cooler for cooling with chilled water with drain connection
- Mist eliminator
- Adsorption dryer with rotating adsorber unit
- Electric heater for regeneration, 1 x 100%
- Necessary valves, Instrument and flexible joints
- Dryer control panel and junction box
- Regeneration fan loop with motor and starter panel
- Dew point transmitter

2.3 Refrigeration Plant

1 off Refrigeration Machinery skid designed for plant capacity with associated items
installed and interconnected as marked on the P&ID comprising:
- Condenser
- Evaporator
- Screw compressor with motor and starter panel
- Control valves, shut off valves, by-pass valves, sight glass, instrumentation
and other necessary auxilary equipment for the refrigerant system

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

- Chilled water system with evaporator, water pump, instrumentation

and auxiliary parts for proper and safe operation
- Starter/control panel with
Starters for compressor motors,
Electronic capacity controller,
Expansion valve and other auxillary control panel parts
- Expansion tank
- Chilled water pump
- First charge of refrigerant

2.4 Other
- 1year spare parts for dry inert gas system according to KANGRIM standard
and requirements of classification societies and POS.
- Documentation as part of the overall system documentation and instruction
Manuals to KANGRIM standdard.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

3. Technical description

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

3. TECHNICAL DESCRIPTION
3.1 Dry inert gas denerator(DIGG)
D-IGG system consists of an inert gas generator combined with a standalone single
dryer skid consisting of a cooler, mist eliminator and dehumidifier.
The cooler unit is served by a refrigeration compressor operating a chilled water
loop.
The Inert gas generator comprises of a burner unit with pilot burner, main burner,
combustion chamber and combining scrubber tower for cooling and cleaning of the
hot combustion gases.

A three-step process is executed in the DIGG system.

The generator produces a humid inert gas with dew point in the range of +35~37º
C.
The humidity is reduced to a +5ºC dew point in the cooler. Finally the dryer
reduces the gas humidity by adsorption to between ÷40ºC and ÷60ºC

Inert Gas Generator

Two air blowers supply combustion air to the wind box on the top of the scrubber.
When the generator is started the pilot burner will be activated glow plug, which
ignites the diesel oil / air mixture supplied to the pilot burner.
Time from when the ignition glow plug is activated and the main burner is
supplied with fuel oil is approximately 35 seconds.
The photocells mounted on the burner and at the top of the combustion chamber,
detect the intensity of the combustion. This signal is measured by the flame detect
relay, who will initiate the main burner after some seconds of pilot operation if the
flame intensity is acceptable. The main burner is activated and combustion is
started and after some seconds more the pilot burner will be shut of and the plant
is operating solely by the main burner.

The heat from the combustion is removed by the seawater flow in the cooling
jacket.
The seawater flowing in the cooling jacket is ejected into the lower part of the
scrubber tower by small holes situated around the lower of the cooling jacket.
When the gas leaves the central shell in the bottom pan of the scrubber and turns
180°C it flows upwards through a stainless steel wet filter fitted in the lower pan of
the scrubber.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

After passing the wet filter, the gas is forced further upwards through a spray of
seawater coming from a set of spiral spray nozzles (Item No. 1170) fitted into a
seaeater distribution ring in the upper half of the scrubber. The purpose of the wet
filter is to obtain good contact between the hot gas ans the cooling water.

The gas finally passes through a demister (ITEM No. 1310) before it leaves the
scrubber through the outlet duct on the upper of the tower.
The demister is abundarntly dimensioned to effectively prevent any water dropets
to be carried away form the scrubber.

Access openings for ease of inspection and maintenance and provided in the
tower, just above both wet filter and the demister pads.

Cooler and Dryer skid

The two stage dehumidification system is based on cooling and adsorption by
means of which the dew point of the inert gas is lowered to the required -40°C.

The gas produced by the inert gas generator is led into the cooler and dryer skid
through an inlet box designed to produce a uniform bulk flow through the cooler.
The cooler is of the finned type and designed to reduce the humidity to +5°C dew
point before the inert gas is led into the dryer. The cooling effect in the cooler is
provided through a glycol/water based system from the separate refrigeration plant.

Condened water from the cooled inert gas leaves the cooler unit via the bottom
drain lines.

From the cooler the saturated inert gas is passed through a filter to eliminate any
mist due to gas saturation.

The inert gas is dehumidified in a ratating adsorption dryer. This is a ratating, heat
regenerated, dryer where the drying is carried out by a metal silcate rotor with high
adsorption capacity.

The wet gas blower provides regeneration loop of the metal silicate rotor by
transporting inert gas via a heater through a quarter of the dryer rotor back to the

____________________________________
cooler inlet.

KANGRIM HEAVY INDUSTRIES CO., LTD.

 OPERATION MANUAL

Before the dry inert gas is led to deck and cargo tanks, the dew point is stabilized
during the start up period by passing the produced inert gas through an
atmospheric blow off line installed upstream of the delivery valve.

3.2 Major Components

- Combustion air blower
- Oil burner for inert gas generator
- Ignition buerner for inert gas generator
- Fuel Oil system for inert gas generator
- Cooling water system for inert gas generator
- Drain system for inert gas generator
- Inert gas capacity valve for inert gas generator
- Blow off valve for inert gas generator
- Delivery valve for inert gas generator
- Oxygen analyzer
- Cooling & Dryer unit
- Wet gas regeneration fan
- Dew point transmitter
- Pressure transmitter
- Non return valve

Three combustion air blowers are equipped with electric motor, silencer, flexible
joint connection, manual valves, control valves for combustion air outlet blower.
Each blower with electric motor is fitted on a common base frame which is
equipped with resilient mountings.

1) Combustion Air Blower

To avoid vibrations in the pipes, a flexible joint connection is mounted on the
outlet side of the blower.

2) Oil burner
The Oil Burner is of the mechanical high pressure atomising type. Oil gun and
fuel oil nozzle are of by-pass type. In the return line a pneumatically controlled

____________________________________
capacity regulating valve (Item No. 0230) is mounted.

KANGRIM HEAVY INDUSTRIES CO., LTD.

 OPERATION MANUAL

The burner runs as a duplex burner, where the oil consumption depends on
size of nozzle and oil pressure in the return line.

For safe start of the plant it is advisable to ignite the burner at low capacity,
which means reduced oil and air to the burner. This IGG is built for running on
light marine diesel / gas oil.

The capacity is selected by operation of push buttons in front of main

control panel.
The oil nozzle is as mentioned above of pressure atomising by-pass type. The
oil is directed to the orifice through tangential slots, thus the oil gets a rotating
motion and the oil to the burner leaves the nozzle as a thin rotating
membrane, which is atomised just after the nozzle. The atomised oil forms a
cone, in which the top angle depends on the nozzle type and oil pressure.
When oil pressure thus oil quantity is increased, the rotating velocity increases,
and the atomising cone increases.(Higher oil pressure = higher oil quantity =
higher rotating velocity = greater atomising cone.)

The oil gun is adjustable in axial direction to find the best position for the
oil nozzle.
The oil gun is adjustable in axial direction to find the best position for the oil
nozzle.
A stuffing box around the oil gun with fibre-glass gasket avoids gas leakage.
The combustion air is supplied tangentially to the upper inlet duct on top of
the burner unit. This means that the air, already when entering the outer gas
chamber, is brought into rotation.

The rotation is strengthened at the same time as the velocity increases

through a number of vanes on the way via circular distribution opening (burner
throat) into the combustion chamber, where combustion air and fuel oil are
mixed. A small part of air passes through a tube around the oil gun as “primary
air”.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

The primary air, blowing along·the oil gun prevents setting of uncombusted oil
particles on the fuel oil nozzle. For complete combustion it is necessary to mix
the atomised fuel oil and combustion air as good as possible. This is obtained
by high relative velocity between oil and gas. The axial air velocity at the oil
nozzle must, however, not be higher than the rate of combustion, as this would
mean that the flame would be blown away from the nozzle. As mentioned
before, a high rotating velocity is therefore obtained even at a low axial velocity
at the center of the burner.
Oil and air are rotated in opposite directions to increase the relative velocity.

Although the combustion chamber is manufactured in one piece, it may be

considered as three parts. Each of these parts, the upper which has the shape
of a cut cone, the one in the middle being cylindrical and the lower, which also
has the shape of a cut cone, is made with water jackets avoid too high thermal
stresses.
In the front of the burner, there are openings for oil gun, ignition burner and
view ports with glasses and gate valves for flame control and inspection.

3) Ignition burner
Which is welded into an opening in front plate of the oil burner, consists mainly
of a cylindrical combusion chamber with internal linings, 0.6 US gal/h fuel oil
nozzle (Item No. 0880) and an ignition glow plug (Item No. 0890). Combustion
air, which flows outside the internal lining for cooling, is supplied from the 5~7
bar working air system, and in this line a solenoid valve (Item No. 1520) is
mounted.

The top plate into which the oil nozzle and glow plug are fitted, is removed by
opening a cap nut. In the oil supply line two solenoid operated shut-off valves
(Item No. 1580 / 81) are mounted.

The 10-15 cm long pilot flame comes out through the tube, which connects the
ignition burner to the front side of the main burner.

Time from when the ignition glow plug is activated and the main burner is
supplied with fuel oil is approximately 35 seconds.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

4) Fresh water injection

A full cone nozzle is installed to spray a mist of fresh water into the
combustion.
The internals of the fresh water injection nozzle are easily accessible for
inspection and maintenance by opening the blind flange on the wind box.
Fresh water is automatically injected into the flame after ignition in order to
reduce the CO and NOx content of the gas in the low oxygen range O2<1.0%.

The water evaporates and water vapour acts as a catalyst for the combustion
resulting in improved combustion.

5) Fuel Oil Systems

Main burner system consists of :
Two oil pumps with electric motors (Item No. 6040 and 6050).
Duplex oil filter with double way valve (Item No. 6020/6030).
Connections to oil gun are made by flexible hoses. (Item No. 0840).
The oil supply to main burner and oil return pipes are fitted with two
pneumatically operated valves with solenoid for control (Item No. 1530 and
1560) and a pneumatic control valve (Item No. 0230) for fuel oil capacity
control.

Fuel oil consumption is determined by the divided values on a pressure gauge

(Item No. 1660) fuel oil return.

A pressure control valve (Item No. 6100) is fitted to the fuel oil pump by-pass
line, between pipe line to burner and pipe line to fuel oil pump lnlet.

Connection to ignition burner is made by a solenoid valve (Item No. 1580) and
a flexible hose (Item No. 0850)

To protect the ocean environment from possible oil pollution, the unit is fitted
with solenoid valve No. 1570 for blocking of the oil nozzle after shut down.
Fuel Oil Control Loop
The fuel oil control valve (Item No. 0230) can be controlled manually or
automatically by putting auto / manual selector switch inside main control

____________________________________
panel into desired operation.

KANGRIM HEAVY INDUSTRIES CO., LTD.

 OPERATION MANUAL

When operated manually, the buttons in front of main control panel are to be
opened for opening or closing of the valve. The indicator shows the output
signal to the valve.

When the loop is automatically controlled, the blower load signal is to most
significant input for control-signal to the fuel valve. however, this signal is
corrected according to signal from oxygen analyzer compared with set point.

The D-IGG to be fixed values the valve position in accordance with operating
capacity of 100% mode. And the speed of fuel oil pump is controlled by a
frequency converter according to signal from oxygen analyzer.

6) Cooling Water System

For cooling and cleaning of the inert gas seawater is used. The main amount
of seawater is used through the spray nozzles. The rest is used for cooling of
the burner and precooling of the gas in the central tube.

7) Drain System
Permits the seawater effluent from the scrubber tower to be drained without
loss of inert gas. This is obtained by fitting an effluent control valve (Item No.
0220) in accordance with pressure control between inert gas outlet pressure
(Item No. 2140) and effluent line static pressure ( Item No. 2120). Manual bilge
tank select in operation screen : In manual mode, the bilge valve opens and the
seawater drain valve closes. Manual overboard drain select in operation screen :
In manual mode, the seawater drain valve opens. Auto drain select in operation
screen : When a flame fail occurs, the bilge valve opens and the drain valve
closes when the sea water drain pressure falls below the set value (Auto bilge
drain pressure). When the set time (Bilge drain time) is reached, the bilge valve
closes and the drain valve opens.

8) Inert Gas Capacity Valve

The plant is started at reduced oil/air quantity (reduced capacity). The
pneumatically operated valve (Item No. 0100) is partly open during the start-up

____________________________________
period reducing the air flow to the burner to desired capacity.

KANGRIM HEAVY INDUSTRIES CO., LTD.

 OPERATION MANUAL

The valve operates under normal running conditions, controlling the pressure
automatically as well as avoiding pressure fluctuations in the combustion
chamber.
The capacity is controlled by the blower outlet valve setting (100% mode), and
is operated by the select button on the main control panel.

9) Blow Off Valve

One butterfly shut off valve (Item No. 0020) for gas venting.
The valve is operated by the oxygen contents and dew point leading gas to
atmosphere, when oxygen analyzer and dew point transmitter are not within
the set limits.

10) Delivery Valve

The butterfly shut off valve (Item No. 0010) is operated by a pneumatic
actuator.
The valve is activated from the main control panel ("SELECT CONSUMER") and
will automatically open when the gas and dew point analysis meets the
requirements, otherwise it is closed.
During start-up and shut-down the valve is automatically forced to closed
position.

11) Oxygen Analyzer

Oxygen analyzer is installed, sampling the inert gas after the scrubber.

12) Cooling unit

The cooler unit consist of a cooling coil that is served by a refrigeration
compressor operating a chilled water loop. The cooler is of the finned type and
designed to reduce the humidity to +5°C dew point before the inert gas is led
into the dryer.
The cooling effect in the cooler is provided through a glycol/water based
system from the separate refrigeration plant.

The chilled water pump circulates a mixture of glycol and water in a loop
between the cooler and the separate refrigeration plant. This glycol/water

____________________________________
mixture will cool down the inert gas while it passes the cooler finned surface.

KANGRIM HEAVY INDUSTRIES CO., LTD.

 OPERATION MANUAL

Water vapor is condensed on the surface into water drops that leaves the
cooler unit via the bottom drain line.

The heated cooling medium returns to the separated refrigeration plant and is
cooled down in the evaporator.

Refrigeration is the transfer of heat from the substance to be cooled to some

other substance. During the refrigeration process, the refrigerant undergoes a
number of changes in state or condition, and various terms are used to indicate
when and how these are achieved. Please refer to the vendor manual for
further description of the refrigerator unit.

Saturated inert gas from the cooler passed through a filter to eliminate any
mist due to gas saturation before this gas is passing the dryer.

13) Dryer Unit

The main part of the dryer are the adsorption rotor, casing for regeneration
gas with regeneration heater and wet gas outlet.

The inert gas is dehumidified in the rotating adsorption dryer. This is a rotating,
heat regenerated, dryer where the drying is performed by a metal silicate rotor
with high adsorption capacity.

Filter element are installed after cassettes that have access for replacement and
maintenance.

14) Dryer Fan

The inert gas system is fitted with one wet gas fan, designed to carry 50% of
the required inert gas capacity for regeneration of dryer rotor.
The fan is driven by an electric motor, fan and motor are mounted on dryer
body. The units are equipped with flexible connetions.

The fan is of the single-stage contrifugal type with overhung impeller.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

The wet gas fan provides regeneration loop of the metal silicate by
transporting dry inert gas via a electrical heater through a quarter of the dryer
rotor back to the cooler inlet.

The speed of the wet gas fan is controlled by a frequency converter.

A software controller receives input from a flow transmitter installed down
stream the dryer. An output signal to the frequency converter is determining
the speed of fan.
15) Dew point transmitter
The stationary dew point analyser is designed to continuously monitor the dew
point of dry inert gas.

The dew point transmitter is factory calibrated. It should require no

maintenance from the operator of the system.

16) Pressure transmitters

The pressure transmitters convert the inert gas pressure input to a
corresponding output signal of 4~20mA, which is read by the PLC.

These transmitters are factory calibrated and should require no maintenance

from the operator of the system.

The differential pressure transmitter is used for flow measurement and is "the
heart" of the regulation for the inert gas system. When the system is in
operation the transmitter measures a differential pressure across the orifice
befor and after, proportional to inert gas flow, and converts this into a 4~20mA
signal.

17) Non return valve (Item No. 0640/50)

The purpose of this valve (type : swing check) is to prevent even the smallest
amount of gas from the cargo tanks getting back to the inert gas production
line.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

4. Instumentaion and control system

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

4. INSTRUMENTATION AND CONTROL SYSTEM

4.1 Indication Instruments
Item No. refer to "P&I diagram"

1) Thermometer (TI)
Seawater main inlet temperature of scrubber (Item No. 1750)
Inert gas outlet temperature of scrubber (Item No. 1790)
Seawater outlet temperature of cooling jacket (Item No. 1780)
Chilled water inlet temperature before cooler (Item No. 5140)
Chilled water outlet temperature after cooler (Item No. 5130)

2) Temperature Indicator (TT)

Combustion air temperature to burner (Item No. 1404)
Inert gas outlet temperature of scrubber (Item No. 1880)
Regeneration gas return temperature before cooler (Item No. 2020)
Inert gas inlet temperature of cooler (Item No. 3110)
Inert gas outlet temperature of cooler (Item No. 3130)
Regeneration gas inlet temperature of dryer (Item No. 4110)
Regeneration gas outlet temperature of dryer (Item No. 4120)

3) Pressure Indicator (PI)

Fresh water injection pressure of blower No.2 (Item No. 1402)
Fresh water injection pressure of burner (Item No. 1405)
Instrument air inlet pressure (Item No. 1600)
Combustion air pressure burner inlet (Item No. 1610)
Seawater pressure cooling jecket (Item No. 1620)
Seawater pressure to water nozzles (Item No. 1640)
Oil pressure to main burner (Item No. 1650)
Fuel oil return pressure (Item No. 1660)
Inert gas pressure outlet cooling tower (Item No. 1670)
Dry inert gas pressure after dryer (Item No. 1680)

4) Flow Meter (FI)

Flow gas to O2 senser (Item No. 7060)

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

5) Analyzer Indicator (AI)

O2-content in inert gas (Item No. 7040/41) in main control panel
Local indication on analyzer.

4.2 Safety Interlocks

1) Set Points
The various set point values for pressure, temperature, O2 switches are listed in
part list. (Ref. notes)

2) Temperature Switch
Inert gas temperature high, cooling tower outlet, alarm and stop of plant.
(Item No. 1885)
Cooling water temperature high, burner cooling jacket, alarm and stop of plant.
(Item No. 1910)
Dryer regeneration gas temperature high, alarm and stop of plant.
(Item No. 4310)
Dryer regeneration gas temperature high, alarm and stop of plant.
(Item No. 4320)

3) Pressure Switch
Low instrument air pressure, alarm and stop of plant. (Item No. 1830)
Low seawater pressure main inlet scrubber, alarm and stop of plant.
(Item No. 1840)
Low fuel oil inlet pressure to burner, alarm and stop of plant. (Item No. 1850)
Low seawater inlet pressure to scrubber cooling jacket, alarm and stop of plant.
(Item No. 1810)
Low combustion air to burner, alarm and stop of plant. (Item No. 1960)

4) Level Switch
High seawater level in cooling tower, alarm and stop of plant. (Item No. 1930)

5) Oxygen Switch
High / low O2 content, alarm and vent to atmosphere (Item No. 7040 / 41)
O2 analyzer malfunction, alarm and vent to atmosphere (Item No. 7040 / 41)

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

6) The Ignition Transformer (Item No. 2090)

It is a glow plug transformer, which is connected to 220V and gives DC 12V to
the glow plug fitted on the ignition burner.

7) The Flame Control

The flame control registers the burner flame, and in the contrary case takes
care of stopping the plant and gives an alarm.
The flame control consists mainly of a scanner unit with a potocell detector
and an amplifier which amplifies the weak signals from the potocell detector to
impulses that are able to operate a flame relay.

4.3 Instrumentation and Control Panels

1) General
In the following are listed all instrument and control panels within the system,
with the main items and the function of same. The operation and use of the
panels during plant operation are covered in detail in following section 5.

2) Main Control Panel

This panel is the generators main panel, from which the plant start up is
initiated.
The panel contains the programmable controller. On the front of the panel, the
I.G. Plant is visualized in form of a mimic diagram including switches with
lamps,indicating LEDs, and alarm LEDs with the following work principle:

(1) At normal running the alarm LEDs are dark.

(2) Alarm is indicated by an acoustic signal and a flashing light for the actual
alarm.
(3) The acoustic signal and the flashing alarm light are accepted by a push
button
(4) Until the acoustic signal is accepted, they will remain on even if the alarm
cause
(5) Upon resetting the alarm, the alarm light will turn from flashing to steady.
The steady light disappears when the alarm cause disappears.
(6) A normal closed contact for common alarm is provided for external use.

The items mounted on the front of the main control panel can be seen on the

____________________________________
touch screen.

KANGRIM HEAVY INDUSTRIES CO., LTD.

 OPERATION MANUAL

3) Oxygen Analyzer and Analyzing

The oxygen analyzer is located in the vicinity of the generator.
Variation in oxygen content is registered directly. by the O2-analyzer
The filter cleans the inert gas and indicates flow.
Sample gas is taken from generator outlet nozzles pressurized to the analyzer.

Calibration with N2 (99.999%) bottle & air(20.9%)

For further information, refer to Oxygen Analyzer Instruction Manual

4) The Instrument Air

Simply to the pneumatically operated valves and control devices shall have a
pressure of 6~9 barg, and be supplied dry and clean.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

5. Instruction for plant start, operation

and stop

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

5. INSTRUCTION FOR PLANT START, OPERATION AND STOP

5.1 HMI Description
1) System monitor

2
9 10
1

4 5 7
6

(1) Alarm indication : <touch> move to alarm history.

(2) IGG sequence indication.
(3) IGG operation mode
Inert gas mode : <touch> select igg inert gas mode (blue)
Fresh air mode : <touch> select igg fresh air mode (blue)
Manual mode : <touch> select igg manual mode(blue)
(4) Sea water drain select
Manual bilge tank : <touch> select manual bilge tank mode (green)
Auto drain : <touch> select auto drain mode (green)
Manual overboard drain : <touch> select manual overboard drain(green)
(5) System start : <touch> the system starts in the selected mode.
(6) System ready to start : appears when the system is ready to start.
(7) System stop : manually igg stop
(8) Select consumer : inert gas or air supply to Deck
(9) Common alarm indication

____________________________________
(10) Display current time : <touch> move to time setting screen

KANGRIM HEAVY INDUSTRIES CO., LTD.

 OPERATION MANUAL

12 14

13

11 15

(11) Under manu : <touch> move to alarm history, data, plc in/out, hourmeter,
trend, parameter, engineer setting.
(12) Status display : run => green, red => failure, gray => stop
(13) Display the current value of each item : If you have a parameter,
touch the value to go to the parameter page.
(14) Glow plug, ignition burenr, main burner : Appears only in manual mode.
<touch> Each command begins (green).
(15) Alarm accept : <touch> alarm accept and buzzer stop
(16) Alarm reset : <touch> alarm reset

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

2) Alarm history

1 2 3

4 5 9

(1) Alarm occurrence time display

(2) Alarm message display
(3) Alarm Recovery time display
(4) All alarm delete : it is activated by pressing the button for 3 seconds.
(5) Selected alarm delete : it is activated by pressing the button for 3 seconds.
(6) Move the selected list up one line
(7) Move up one page
(8) Move the selected list down one line
(9) Move down one page

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

3) Commising data

2 3 4 5
1

(1) Manual : (gray)auto / (green)manual

PV : present value
SP : setpoint value
MV : manipulated variable (0~100%)
(2) Parameter : <touch> move to blower outlet pressure parameter page
(3) Parameter : <touch> move to inert gas pressure parameter page
(4) Parameter : <touch> move to oxygen content parameter page
(5) Parameter : <touch> move to sea water drain line pressure parameter page
(6) Manual output
When the manual button is changed to manual (green), enter manual output
values.
(7) Manual up and down arrow
When the manual button is changed to manual (green),
MV can be adjustble by up and down arrow

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

4) Plc digital input, output and analog in/output

1 2

3 4

(1) Adr. : PLC address

(2) Status : displays the input status of the address.
ON (green), OFF(red)
(3) Digital output : <touch> move to digital output screen
(4) Analog in/output : <touch> move to analog in/output screen

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

1 2

3
4

(1) Plc channel number

(2) Item description of the channel
(3) Analog input value of the item (0~20mA)
(4) Channel sensor status indication
G : good (green), F : fault (red)

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

5) Hour meter

1
3
2

(1) Description of each item

(2) The operating time appears. It is an hourly unit. It is expressed
up to 10 digits.
(3) Touch the reset button for 3 seconds to clear the run hours.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

6) Data trend

3
4
2

4
5 6 7 8 9 10

(1) It shows the current value for each item.

(2) Displays the data trend. Approximately two days of data appear.
(3) The current value of each item is displayed as a graph bar.
(4) When you touch the trend screen, a vertical bar appears.
The value of the trend line intersecting the vertical bar is displayed.
(5) It moves to the left data based on the time on the left. Number of
moving data: 50
(6) It moves to the left data based on the time on the left. Number of
moving data: 1
(7) Bookmark on the trend screen.
(8) Go to the bookmarked place.
(9) It moves to the right data based on the time on the left. Number of
moving data: 1
(10) It moves to the right data based on the time on the left. Number of
moving data: 50

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

7) Parameter

7 2 3

6 4
5

(1) Description of each item

(2) Data : This is the value currently applied to the system.
(3) Set : This is where you enter the value you want to change.
Input values may be limited for safety reasons.
(4) Save the value of set as a data value.
This bThis button must be touched for 3 seconds.
A password is set for this button. The initial password is hull number.
If you want to change your password, you need to request to the kangrim.
(5) When the data is saved, the message “Data has been saved.” appears.
(6) Moves to the next parameter screen or moves to the previous screen.
(7) It shows the current value for each item.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

8) Time setting

1 2 3 4 5 6

(1) Day information (1-31) New date for change.

(2) Mounth information (1-12) New date for change.
(3) Year information New date for change
(4) Hour information (0-23) New time for change
(5) minute inforamtion (0-59) New time for change
(6) second information (0-59) New time for change
(7) After setting the time, touch the button to change to the set time.
(8) Current time and date display

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

9) Engineer setting

1 2 3

4 5

A password is set for this screen. The initial password is hull number.
If you want to change your password, you need to request to the kangrim.

(1) Description of each item

(2) Data : This is the value currently applied to the system.
(3) Set : This is where you enter the value you want to change.
Input values may be limited for safety reasons.
(4) Moves to the next parameter screen or moves to the previous screen.
(5) Save the value of set as a data value.
This bThis button must be touched for 3 seconds.
A password is set for this button. The initial password is hull number.
If you want to change your password, you need to request to the kangrim.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

This screen is where you set up all analog sensors and sequence time.

(1) If you touch the button for 3 seconds, a caution window appears.
All screen data is changed to the factory value.
If you want to proceed, please touch "save" button durnig 3 seconds.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

5.2 Auto operation

1) Before start
(1) Alarm reset and Check that there is no alarm condition.
(2) Check the oxygen analyzer for correct calibration.
(3) Check the sea water in/outlet valve for scrubber.
(4) Select blower 1 or(and) 2 and fuel oil pump 1 or 2 on the touch screen.
(5) Select blower, fuel oil pump, chiiler unit and dryer paenl control location remote
(6) Check the valve Indicator manual switch off position
(Blower outlet valve, F.O capacity valve, S.W. regulation valve,
Dryer outlet gas vavle indicator)

2) Starting for inert gas mode

(1) Carry out checks listed “Before Start” and select "OPERATION"
page on the touch screen
(2) Select "inert gas mode" and touch "system start" button on the touch screen.
(3) The start sequence is indicated on the touch screen.
(4) Wait until the “FLAME ” is energized and plant is running steady with
acceptable O2 content.
(5) Check that all air is evacuated from cooling jacket outlet in sight glass.
(6) It may be occurred fluctuation minutes to stabilize the O2 content.
Wait until the stabilization O2 content.
(7) Check that there is a flow to the O2-analyzer, adjust if necessary.

3) Starting for fresh air mode

(1) Carry out checks listed “Before Start”.
(2) Select "fresh air mode" and touch "system start" button on the touch screen.
(3) The start sequence is indicated on the touch screen.
(4) The plant is now ready for production of fresh air to consumers.
Further control from the sub panel in cargo control room.

4) Starting for manual mode

(1) Carry out checks listed “Before Start” and proceed "OPERATING"
page on the touch screen
(2) Select "manual mode" and touch "system start" button on the touch screen.
(3) Start sea water pump to press the button “START/STOP”.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

(4) Wait 20 sec. Start blower to press the button “START/STOP”.

(5) Start sea water cooling system to press the button “START/STOP”.
(6) Wait 20 sec. Start blower to press the button “START/STOP”.
(7) After a pre purging time start fuel oil pump to press the button
“START/STOP”.
(8) Energize the ignition glow plug to press the button “GLOW PLUG”
(9) Wait approx. 30sec and admit fuel oil and air to the ignition burner
to press the button "IGNITION BURNER"
(10) Wait another 5 seconds and admit fuel oil to main burner to press
the button “MAIN BURNER”
(11) When flame is established and indicated with “FLAME ” allow a few seconds
stabilizing time before stopping ignition burner by depressing buttons
"GLOW PLUG” and "IGNITION BURNER"

5) System stop
(1) Close I.G. main valve to press button “SELECT CONSUMER.” on the
touch screen at sub panel in cargo control room
(2) The plant can be stopped to press the "SYSTEM STOP" button on the
touch screen in main or sub.
(3) The sea water cooling system and the air blower will continue running for
a cooling down period except in air venting mode, and if push button
“EMERG. STOP.” has been used.

* If you need to adjust the blower outlet valve, f.o capacity valve, s.w. regulation
valve,
Dryer outlet gas valve by manualy. It can be adjusted by emergency operation
plate.
(1) Turn on the indicator power
(2) Press the mode button of the indicator you wish to perform manual operation.
(3) Insert the wanted value to indicator.
(4) Turn on the manual switch "ON" which valve indicator want to manual
control.
(5) You can continually operate the valve manually by changing the indicator
value.
* in auto mode,emergency operation switch must be located "OFF" position.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

5.3 Emergency operation

-Following instrution must be observed step by step during change over to
emergency operation.
-Required that the operator to continue monitoring the status each device
in the field manualy.

1) Before start
(1) The led marked "source" shall be energized at all times.
(2) Check the oxygen analyzer for correct calibration.

2) Starting for emergency mode

(1) Turn the "emergency operation" switch (key-operated) to position "on"
(2) Check the shutdown alarm.
(3) Check the sea water inlet/outlet valve open (local side)
(4) Check the overboard valve open (local side)
(5) Turn the "(blower 1/2, s.w. reg., dryer outlet gas, fo capacity)
valve manual" switch to position "on"
(6) Change to the manual mode valve indicator.
(push the "mode" button in indicator)
(blower 1/2 outlet v/v, dryer outlet gas v/v. fo capacity v/v indicator)
(7) Open the blower 1 or/and 2 outlet valve manually by the indicator.
position (50% load) :
(8) Open the dryer outlet gas valve manually by the indicator.
position (50% load) :
(9) Start the sea water pump at the sea water pump starter (local side).
(10) Start the blower 1 or/and 2 at the blower start after 30sec (local side).
(11) Start the chiller and chilled water pump at chller control panel.
(12) Turn on the heater and start rotor motor at dryer panel.
(13) Start the dryer fan at dryer fan starter.
set frequency (50% load) :
(14) Start the fo pump 1 or fo pump 2 at fo pump starter.
set frequency 60Hz
(15) Open the fo capacity valve manually by the indicator.
position ( %)

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

(16) Wait approx. 20sec, continue press "glow plug" push button.
(17) Wait approx. 30sec, continue press "pilot burner" push btton.
(18) Check the flame on lamp on the emergency mimic board.
(19) Wait approx. 5sec, press main burner "on" push button.
check the flame on led.
(20) Wait approx. 5sec recede "glow plug" push button.
(21) Wait approx. 5sec recede "pilot burner" push button.
wait until the steady withacceptable oxygen content.
(22) Oxygen control
to increase or decrease F.O capacity valve manually by the indicator.
monitoring the oxygen content to adjust the oil capacity little by little, slowly
(23) Inert gas supply
push main valve "open" push button. Check the man delivery valve open.
monitoring thee main line pressure and oxygen content.

3) System stop
(1) Push the main valve "close" push button in mimic board
(2) Push the main burner "off" push button in mimic board
(3) Stop the fo pump, dryer and chiller at local side.
(4) After cooling(approx. 2min), stop the sea water pump and blower.

* When shutdown alarm or emergency operation switch "off",

immediately ststem stop without cooling.

* In emergency operation the safety interlocks are reduced to

blower failure, scrubber sea water level high, emergency stop,
combution air pressure low, scrubber sea water pressure low,
flame failure, inert gas temperature high.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

5.4 Trouble Shooting

Trouble Cause What to do
Check MSBD breaker
Breaker power off
Power not ON Check main panel inside breaker
Loose cable Check cable tight and retighting

Emergency Check line connection and switch condition

Switch are interlocked
stop Check if the switch position has been restored
Pipe blocking Clean inside air pipe

Instrument air None sufficent air supply Check air pressure

pressure low Loose cable Check cable tight and retighting
Switch malfunction Change new one
Glow plug not power supply Check power supply in junction box
Check power supply to solenoid valve
Solenoid valve not open
Change new one
Flame failure
Flame scanner fail Change new one
Loose cable Check cable tight and retighting
Oil not supply Check F.O pump and pipe blocking
Level switch malfunction Change new one
Drain valve not open Check valve position
Scrubber
water level Loose cable Check cable tight and retighting
high
Check power supply to solenoid valve
Solenoid valve not open
Change new one
Pump not run Check starter panel
Scrubber
water Valve close Open valve
pressure low
Loose cable Check cable tight and retighting
Pump panel power off Check starter panel power on
Motor failure
Loose cable Check cable tight and retighting
for S.W pump
Overload Check to see that power supplied agrees
Water flow low Check valve position
Sea water
temperature Loose cable Check cable tight and retighting
high
Switch malfunction Change new one
Not power supply Check breaker 3F5
Oxygen The power fuse is cut in analyzer Check the fuse and replace it
content
low/high Change new one or connection change to
Analyzer relay malfunction
another relay

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

Trouble Cause What to do

Fluid level in tank too low Fill tank to nessary fluid level
Fuel oil Motor not run Check power supply
pressure low Pressure switch malfunction Change new one
Fluid leaking Leaking of oil from pump or pipe

Combusion Loose cable Check cable tigh and retighting

air pressure Blower air intake cover block Clean air intaker cover
low Pressure switch malfunction Change new one
Signal lost Check line connection and tighting
Loose cable Check cable tight and retighting
Wire breakage Change new cable or connected
Inert gas
Seawater spray nozzle block Clean spary nozzle in scrubber
temperature
high Check sea water pressure and flow to
None sufficent seawater supply
scrubber
Mesh for scrubber damage Change new one
Sensor malfunction Change new one
Power off Check starter panel power on
Overload trips Check and reset overload in starter
Motor failure Improper power supply Check to see that power supplied agrees
of F.O pump Improper line connections Check connections with diagram
Check to see if motor and drive turn
Machanical failure
freely. Check bearings and lubrication
Power off Check starter panel power on
Overload trips Check and reset overload in starter
Motor failure Improper power supply Check to see that power supplied agrees
of blower Improper line connections Check connections with diagram
Check to see if motor and drive turn
Machanical failure
freely. Check bearings and lubrication
Breaker off Check breaker or power line cable
Control
Loose cable Check cable tight and retighting
power
None sufficent power supply Check control power supply
fail
Relay malfunction Change new one
Power off Check breaker
PLC Failure Run with emergency mode and cotact to
PLC Failure
KANGRIM

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

Trouble Cause What to do

Not operated with input signal
Short or open circuit of termianl motor
applied
Butterfly
Too low or none supply air Check air pressure and blocking
valve
Valve track not match Re-calibration according valve manual
operation
Loose cable Check cable tight and retighting
Analog output card malfunction Change new one
Pressure Analog signal not come Check the cable tighten
transmitter Loose cable Check cable tight and retighting

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

6. Adjustment and tolerances

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

6. ADJUSTMENT AND TOLERANCES

6.1 Adjustment and Tolerance
1) Oil Burner
The oil atomizer position, relative to the air deflecting cone, can be adjusted
by loosening the gland nut on the burner gun carrier tube and moving the oil
gun outwards or inwards.
The best position is easiest found if the adjustments are made with the burner
in operation, and by measuring the inert gas CO-content.
The correct position is normaly indicated by a distinct drop in measured CO-conten
Without an instrument for measuring the CO-content, the best position for the
atomizer is to be found as follows:
Start the I.G. generator. Adjust the atomizer slow-upwards or downwards
whilst at the same time observing the flame colour in the sight glass. The best
position is achieved when most of the flame burns clear / blue. Further
improvement is only obtained with equipment for measuring of CO-content.
The improvement is only in range of some ppm CO.
The atomizer is set to the theoretically best position by our workshop.
During operation the best position will be found by our service engineer.

2) The Combustion Air System

The combustion air pressure to the main burner is indicated on pressure gauge
(Item No. 1610 ). Normal value: 0.57 – 0.65 barg.

3) The Fuel Oil System

The fuel oil pressure to the main burner is indicated on pressure gauge (Item
No.1650).
Normal value approx.: 25 barg.
The pressure may be adjusted with the pressure relief valves in the fuel oil
pump, but should normally not be touched, once it is set correctly on initial
commissioning.
The pressure should equal an now of oil consumption rate at I.G capacity. The
fuel oil capacity is controlled from the oxygen analyzer.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

4) The Gas System

Gas pressure outlet cooling tower pressure gauge (Item No. 1670)
Pressure at full capacity : Approx. 0.44barg.

This is controlled by the pneumatic controlled valve (Item No. 0100).

Gas temperature outlet cooling tower (Item No. 1790).

Gas pressure outlet cooling tower is equal to the combustion air pressure, less
the pressure loss through the burner/scrubber unit.

5) The Seawater System

Water pressure in cooling jacked center tube:
Pressure gauge (Item No. 1620): approx. 0,8 barg.

Water pressure to nozzles:

Pressure gauge (Item No. 1640).
Sea water inlet pressure : 1.5~2.5barg.

6) Alignment of Combustion Control

Calibration of I/P Converter PY 2110 and EP Positioner EP 0101

I/P converter PY 2110 for fuel oil capacity control valve must be calibrated to
obtain 3 psi(4mA) outlet sight at 0% and 15 psi(20mA) at 100%.

EP positioner EP 0071 and EP 0081 for blower capacity control valve must be
calibrated to obtain 0%(4mA) outlet sight at 0% and 100%(20mA) at 100% set
point.

EP positioner EP0102 for blower capacity control valve must be calibrated to

obtain 0%(4mA) outlet sight at 0% and 100%(20mA) at 100% set point

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

7. Maintanence

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

7. MAINTENANCE
7.1 General
The dry inert gas system is designed to protect the ship from a hazardous build-up
of famemable gases in the cargo tanks. It should therefore be subject to regular
maintenance to keep the whole installation at a high degree of availability,
reliability and efficiency.
Overhaul maintenance instructions are given in the respective vendor manuals.
The maintenance instructions here provided are for routine inspections and
maintenance only and deals with:

- Inert gas generator

- Dryer & Cooler unit

Maintenance routines for the refrigerator plant and air compressor units are
described in details in the respective vendor manual. Please read these manuals
to ensure the efficient operation of the equipment.

It is a condition of the warranty caver that the dry inert gas system is properly
maintanined and adjusted, that all checks, routine maintenance and reqular
servicing listed in the maintenance schedules are carried out at the specified
intervals and that an accurate record is kept of the work.

Malfunctions caused by poor and insufficient maintenance are not covered by

KANGRIM warranty conditions. KANGRIM is only liable for the fault caused by
casual fact attributable to the material.

7.2 Safety
Prior to any maintenance or inspection task, all safety precautions are to be
observed most rigidly. Interlock of circuit breakers and warning signs are to be
put up when maintenance is being carried out to avoid the possibility of
accidental or unauthorized operation of the plant.

Personnel who carry out maintenance work must use proper protective equipment
suitable for the task and environment. Pay especially attention to noise level,
entering of enclosed space, work on electric equipment, hot surfaces, work

____________________________________
on pressurized or rotating equipment and handling of chemicals, oil and gases.

KANGRIM HEAVY INDUSTRIES CO., LTD.

 OPERATION MANUAL

7.3 Routine maintenance

The following routines must be carefully followed and maintained in an
operation log.
- Inspection schedules
- Maintenance schedules

Intention of a service & maintenance log is to gather documentation of importance

for tracking duty cycle. If it is correctly maintained it will uncover and prevent
damages that is caused be poor materials, wrong operation and poor maintenance
routines.
7.4 Inspection Schedules

operation

operation

Monthly
During
Daily

After
No.
Item
1 Check instrument air supply X
2 Check compressor oil and freon level X X
3 Check compressor oil heater X X
4 Check sample gas flow to analyzers X
5 Check system performances X
6 Check pressure drop across mist filter X
7 Start system in dry air mode X
8 Start system in inert gas mode
9 Check blower and shaft sealing X
10 Function check off all transmitters
11 Check motor starter panels
12 Check modulating valves
13 Check wet gas regeneration fan
14 Inspection of dryer
15 Inspection of scrubber
16 Check calibration of transmitters
17 Check access doors, locks and seals
18 Inspections for R-407C compressor X X X X

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

3 Month

6 Month

Yearly
No.
Item
1 Check instrument air supply X
2 Check compressor oil and freon level X
3 Check compressor oil heater X
4 Check sample gas flow to analyzers X
5 Check system performances X
6 Check pressure drop across mist filter X
7 Start system in dry air mode X
8 Start system in inert gas mode X
9 Check blower and shaft sealing X
10 Function check off all transmitters X
11 Check motor starter panels X X X
12 Check modulating valves
13 Check wet gas regeneration fan
14 Inspection of dryer
15 Inspection of scrubber
16 Check calibration of transmitters
17 Check access doors, locks and seals
18 Inspections for R-407C compressor X X X
- Notes
1. Check that the instrument air supply to the system is 7barg.
2. Check the refrigerator compressor oil and Freon level.
3. Check that oil heater for the refrigeration compressor is energised.
Must be energized at least 12 hours. Prior to start-up.
4. Check sample gas flow indicators for positive flow.
5. Check pressures of all manometers and temperature gauges to verify the
operating condition parameters are not abnormal.
6. Check presusre drop over the mist filter on dryer unit. High pressure may
indicate dirty or clogged filters.
7. The system must be started and in operation in dry air mode least once in a
month. The system should run for approximate 30 minutes. This must be logged.
8. The system must be started and in operation in dry IG mode least once every
third month. The system should run for approximate 30 minutes with inert gas

____________________________________
delivered to dryer. (Dry inert gas to atmosphere) This must be logged.

KANGRIM HEAVY INDUSTRIES CO., LTD.

 OPERATION MANUAL

9. Check that drains in the casings are clear and that no water is standing.
Check that there is no gas leakage from any of the blower casings during plant
operation. If the seal rings are worn, they must be replaced.
Check yearly the internal and external surfaces of blowers. Check tightness
of bolts and set screws with particular attention to the transmission.
10. Test the operation of all pressure and temperature sensors by verifying
reading in the operator terminal are correct. Remove the level sensor and
immerse it in the water to see if the sensor is operating properly.
11. Check motor starter panels for loose wiring, burned contacts or other
machanical failure.
12. Check the adjustments of the modulating valves positioners. This can be done
from the operator terminal.
13. Internal and external surfaces of wet gas fan should be examined for signs of
deterioration of finish. Check shaft seal for leaks or wear. Check the tightness of
bolts and set screws with particular attention to the impeller and motor mountings.
14. The following items on the dryer unit should be inspected and if necessary cleaned
with a vacuum cleaner. Do not use any cleaners on the rotor surface.
(Chemicals may be destructive on the dryer rotor.)
- Rotor surface
- Be careful not to damage the rotor surface.
- Gear motor and belt transmission
- Regeneration heater surface
Check internal rotor sealing and repair or replace defects. Check condition of
the outlet filter. Replace if necessary.

15. Open the inspection covers and inspect the internal lining in the scrubber unit.
Repair and damages. Inspect demister and spray nozzles clean out if necessary.
Use only mild cleaner. (Chemicals may be destructive on the demister.)
16. Check calibration of all transmitters yearly or after vessel inspection schedules.
Test and verify all alarms. Use the alarm list for reference.
17. In order to avoid leaks that may cause reduced system performance or inert gas
escape, all access doors, locks and seals must be checked. Repair or replace
replace defects.
18. Carry out routine inspection on refeigeration unit according to vendors manual.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

7.5 Maintenance Schedules

operation

operation

Monthly
Weekly
Before

Atter
No.
Item
1 Clean filter in oxygen analyzer X
2 Clean filter of instrument air line X
3 Clean filter of pressure regulators X X
4 Flush cooling jacket & comb. chamber X
5 Wash of cooling coil X
6 Drain wet gas regeneration fan X
7 Clean flame sensors X
8 Clean fuel nozzles X
9 Clean mist filter X
10 Clean demister X
11 Clean steam strainers X
12 Drain air supply lines X
13 Rotate blower
14 Grease blower motors
15 Calibrate oxygen analyzer X
16 Maintenance for R-407C compressor X X X X
17 PLC battery X

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

3 Month

6 Month

Yearly
No.
Item
1 Clean filter in oxygen analyzer
2 Clean filter of instrument air line
3 Clean filter of pressure regulators
4 Flush cooling jacket & comb. chamber X
5 Wash of cooling coil X
6 Drain wet gas regeneration fan
7 Clean flame sensors
8 Clean fuel nozzles
9 Clean mist filter X
10 Clean demister X
11 Clean steam strainers
12 Drain air supply lines
13 Rotate blower X
14 Grease blower motors X
15 Calibrate oxygen analyzer X X
16 Maintenance for R-407C compressor X X X
17 PLC battery X

- Notes
1. Dip the filter in Acetone for 5~10min. Wash the filter in water with a little soap,
then clean the filter in fresh water until all soap in removed. Please note that
the filter is PTFE material and must be handled with care.

2. Open the door of pneumatic panel and check the filter condition.
Clean the filter of regulator if necessary.
3. Check the condition of the filter at the butterfly valves where the air filter
regulator is installed. Clean the filter of regulator if necessary.
4. The combustion chamber cooling jacket of the generator must be rinsed with
fresh water after each stop. (only if the installation is stopped for a period of
one day or longer.) The fresh water is entered into the combustion chamber
cooling jacket. Rinse the chamber with fresh water for about 20 minutes.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

CAUTION : Do not use salt water

5. The cooling coil of the cooler must be washed with fresh water after each stop.
(only if the installation is stopped for a period of one day or longer.)
Open the filter hatch and the inspection manhole to access both sides of the
cooling coil. Wash all surface of the cooler unit and the cooling coil with fresh
water to prevent build up of dust or corrosion damages.

CAUTION : Avoid water accumulation into the dryer. Do not point a water
jet towards the droplet eliminator.
6. Check the regeneration fan and piping to verify if any water has accumulated.
Drain out if necessary
7. Clean flame sensors and ignition glow plug. Do not touch the glass surface on
flame sensors by hands. Use clean rags only.
8. The oil gun to be removed on the burner top side and oil nozzle to be
disassembled and internals inspected. Clean out if necessary. Clean the fuel
nozzle of ignition burner and main burner.
CAUTION : No steel or metal wire etc. must be used to open dirty or
clogged openings in the nozzle. It is absolutely essential for good
performance of the plant that the atomizing nozzle is in good condition.
9. Inspect and clean or replace mist filters if necessary.
10. Open the manhole access both sides of the scrubber.
Wash all surface of the demister with fresh water to prevent build up of dust
or corrosion damages. Clean the wet fillter demister in the same way.
11. Clean the steam strainers for the steam heater.
12. Drain the instrument air supply line.
13. Rotate the blowers that have not been used. Either by hand or by starting the
blower. Let the blower run until start current is normal before stopping to avoid
high load on start contactor.
14. The blower motors require re-greasing as recommended by vendor. Check the
reading of the hour counter and determine if re-greasing is necessary. Please
also remember that re-greasing intervals are dependent on running
temperarture of the motors.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

15. For analyzer maintenance and calibration instructions.

If there is an absolute need for gas with an oxygen content of less than 1%,
the plant may be operated at a lower value, if special attention is paid
to the below listed items.
- Carefully calibrate the oxygen analyzer.
- Use a clean oil atomising nozzle in best possible condition.
- Check stability during running conditions.
- Sample the gas at regular interval.
- The operator should always be present.

16. Carry out routine maintenance on refrigeration unit accroding to vendors manual.
17. Battery life
A battery’s life may be different depending on the conditions of blackout time,
service temperature, etc. When the voltage of a battery gets lower, the basic
unit sends ‘Warning on Battery’s Voltage Drop’. The situation also can be
checked through the basic unit's error LED and XG5000's error message.
(Warning on a battery’s voltage drop occurs within 10 second after detaching
the battery) In the system with routine inspection, you can take measures after
the fact since the battery works normally for substantial amount of time even
after the warning on a battery’s voltage drop occurred.

How to replace a battery

The battery used for backup in case of power failure of programs and data
requires the periodic replacement. Although the battery is removed, the
program and data electrostatic holding data are maintained by the Super
Capacitor for about 30 minutes, however, it should be replaced as soon as
possible. The procedures to replace the battery are as below.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

8. Some possible causes to faults

during start and operation.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OPERATION MANUAL

8. SOM POSSIBLE CAUSES TO FAULTS DURING START AND OPERATION

8.1 If Control Current is not on:
Check that fuses are all right.
Check that circuit breaker in main switchboard is ”ON”

8.2 If Ignition Does not Take Place:

Check that the ignition glow plug is glowing.
Check fuel oil pressure to ignition burner.
Check and clean oil nozzle in ignition burner.
Check HIC 2140 to be in marked start set-point.
Check fuel oil flow.
Check and clean main oil nozzle and oil system for possible clogging.

8.3 If Fuel Oil Pressure is too Low:

Check that fuel oil pump is running. Fuel oil pump must never run without oil
supply.
Check that fuel oil valves are in right position.
Check that valves are correctly adjusted.
Change oil filter with the built-in 3-way valve.
8.4 If Sea Water Pressure is too Low:
Check the sea water supply system.
Check that the pressure gauge, pressure switch and pipes are all right and not
clogged by salt.

8.5 If Sea Water Level in Cooling Tower is too High:

Check that sea water pressure is approx. 1.5~2.5 barg
Check that the overboard valve is open.

8.6 If Inert Gas Temperature is Higher than Approx. 5 °C Above Sea Water
Inlet Temperature :
Check that sea water pressure is approx. 1.5~2.5 barg
Clean the sea water spray nozzle.

8.7 If the Instrument Air Pressure is too Low:

Check the instrument air system : Air pressure should be 6~9barg.

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 PART DOCUMENTATION

7. PART DOCUMENTATION

____________________________________
KANGRIM HEAVY INDUSTRIES CO.,LTD.
CONTENTS

1. OXYGEN ANALYZER

2. P.L.C

3. FUEL OIL PUMP

4. ROTOR

5. CHILLER UNIT

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

INSTALLATION OPERATION
AND MAINTENANCE INSTRUCTION

1. OXYGEN ANALYZER

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

TABLE OF CONTENTS

PAGE
1. Introduction ----------------------- 3

2. Analyzer Specifications ----------------------- 6

3. Analyzer Installation & Connections ----------------------- 6

4. Analyzer Operating Instructions ----------------------- 15

5. Trouble Shooting ----------------------- 36

____________________________________
2 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

1. Introduction
1.1 About This Manual
This manual describes the correct procedures for operation, installation, and
services of the OA-Z-IG2 Oxygen Analyzer and satisfies the manual composition
requirements of EN 50104. Drawings, diagrams and tables have been provided
to facilitate understanding and some parts include categorization by color.
Therefore, you are advised to print this manual in color.

Persons who install, operate, or provide after-sales services should be well-

acquainted with the contents of this manual before starting installation,
operation, or services so as to prevent any potential dangers. When the printed
manual is damaged or deformed, replace it with a new one as soon as possible.

This manual was produced by Oxus Co. Ltd. It is strictly prohibited for any
unauthorized third parties to use this for commercial purpose.

1.2 About the Analyzer

This OA-Z-IG2 Oxygen Analyzer is designed to measure the Oxygen
concentration in an environment where the combustion gases of oil or gas
fuels flow and to transmit the Oxygen concentration and other required
information through visual or electric signals to users and related equipment.

This OA-Z-IG2 Oxygen Analyzer uses a Zirconia sensor. The Zirconia used here
is an yttrium-doped zirconium dioxide which has Oxygen ion conductivity at
high temperatures. There are electrodes at both sides of Zirconia. The Oxygen
gas is ionized to Zirconia at the anode (+), moves to the cathode (-) and
transforms back to gas. Because the current amount for the applied voltage
varies by the Oxygen concentration, the Oxygen concentration can be
calculated. Because the Zirconia sensor uses the nature of Zirconia, it is non-
consumable, has long life-span, has few measurement drifts, and outputs purity
in a stable manner.

____________________________________
3 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

Figure 1.1. Oxygen sensor cell in OA-Z-IG2

The cell consists of two Zirconia squares coated with a thin porous layer of
Platinum which serve as electrodes. The Platinum electrodes provide the
catalyst necessary for the measured Oxygen to dissociate allowing the Oxygen
ions to be transported in and out of the Zirconia. The two Zirconia squares are
separated by a Platinum ring which forms a hermetically sealed sensing
chamber. At the outer surfaces there are two further Platinum rings which
along with centre Platinum ring provide the electrical connections to the cell.
Two outer Alumina discs filter and prevent any particulate matter from entering
the sensor and also remove any un-burnt gases.

For clear understanding about this manual, See Figure 1.2 below.

____________________________________
4 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

Figure 1.2. Exploded view drawing of a OA-Z-IG2 Oxygen Analyzer

____________________________________
5 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

2. Analyzer Specifications
Measuring method Zirconia Sensor
Measurement range 0.1 ~ 25.0 %O2
Accuracy ±0.5% of the measuring range
Repeatability ±0.1% of the measuring range
Measurement Drift on Month ±0.1% of the measuring range
Performance Less than 10 seconds
Time of response
(Time to 90% of measuring range)
Warm-up time 150seconds
Stabilization time 150seconds
Proper flow 0.1~1 LPM
85-264VAC - 50/60Hz or
Power Power Supply
110-340VDC or 12VDC
Performance
Power Consumption 10VA per analyzer
Analog Output Active 4 ~ 20 mA
Load output(max.) 600 ohm / 24VDC
Signal Digital Output RS485 Protocol
Transmission Low, High-Caution, High-warning;
Alarm functions
O2 level System failure,
Relays 5 relays
Dimensions 180 x 220 x 100
Properties of Weight 2.7kg
Solid Case Material Aluminum alloy
Case Protection IP67
temperature limits -10~60ºC
Environment
humidity limits Below 90%, no condensation
Limits
pressure limits -40~500kPa

____________________________________
6 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

3. Analyzer Installation & Connections

3.1. Before Installing
If the product that you received is different from the product that you ordered,
or if it was delivered in damaged condition, or if you believe that it does not
meet the warranty requirements, you are entitled to ask for a refund or
exchange of the product. In this case, please contact the supplier.

3.2. Where to Install the Analyzer

Please comply with the following precautions for installation to guarantee
proper operation:

a. Do not install the product on a shaky support or a slanting place.

b. Do not install the product in a place where vibrations from other machines,
etc. are transmitted.
c. Do not put other products on this product.
d. The proper flow stated in Measurement Performance of the Specifications
(see 2) must be satisfied.
e. The product must be installed in an environment that satisfies the
Environment Limits of the Specifications (see 2).
f. It is recommended to use a filter for filtering out dusts, water, and oil
mists which can shorten the replacement cycle of the sensor (see 4.2.3).

____________________________________
7 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

3.3. Safety Aspects

Warning

Always make sure that the all the power supplies and signal cables are correctly
connected before applying the power!

Never use this product in an environment with potential danger of explosion.

Only the trained, skilled, and certified personnel must install and operate the
OA-Z-IG2 Oxygen Analyzer. Oxus Co., Ltd. does not take responsibility for
installation and operation by other persons than those sent out from our
company.

Thoroughly read and understand the contents of this manual and comply with
them. Oxus Co., Ltd. does not take responsibility for any accidents by people
who do not understand this manual or any accidents resulting from installation
and operation that violate the instructions in this manual.

Hazardous voltage!

Cut off the power supply when installing or servicing the product. Furthermore,
accurately follow the instructions in this manual to ensure correct connections
of all power supplies and signals.

Ignoring this warning can cause damages to machines or serious injuries to

people.

Circuit breaker!
You must always include means of power separation by circuit breakers and
marked switches outside the Analyzer. Furthermore, the external switches and
circuit breakers must be located near this Analyzer and must be easily
accessible by operator.

____________________________________
8 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

Overload protection!
Means of overcurrent protection must be included in the installation so that
this Analyzer can be protected from excessive energy leaked from the power
supply in the event of a defect in this Analyzer.

Protective earth!
The Analyzer must be always connected to a protective earth terminal.

Installation and fault finding!

Electrical connections and defect analysis of the Analyzer must be performed by
engineers who are properly trained and qualified.

EMC!
The cables for main power supply, relays, and analog signal connections must
be shielded or protected.

Connections!
All the electrical connections and power supplies are connected inside the
Analyzer. To make connections, open the top cover and insert cables through
the external connectors of the Analyzer.

Poisonous gases!
Combustible gas atmosphere such as methane, alcohol, hydrogen, and carbon
monoxide can cause measurement errors.

Silicon gases containing siloxane can greatly shorten replacement cycle because
they damage performance by reacting with sensors and the oxides of sensors.

Sulfuric acids (SOX) and hydrogen gases (H2) can greatly shorten replacement
cycle because they damage performance by reacting with sensors.

Preon gas and gases containing halogens (F, Cl, Br) can decrease performance
and destroy sensors by reacting with materials inside the sensors.

____________________________________
9 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

Heating temperature!
Because the sensors are heated to 450°C, gases that are ignited at
temperatures below it cannot be used.

Gas Conditions!
If filters in the sensors are blocked, it can cause problems such as measurement
errors and wrong responses. Protect the sensors from the approach of water
and condensed water because contacting with water can destroy the sensors.

Physical shock!
Do not apply to the sensors a shock of 10G or higher or shocks that can break
internal connections and crack the sensor chips.

Recycling!
Do not dispose of this product as general waste. Always follow the
requirements of applicable laws when discarding this product.

Symbol identification

Caution, risk of danger

Caution, risk of electrical shock

Caution, hot surface

Protective earth

The CE mark proves the compliance of the instrument with the

requirement of the relevant EU directives

____________________________________
10 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

3.4. Adjustment Procedure

Please follow the following installation sequence for correction installation:

1) Instruments Mounting (See 3.6)

2) Electrical Connection (See 3.7)

3) Initial settings of a) to d) below:

a) Clean all the parts with visual displays including the display screen.
b) Perform the time set process. (See 4.1.3, Time Set)
c) Perform the calibration process. (See 4.1.4)
d) Perform the setting process for alarms and relays.(See 4.1.3, Alarm Set and
Relay Set)

3.5. Instruments Mounting

Analyzer should be equipped in the comfortable direction when operator reads
the display window. Display window should be equipped not too high or not
too low from the eyesight.

There are 4 screw halls for monitoring in the rear of analyzer. The gap of each
hall is 168ⅹ208mm and the screw size is M5. See Figure 1.2 below.

____________________________________
11 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

3.6. Electrical Connection

All terminals are on the bottom PC-Board. See Figure 3.1 for details.

Figure 3.1. Bottom PC-Board with Electrical Connections

____________________________________
12 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

3.6.1. Power Supply

Both alternating-current and direct-current power sources can be used for the
OA-Z-IG2 Oxygen Analyzer.

For alternating current power source, a voltage in the range of 100 -

240V(50/60Hz) can be used. The terminal is at bottom left.

For direct current power source, a 24V voltage can be used. The direct current
power source of 24V voltage is connected to the terminal at bottom center (a
little to the right).

See Figure 3.1 for clear understanding.

3.6.2. Relay Outputs

The OA-Z-IG2 Oxygen Analyzer has terminals for five relays. These terminals are
located at top right. See Figure 3.1 for clear understanding.

3.6.3. Analog Output Connections

Analog signal output specification ranges from 4 to 20mA, which applies power
supply for signal output (Active). Terminals are those two on the left hand of
Terminal 4 Block on the right bottom.

See Figure 3.1 for clear understanding.

3.6.4. Digital Output Connections

Digital signal is sent in accordance with the RS485 communication protocol, the
transmission speed of which reaches 9600bps on a non-echo mode basis. In
addition, data bit is 8 bit while stop bit is 1 bit, not using parity bit. Terminals
are those two on the right hand of Terminal 4 Block on the right bottom.

For a clear understanding, please see Figure 3.1.

Transmitted data is a 10-byte hexa-code in accordance with Table 3.1 with

which you should comply when reading a data code.

____________________________________
13 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

Table 3.1. Output data interpretations for digital communication

____________________________________
14 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

4. Analyzer Operating Instructions

4.1. Analyzer & Software Operating
4.1.1. User interface Structure

Figure 4.1. User interface Structure

____________________________________
15 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

4.1.2. Main Menu

See the example of Main Display in Figure 4.2 below.

Figure 4.2. Example of Main Display

You can check on Main Display: ① name of display, ② Oxygen fraction(The
degree of fraction with a single digit decimal point on the upper side is
indicated on all displays), ③ date and time, and ④ alarm. With ‘① name of
display’ you can check the current location in a user interface structure (See
Figure 4.1). With ‘③ date and time’ you can select time on Setting Display and
adjust it on Time Set Display (see 4.1.3, Time Set). With ‘④alarm’ you can select
alarm on Setting Display and adjust it on Alarm Set Display (see 4.1.3, Alarm
Set). ⓐ, ⓑ, ⓒ, and ⓓ are a button by which you can move to Setting Display,
Calibration Display, Check Display, and Information Display, respectively.

____________________________________
16 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

4.1.3. Setting Menu

See the example of Setting Display in Figure 4.3 below.

Figure 4.3. Example of Setting Display

You can check on Setting Display: ① name of display, ② Oxygen fraction, ③
date and time, ④ alarm. ⓔ, ⓕ, and ⓖ are a button by which you can move to
Time Set Display, Relay Set Display, and Alarm Set Display, respectively while ⓗ
is a button returning to Main Display.

Setting Process
Time Set Process, Relay Set Process, and Alarm Set Process all follow Setting
Process in the following steps.

1) Press the ▲ or ▼button to move the ▶ cursor to the setting you want to
adjust.
2) Press ▶ button; the ▶ cursor will be moved to the front of the next set
value.
3) Adjust the set value with ▲ or ▼ button.
(For more than one set value, repeat 2) and 3))
4) Press ▶ button; The SET text and highlight color will be invert such as SET,
and ▶ button will be changed to button.

____________________________________
17 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

5) Press button; Setting Process will be completed, and the ▶ cursor will
appear to the front of 1st Column.
(without this process, the modified set value is not applied)

If you want to cancel Setting Process, you can press the ⓗ Home button for
return to Main Display when any step.

Time Set
Time Set is a function to set time on display. See the example of Time Set
Display in Figure 4.4 below.

Figure 4.4. Example of Time Set Display

You can check on Time Set Display: ① name of display, ② Oxygen fraction, ③
date and time, and ④ alarm.
The Time Set Process follows the Setting Process (see 4.1.3, Setting Process).
The factory initial value of Time Set is 01/01/2014 00:00. All the applicable
settings of Time Set are shown in Table 4.1 below.

Table 4.1. All settings of Time Set

____________________________________
18 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

Relay Set
Relay Set is a function to set the control of external power connection. See the
example of Relay Set Display in Figure 4.5 below.

Figure 4.5. Example of Relay Set Display

You can check on Relay Set Display: ① name of display, ② Oxygen fraction, ③
date and time, and ④ alarm. RLY stands for relay.
The Relay Set Process follows the Setting Process (see 4.1.3, Setting Process).
The factory initial value of Relay Set is "-- Close". All the applicable settings of
Relay Set are shown in Table 4.2 below.

Table 4.2. All settings of Relay Set

When you set the value (--) in the 2nd column, you can set either of OPEN or
CLOS in the 3rd column. CLOS stands for close, which is set to make Relay
being applied of current all the time while it is set as OPEN to make the

____________________________________
relevant Relay set in outage all the time.

19 KANGRIM HEAVY INDUSTRIES CO., LTD.

 OXYGEN ANALYZER

If you set either of NO or NC values in the 2nd column, you can set one of
ALM1 ~ ALM5 in the fourth column. ALM stands for alarm (for setting alarm,
see Alarm Set in 4.1.3). If NO is set, the relevant relay is applied of current in an
ordinary situation while the set alarm works to make the relevant relay set in
outage. If NC is set, the relevant relay is in outage in an ordinary situation while
the set alarm works to make the relevant relay being applied of current.

If you set the value of TIME in the 2nd column, you can set the value between
00:00 to 23:59 in the 4th column. After the setting, timer works to apply the
current for as many as the set minute and second in the 3rd column and then
the power is disconnect for as many as the set minute and second in the 4th
column, both of two processes continuously being repeated.

____________________________________
20 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

Alarm Set
Alarm Set is a function to set alarm for the Oxygen fraction. See the example of
Alarm Set Display in Figure 4.6 below.

Figure 4.6. Example of Alarm Set Display

You can check on Alarm Set Display: ① name of display, ② Oxygen fraction, ③
date and time, and ④ alarm. ALM stands for alarm.
The Alarm Set Process follows the Setting Process(see 4.1.3, Setting Process).
The factory initial value of Relay Set is shown in Table 4.3 below.

Table 4.3. Factory initial values of Alarm Set

All the applicable settings of Alarm Set are shown in Table 4.4 below.
Table 4.4. All settings of Alarm Set

____________________________________
21 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

Among the set values in the 2nd column, LO stands for low, which alarms that
the Oxygen fraction in the air currently being measured is less than the set
value in the 3rd column. LL stands for low-low, alarming that the Oxygen
fraction is below the set value in the 3rd column. In addition, HI stands for high
alarming that the Oxygen fraction is more than the set value in the 3rd column
while HH stands for high-high alarming that the Oxygen fraction is above the
set value in the 3rd column.

____________________________________
22 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

4.1.4. Calibration
Calibration is a function to correct the margin of error of the measured Oxygen
fraction. See the example of Calibration Display in Figure 4.7 below.

Figure 4.7. Example of Calibration Display

You can check on Calibration Display: ① name of display, ② Oxygen fraction,
③ date and time, and ④ alarm. CAL stands for calibration.
The sequence of the Calibration Process is described below.

1) Press the ▲ or ▼ button to move the cursor to CAL setting of either of

LO CAL (low calibration) or HI CAL (high calibration) you want adjust.
2) Press the ▶ button; the ▶ cursor will move to the front of the set value.
3) Press the ▲ or ▼ button to adjust the set value the same as the Oxygen
fraction of reference gas.
4) Press ▶ button; The SET text and highlight color will be invert such as SET,
and ▶ button will be changed to button.
5) Press the button(at this moment, reference gas is being flown); Calibration
Process will be completed, and the ▶ cursor will appear to the front of 1st
column again (without this process, calibration set is not applied).

If you want to cancel the progress of Process during Calibration Process, press
the button of ⓗHome to return to Main Display. When you press ⓗHome in a
situation where the processes after Paragraph 3) above is already done and you
return to Main Display, the process until 3) is not canceled but the set value in
the 2nd column is saved.

The factory initial value for Calibration is: 00.0 for Low Cal Point and 25.0 for
High Cal Point.
____________________________________
23 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

All the applicable Cal Point values of Calibration are shown in Table 4.5 below.
Table 4.5. All Cal Point values of Calibration

The following Calibration Concept graph in Figure 4.8 shows how calibration
progresses inside the program. The Default Line is the function of the received
input signal voltage and the percent Oxygen.

Figure 4.8. Calibration Concept Graph

____________________________________
24 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

If High Calibration is attempted at a value lower than the input Low Calibration
Input Signal Voltage or Low Calibration is attempted at a value higher than the
input High Calibration Input Signal Voltage, the message “O2 HI INPUT VALUE
ERROR” or “O2 LO INPUT VALUE ERROR” message is output and the Calibration
Process does not proceed. If you experience difficulties due to incorrect
Calibration Process, perform Default Process (see 4.1.6) and then perform
Calibration Process again.

____________________________________
25 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

4.1.5. Check Menu

See the example of Check Display in Figure 4.9 below.

Figure 4.9. Example of Check Display

You can check on Check Display: ① name of display, ② Oxygen fraction, ③
date and time, and ④ alarm. CHK stands for check. ⓘ, ⓙ, and ⓚ are a button
that moves to Signal check Display, Relay check Display, and Log check Display,
respectively while ⓗ is a button to return to Main Display.

____________________________________
26 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

Signal Check
Signal Check is a function to set the analog output value according to the
Oxygen fraction, and to check the connection status by sending a wanted value.
See the example of Communication Check Display in Figure 4.10 below.

Figure 4.10. Example of Communication Check Display

You can check on Signal Check Display: ① name of display, ② Oxygen fraction,
③ date and time, and ④ alarm. SIG stands for signal.

____________________________________
27 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

The setting of analog output according to the Oxygen fraction determines

maximum output value of 20 mA according to whether 10 %O2 or 25 %O2.
According to the setting, the output value corresponding to the Oxygen
fraction is shown in Table 4.6 below.
Table 4.6. All Cal Point values of Calibration

The factory default is 25 %O2. Can change on “O2 at 20mA” row and the
setting process follows Setting Process(see 4.1.3, Setting Process).
Through the Signal Check Process, it can be transmitted the analog output
value you want. The sequence of the Signal Check Process is described below.

1) Press the ▲ or ▼ button to move the ▶ cursor to the output value you
want.
(In the “O2 VALUE” row, it can output the mA value calculated based on %O2
you want, and in the “mA VALUE” row, it can output the mA value you
want.)
2) Press the ▶ button; the ▶ cursor will move to the front of CHECK.
3) Press the ▲ or ▼ button; CHECK will turn red such as CHECK, and the signal
value will be output for wanted Oxygen fraction level.

If you press ⓗHome during processing, you return to Main Display to transmit
the normal signal value equivalent to the Oxygen fraction.

____________________________________
28 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

Relay Check
Relay Check is a function to check the connection status by randomly changing
the control of external power connection. See the example of Relay Display in
Figure 4.11 below.

Figure 4.11. Example of Relay Check Display

You can check on Relay Check Display: ① name of display, ② Oxygen fraction,
③ date and time, and ④ alarm.
The 2nd column shows the current applicable status of relay while the 3rd
column shows the set value. All the applicable set values are OPEN or CLOS.

The sequence of the Relay Check Process is described below.

1) Press the ▲ or ▼ button to move the ▶ cursor to the relay you want.
2) Press the ▶ button; the ▶ cursor will move to the front of the set value.
3) Select Open or Close you want using the ▲ or ▼ button; the set
OPEN/CLOS value is applied regardless of the measured value.

If you press ⓗHome during processing, you return to Main Display and the
relay comes to the normal OPEN/CLOS equivalent to the setting, again.

____________________________________
29 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

Log Check
Log Check is a function to check the records of the alarms which have been
worked. See the example of Log Check Display in Figure 4.12 below.

Figure 4.12. Example of Log Check Display

(a) When no log data is saved, (b) first page of log, (c) second page of log

____________________________________
30 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

You can check on Log Check Display: ① name of display, ② Oxygen fraction, ③
date and time, and ④ alarms.

Without log data, display like Figure 4.12 (a).

In the log data, when an alarm occurs or clear, the time, the alarm, and the
occurrence/clearance are stored in a list. Five log data are listed per page, and
you can press ▲ or ▼ button to move to the page. Also, depending on date
and time setting, The way the time is expressed in log is different(see 4.1.6). For
easier understanding, see (b) and (c) in Figure 4.12.

The total structure of logs displayed in Log Check Display is shown in Table 4.7
below.

Table 4.7. Total structure of logs in Log Check Display

You press ⓗ Home to return to Main Display.

____________________________________
31 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

4.1.6. Information Menu

See the example of Information Display in Figure 4.13 below.

Figure 4.13. Example of Information Display

You can check on Information Display: ① name of display, ② Oxygen fraction,
③ date and time, and ④ alarms, as well as ⑤ signal original value, ⑥ signal
calibrated value, ⑦ run time, and ⑧ software version. ⑤ signal original value
and ⑥ signal calibrated value are the values receiving the signal transmitted
from the sensor: ⑤ signal original value indicates the same value as received
while(black line in Figure 4.8) ⑥ signal calibrated value is a calibrated value
during the latest Calibration Process(red line in Figure 4.8). ⑦ run time is the
total operating hours of equipment while ⑧ software version is a software
version loaded on an analyzer. ⓛ Default is the button for perform the
initialization calibration set and time set. When DEF button is pressed, DEF
blinks, and Default Process is performed when pressed DEF button during 5
seconds. ⓜ Time is the button for perform the format changing function for
displayed time. ③ date and time can be changed to set-time/date or total
operating hours by pressing the button. Figure 4.13 is an example when ③
date and time is set to display the current time or the total operating time,
respectively.

____________________________________
32 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

4.2. Maintenance
4.2.1. Routine Check
Inspect the product regularly when it is used continuously to maintain the
product performance. The regular inspection items are described below.

Calibration
You must perform calibration at least once a month to guarantee the reliability
of measurements.

Analyze
The Analyzer does not require special maintenance. However, you should wipe
the display window with a soft cloth to maintain vividness. Furthermore, if there
is any stain on the surface of the Oxygen Analyzer, wipe it with a soft cloth and
a neutral detergent.

Alarm log
Check the alarm logs at least once a week or more frequently if possible. You
can find intermittent defects or operation errors by checking the alarm logs.

Cable
Check the cable condition at least once a month. Look out for any risks from
the device or external risks due to corrosion of sheath, softening, damages, etc.
Furthermore, check the wiring status.

Gas flow
Take special attention to inoperable state due to external parts in the path
where sensors are installed. The following lists are the expected checkpoints for
external parts.

a) Limitation of gas flow to sensors by pipe blocking

b) Limitation of gas flow to sensors by filter contamination
c) Limitation of gas flow to sensors due to blocking of the narrow paths of
various valves and instruments by foreign substances

____________________________________
33 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

4.2.2 Storage
When storing the Analyzer, always combine the case cover with the case body.
Furthermore, disconnect all cables and close all the holes with hole stoppers
(see 4.2.3) before storing the Analyzer.

The Oxygen Analyzer can be stored for up to one year in an environment with
no condensation in the temperature range of -20℃ to 70℃ and the humidity
range of 5% and 95%. It is very unlikely that any fatal problems would occur
when the Analyzer is stored for longer than one year, but we do not take
responsibility for any problems that may occur.

To use the product again after storage and suspension of use, you must
perform the initial settings (see 3.4.3)).

4.2.3. Replacement
If you have any parts that need to be replaced, please contact the after-sales
service company (see 1.2).

You should always use the spare parts supplied by Oxus or use specified
fungible products. Oxus does not take responsibility for any problem resulting
from the use of unauthorized parts.

Spare parts list of OA-Z-IG2 Oxygen Analyzer is shown in Table 4.6 below.

Table 4.7. Spare parts List of OA-Z-IG2 Oxygen Analyzer

____________________________________
34 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

[Link]. Sensor Replacement

It is able to replace the sensor didn't work such as lifetime ended. The sensor
located inside the analyzer, for clear understanding for replacing method, see
the Figure 4.14.

Figure 4.14. Method of sensor replacing

Must disconnect the connector between PC-Board and the sensor, before
replacing the sensor. By turning counterclockwise, the sensor is detachable in
an upward direction.

____________________________________
35 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

5. Trouble Shooting
Symptom Probable cause Countermeasure
No output on Outage - Check whether power cable is connected.
Display screen - Check whether external power breaker is in
short-circuit; if a switch is off, turn it to on.
- Check whether the power applied to the device
is appropriate for its electrical specification.
(See 2. Analyzer Specifications)

Short circuit of - Check the state of fuse; if required, replace it.

power fuse (located lower the bottom PC-board)
Poor cable - Check the connection state of the cable
connection between
bottom PC-board and upper PC-board; if poor,
Failure - If not resolved, contact the A/S service provider.
Poor output Wrong power - Check whether the power applied to the device
on Display supply is appropriate for its electrical specification.
screen (See 2. Analyzer Specifications)
Failure - Double check after rebooting the device.
- If not resolved after rebooting, contact the A/S
service provider.
Wrong degree Wrong calibration - Proceed with Calibration again. (See 4.1.4.)
of Oxygen Poor installation of - Check the state of connecting of A connector
fraction is sensor between PC-board and the sensor.
displayed - Check whether the sensor is correctly installed.
Poor connection of - Check whether an external silicon tube is
tube correctly connected to A sensor.
Sensor failure - Replace the sensor.
Poor inflow path - Check any section interrupting the flow of air in
this device and throughout the connected
pipelines before and after the device.
Others - If not resolved, contact the A/S service provider.
Screen is Failure - Double Check after rebooting the device.
locked - If not resolved after rebooting, contact the A/S
service provider.

____________________________________
36 KANGRIM HEAVY INDUSTRIES CO., LTD.
 OXYGEN ANALYZER

Symptom Probable cause Countermeasure

No response Failure - Double check after rebooting the device.
when pressing - If not resolved after rebooting, contact the A/S
a button service provider.
Poor relay Poor connection of - Check the state of cable connection between
function cable this device and the device you want to connect.
Wrong setting - Check the relay setting for correctness.
(See 4.1.3, Relay Set)
- Check alarm setting for correctness.
(See 4.1.3, Alarm Set)
Exceed the - Check whether the power rating appropriate for
performance the relay performance is connected.
(See 2. Analyzer Specifications)
Failure - If not resolved, contact the A/S service provider.
Poor connection of - Check the state of cable connection between
cable this device and the unit receiving signals.
(Digital/Analog)
Poor output Wrong protocol - Check the interpretation of signals by the unit
signal (Digital only) receiving signals for correctness.
Failure - Double Check after rebooting the device.
- If not resolved after rebooting, contact the A/S
service provider.

____________________________________
37 KANGRIM HEAVY INDUSTRIES CO., LTD.
 3/&

,167$//$7,2123(5$7,21
$1'0$,17(1$1&(,16758&7,21

3/&

BBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBBB
KANGRIM HEAVY INDUSTRIES CO., LTD.
About User’s Manual

About User’s Manual

Congratulations on purchasing PLC of LSIS Co.,Ltd.
Before use, make sure to carefully read and understand the User’s Manual about the functions,
performances, installation and programming of the product you purchased in order for correct use and
importantly, let the end user and maintenance administrator to be provided with the User’s Manual.

The Use’s Manual describes the product. If necessary, you may refer to the following description and order
accordingly. In addition, you may connect our website([Link] and download the information as
a PDF file.
Relevant User’s Manual
No. of User
Title Description
Manual
It describes how to use XG5000 software especially about
XG5000 User’s
online functions such as programming, printing, monitoring 10310000512
Manual
and debugging by using XGT series products.
It describes how to use the instructions for programming
XGI/XGR/XEC Series using XGB (IEC language) series.
Instruction & 10310000510
Programming

It describes how to use XGB main unit, system configuration,

XBC mechanism ,program function ,input/output function, Built-in
Ultimate Performance High-speed Counter, Datalog, PID Control, Built-in 10310001374
XGB Unit Communication function, Built-in Position, Built-in Analog
input/output..
It describes how to use the specification of analog
XGB Analog
input/analog output/temperature input module, system 10310000920
User’s Manual
configuration and built-in PID control for XGB main unit.
XGB Position It describes how to use built-in Position function for XGB
10310000927
User’s Manual main unit.

XGB Cnet I/F It describes how to use built-in communication function for
10310000816
User’s Manual XGB main unit and external Cnet I/F module.
XGB Fast Ethernet I/F
It describes how to use XGB FEnet I/F module. 10310000873
User’s Manual
CAN open
It describes how to use XGB CANopen Commnunication
Commnunication 0310001245
Module
Module
EtherNet/IP
It describes how to use XGB EtherNet/IP Communication
Commnunication 10310001159
module
Module
XGB Profibus-DP I/F
It describes how to use XGB Profibus-DP I/F
(Master) User’ s 10310001310
(Master) Commnunication Module
Manaual
XGB Profibus-DP I/F
It describes how to use XGB Profibus-DP I/F
(Slave) User’ s 10310001410
(Slave) Commnunication Module
Manaual
XGB DeviceNet I/F
It describes how to use XGB DeviceNet I/F
(Slave) User’ s 10310001414
(Slave) Commnunication Module
Manaual
XGB High speed
It describes how to use High speed counter(XBF-HO02A,
counter module User’s 10310001240
XBF-HD02A)
Manual
 ◎ Contents ◎

Part1. System

Chapter 1 Introduction ..................................................................................................... 1-1~1-17

1.1 Guide to Use This Manual ............................................................................................. 1-1
1.2 Features ........................................................................................................................ 1-3
1.3 Terminology ................................................................................................................... 1-5
Chapter 2 System configuration ........................................................................................ 2-1~2-12
2.1 Table of Products Configuration .................................................................................... 2-1
2.2 Classification and Type of Product Name ..................................................................... 2-3
2.3 High performance XGB’s System Configuration ........................................................... 2-7
Chapter 3 Specifications ........................................................................................................ 3-1~3-9
3.1 Names and Functions of Each Part .............................................................................. 3-1
3.2 Power Specifications ..................................................................................................... 3-5
3.3 Battery ........................................................................................................................... 3-5
3.4 Performance specifications ........................................................................................... 3-7
Chapter 4 Installation and wiring ........................................................................................... 4-1~3-9
4.1 Parameter & Operation data ......................................................................................... 4-1
4.2 Attachment/Detachment of Modules ............................................................................. 4-6
4.3 Wire ............................................................................................................................. 4-14
Chapter 5 Maintenance ......................................................................................................... 5-1~5-2
5.1 Maintenance and Inspection ......................................................................................... 5-1
5.2 Daily Inspection ............................................................................................................. 5-2
5.3 Periodic Inspection ........................................................................................................ 5-2
Chapter 6 Trouble Shooting ................................................................................................ 6-1~6-13
6.1 Basic Procedure of Troubleshooting ............................................................................. 6-1
6.2 Troubleshooting ............................................................................................................. 6-1
6.3 Troubleshooting Questionnaire ..................................................................................... 6-7
6.4 Troubleshooting Examples ............................................................................................ 6-6
6.5 Error Code List ............................................................................................................ 6-12
Chapter 7 EMC Standard ...................................................................................................... 7-1~7-4
7.1 Requirements for Conformance to EMC Directive ........................................................ 7-1
7.2 Requirement to Conform to the Low-voltage Directive ................................................. 7-4
 System
Chapter 1 Introduction

Part 1. System

Chapter 1 Introduction
1.1 Guide to this Manual
This manual includes specifications, functions and handling instructions for XGB series PLC. This manual is divided up into chapters as follows

No. Title Contents

Describes configuration of this manual, unit’s features and

Chapter 1 Introduction
terminology.

Describes available units and system configuration in the XGB

Chapter 2 System Configurations
series.

Chapter 3 Specifications Describes general specifications of units used in the XGB series.
[Link]

Chapter 4 CPU Specifications Describes performances, specifications and operations.

Describes the check items and method for long-term normal

Chapter 5 Maintenance
operation of the PLC system.

Chapter 6 Troubleshooting Describes various operation errors and corrective actions.

Chapter 7 EMC Specifications Describes system configuration following EMC specification.

Program Configuration and Operation

Chapter 1
Method Describes performances, specifications and operations.

Chapter 2 CPU Specifications

[Link]

Chapter 3 Input/Output Specifications Describes operation of basic and input/output.

Chapter 4 Built-in High-speed Counter Function Describes built-in high-speed counter functions.

Chapter 5 Datalog Function Describes Datalog Function

1-1
System

Chapter 1 Introduction

Chapter 6 Built-in PID Function Describes Built-in PID Function

Describes the specification, method to use each positioning

Chapter 1 Overview function, programming and the wiring with external equipment of

embedded positioning function.

Chapter 2 Specifications Describes general specifications of Positing function.

[Link]

Describes the Operation order in case of positioning operation by

Chapter 3 Operation Order and Installation
embedded positioning.

Describes parameter and operation data to be set by software

Chapter 4 Positioning Parameter & Operation Data
package with embedded positioning.

Describes the internal memory used for positioning module if

Chapter 5 Internal Memory and IO Signal
XGB Main unit
[Link]

Chapter 1 Embedded Analog Describes the Built-in Analog Function used in XGB PLC.

Chapter 1 Built-in FEnet Communication Describes the Built-in FEnet Communication used in XGB PLC.
[Link]

Chapter 2 Built-in Cnet Communication Describes the Built-in Cnet Communication used in XGB PLC.

Appendix 1 Flag List Describes the types and contents of various flags.
[Link]

Appendix 2 Dimension Shows dimensions of the main units and expansion modules.

Appendix 3 Instruction List Describes the special relay and instruction list.

1-2
 System
Chapter 1 Introduction

1.2 Features
The high performance XGB basic unit has the following characteristics.

1.2.1 Advanced Performances

(1) Rapid Processing Speed
The processing speed has been improved up to more than 30% compared to the existing XGB PLC.

Items XBC ‘SU’ Type XBC ‘H’ Type XBC ‘U’ Type Remarks
Sequence Based on
94 ㎱ 84 ㎱ 60 ㎱
MLOAD command
command
Data command 2.1 ㎲ 1.54 ㎲ 1.58 ㎲ Based on MOV command
4.99 ㎲ 4.85 ㎲ 3.8 ㎲ RADD command
Real 4.5 ㎲ 4.64 ㎲ 3.8 ㎲ RMUL command
8.5 ㎲ 8.18 ㎲ 5.9 ㎲ LADD command
Long Real 8.0 ㎲ 9.62 ㎲ 6.0 ㎲ LMUL command
(2) Advanced embedded functions
Various and special communication functions that the existing XGB could not provide are embedded.
- Embedded Data logging function through the SD memory
- Embedded Fast Ethernet supporting the switching function
- Embedded 4-axis positioning function supporting CAM operation, multi-axis interpolation(XEC-
DN32UP/DR28UP)
- Embedded analog I/O 8 channels with 14bit resolution (XEC-DN32UA/DR28UA)

1.2.2 Flexibility of System Configuration

(1) The small and medium-sized system can be established, which controls up to 352 points I/O through 10-
stage expansion.
(2) Compact size
Compared to the existing XGB basic unit, this product has various embedded functions to enhance
functionality and has a reduced size so you can install it even in a small space. (Unit : ㎜)
Type Model Size (W * H * D) Remarks
XEC-DN32U/ DP32U/DR28U 150 * 90 * 64
Same size as to
Basic unit XEC-DN32UP/DP32UP/DR28UP 185 * 90 * 64
DC power PLC
XEC-DN32UA/DP32UA/DR28UA 185 * 90 * 64
Expansion module XBE-,XBF-,XBL- 20 * 90 * 60 Based on the minimum size

(3) Securing compatibility of the existing expansion/special/communication module

All types of the existing XGB expansion/special/communication modules are available.
(4) Expanding the applications through various expansion modules
- It provides 8 points, 16 points, 32 points module I/O expansion module (In the case of relay output, 8/16
points module) with single input, single output, mixed I/O module.
- It supports various special modules such as positioning, high-speed counter, analog I/O, temperature
input, temperature control.
- It provides various communication I/F modules such as Cnet, FEnet, RAPIEnet, CANOpen, Profibus-DP,
DeviceNet.

1-3
System

Chapter 1 Introduction

1.2.3 Powerful Embedded Functions

(1) Embedded high-speed counter function
- The high-speed counter with up to 100kpps 8 channels(based on 1 phase 1 input 1 multiplication) is
embedded.
- Various additional functions such as comparative readout, comparative task, frequency measurement,
revolutions per hour, etc. are provided.
- Parameter setting using XG5000, various monitoring and diagnosis functions are provided.
- You can conduct a trial run through XG5000’s monitoring without the program so you can easily check of
abnormalities of external wirings and data setting.
(2) Embedded data log function
- The data log function that can use the SD memory card of up to 6GB is embedded.
- You can save various device data of the PLC for a long time with only parameter setting using XG5000.
- You can save the desired data depending on different conditions such as trigger collection, event collection,
etc.
- It supports the remote data access through FTP communication.
(3) Embedded communication function
- It has embedded Cnet 2 channels and Enet 1 channel at the same time.
- It can communicate with other devices very easily without the special communication I/F module by using the
embedded communication function.
- It enhances convenience by providing various protocols such as dedicated communication, customization,
etc.
-You can check the communication state very easily thanks to the diagnosis function and
transmitting∙receiving frame monitoring function.
- The 2 ports switch function embedded in Ethernet makes the configuration of line topology easier.
(4) Embedded PID function
- It supports the embedded PID control function up to 16 loops.
- It provides parameter setting using XG5000, convenient loop state monitoring through trend monitor.
- You can get the control constant easily by the improved automatic synchronization function.
- You can improve control accuracy by using various additional functions such as PWM output, ∆MV, ∆PV,
SV Ramp, etc.
- It provides various control modes such as forward/reverse mixed operation, 2-stage SV PID control,
cascade control, etc.
-You can secure stability through various alarm functions such as PV MAX, PV change warning, etc.
(5) Embedded position control function(Available for XBC-DN32UP/DP32UP/DR28UP type only)
- The line drive output positioning function with up to 2Mpps 4-axis is embedded.
- It provides parameter setting using XG-PM that is the exclusive setting tool, operation data edition, diverse
monitoring and diagnosis functions.
- You can conduct a trial run through XG-PM’s monitoring without the program so you can easily check the
external wirings and operation data.
(6) Embedded analog I/O function(Available for XEC-DN32UA/DP32UA/DR28UA type only)
- The analog input 4 channels(voltage/current), analog output 4channels(voltage 2 channels, current 2
channels) are embedded.
- It can measure the analog value more accurately thanks to the high resolution of 14bit.
- You can conduct a trial run through XG5000’s monitoring without the program so you can easily check the
external wirings and operation data.

1-4
 System
Chapter 1 Introduction

1.3 Terminology
1.2.1 General term

The following table gives definition of terms used in this manual.

Terms Definition Remark

Example)
Expansion module,
A standard element that has a specified function which configures the
Module Specialmodule,
system. Devices such as I/O board, which inserted onto the mother board.
Communication
module
Example)
A single module or group of modules that perform an independent operation
Unit Main unit, Expansion
as a part of PLC systems.
unit

A system which consists of the PLC and peripheral devices.

PLC System -
A user program can control the system.

A program and debugging tool for the MASTER-K series.

XG5000 It executes program creation, edit, compile and debugging. -
(PADT: Programming Added Debugging Tool)
Software to execute description, edition of basic parameter, high speed link,
XG - PD
P2P parameter, and function of communication diagnosis -
I/O image area Internal memory area of the CPU module which used to hold I/O status.
Cnet Computer Network -
FEnet Fast Ethernet Network -

RAPInet RAPInet Network -

CANopen Controller Area Network -

Pnet Profibus-DP Network -

Dnet DeviceNet Network -

Abbreviation of ‘Real Time Clock’. It is used to call general IC that contains

RTC -
clock function.

Supervisors the pre-set execution times of programs and warns if a program

Watchdog Timer -
is not competed within the pre-set time.

1-5
System

Chapter 1 Introduction

Terms Definition Remark

Current flows from the switch to the PLC input terminal if a input signal
turns on.

Z: Input
Sink Input
− impedance

Current flows from the PLC input terminal to the switch after a input signal
turns on.

Z: Input
Source Input
impedance

Current flows from the load to the output terminal and the PLC output
turn on.

Sink Output -

Current flows from the output terminal to the load and the PLC output
turn on.

Source Output -

1-6
 System
Chapter 1 Introduction

1.2.2 Serial communication term

(1) Communication type

(a) Simplex
This is the communication type that data is transferred in a constant direction. Information can not be transferred in the
reverse direction.
(b) Half-Duplex
Data is transferred in two ways with one cable if time interval provided, though it can’t be transferred simultaneously.
(c) Full-Duplex
Data is simultaneously transferred and received in two ways with two cables.

(2) Transmission type

(a) Serial transmission
This type transmits bit by bit via 1 cable. The speed of transmission is slow, but the cost of installation is low and the
software is simplified.

7 6 5 4 3 2 1 0
0 1 0 0 1 1 0 1

송신
TX 수신
RX

7 6 5 4 3 2 1 0 7 6 5 4 3 2 1 0

RS-232C, RS-422 and RS-485 are the examples

1-7
System

Chapter 1 Introduction

(b) Parallel transmission

This type is used in printer, etc., which transmits data in unit of 1 byte, so the speed is high and the accuracy of data
is reliable. However, the longer the transmission distance is, the higher the cost of installation is geometrically.

7 6 5 4 3 2 1 0
0 1 0 0 1 1 0 1

1
송신
TX 수신
RX
0
1

1
0
0
1

(3) Asynchronous Communication

This communication type transmits characters one by one synchronously in serial transmission. At this time,
synchronous signal (Clock, etc.) is not transmitted. Character code is transmitted with a start bit attached to the head of 1
character, and it is finished with a stop bit attached to the tail.

※ For transmitting KOREA

Transmission Direction

P S P S P S P S P S P S P S
S A E T
S A T
S A T
S A T
S A T
S A T
S A E T
T R O T R T R T R T R T R T R N
O I
T T
A
R
O I
T
A A
R
O I
T
E A
R
O I
T
R A
R
O I
T
O A
R
O I
T
K A
R
O I
T Q
A
R
P P P P P P P
Y
(04H)
T Y T Y T Y T Y T Y T Y
(05H)
T

Stop Bit Parity Bit Data Bits Start Bit

1-8
 System
Chapter 1 Introduction

(4) Protocol
This is communication rule established in relation between the transmission side and the receiving side of information in
order to send and accept information between two computers/terminals or more without error, effectively, and reliably. In
general, this specifies call establishment, connection, structure of message exchange form, re-transmission of error
message, procedure of line inversion, and character synchronization between terminals, etc.

(5) BPS(Bits Per Second)와 CPS(Characters Per Second)

BPS is a unit of transfer rate that represents how many bits are transferred per second. CPS is the number of the
characters transferred for a second. Generally, one character is 1Byte (8Bits), so CPS is the number of bytes which can
be transferred per second.

(6) Node
Node is a term that means the connected nodes of the data in the network tree structure, generally network is composed
of a great number of nodes, and is also expressed as the station number.

(7) Packet
Packet, a compound term of package and bucket used for packet exchange type to send information as divided in a unit
of packet, separates transferred data into the defined length to add a header that presents the correspondent addresses
(station No., etc.) thereto.

(8) Port
Port is meant to be the part of the data process device which sends or receives the data from a remote control terminal in
data communications, but in Cnet serial communication is meant to be the RS-232C or RS-422 port.

(9) RS-232C
RS-232C is the interface to link a modem with a terminal and to link a modem with a computer, and is also the serial
communications specification established by EIA according to the recommendations of the CCITT. This is also used to
link the null modem directly as well as the modem linkage. The disadvantage is that the transfer length is short and that
only 1 : 1 communication is available, and the specifications which have overcome this disadvantage are RS-422 and
RS-485.

(10) RS-422/RS-485
As one of the serial transmission specifications, its transferring length is long with 1 : N connection available compared to
RS-232C. The difference of these two specifications is that RS-422 uses 4 signals of TX(+), TX(-), RX(+) and RX(-),
while RS-485 has 2 signals of (+) & (-), where data is sent and received through the same signal line. Accordingly, RS-
422 executes the full-duplex type of communication and RS-485 executes the half-duplex type of communication.

1-9
System

Chapter 1 Introduction

(11) Half Duplex Communication

Two-way communication is available, however simultaneous communication of transmission & receiving isn’t available.
This communication type is applied to RS-485 for instance. It is used a lot for multi-drop communication type which
communicates via one signal line by several stations. Half Duplex Communication results from the transmission
characteristic performed by stations one by one not allowing simultaneous transmission by multi stations due to the data
damage of data impact caused by the simultaneous multi-transmission of the stations. The figure below shows an
example of structure based on Half Duplex Communication. Each station in communication with the terminal as linked
with each other can send or receive data via one line so to execute communication with all stations, where multi-sever is
advantageously available.

Client
RX TX

RX TX RX TX RX TX RX TX
Server Server Server Server

(12) Full Duplex Communication

Two way-communications of simultaneous transmission & receiving is available. This communication type is applied to
RS-232C & RS-422. Since the transmission line is separated from the receiving line, simultaneous transmission &
receiving is available without data impact, so called as Full Duplex Communication. The figure shows an example of
structure based on RS-422 of Full Duplex Communication. Since transmission terminal of the client station and receiving
terminals of the sever stations are connected to one line, and transmission terminals of the sever stations are linked with
receiving terminal of the client station, the communication between sever stations is unavailable with the restricted
function of multi-sever.

Client
RX TX

RX TX RX TX RX TX RX TX
Server Server Server Server

1-10
 System
Chapter 1 Introduction

(13) BCC (Block Check Character)

As serial transmission may have signals distorted due to undesirable noise in transmission line, BCC is used as data to
help receiving side to check the signals if normal or distorted and to detect errors in signals as compared with the
received BCC after calculating BCC by receiving side itself using the data input to the front terminal of BCC.

(14) XG5000 service

This is the function to remotely perform programming, reading/writing user’s program, debugging, and monitoring, etc.
without moving the physical connection of XG5000 in the network system where PLC is connected to Cnet I/F module.
Especially, it is convenient to control a remote PLC via modem.

Public network Public network

line Relay station line
* XG5000 : Programming software of XGT PLC for Windows

1-11
System

Chapter 1 Introduction

(15) Frame
Frame is composed of transmitted and received data as in a specified form in data communication including additional
information of segments [station No., command, parameter by command], control characters [ENQ, ACK, EOT, ETX] for
synchronization, parity for detecting error, and BCC. The structure of frame used for serial communication of Cnet is as
follows.

Request Frame

E Station Comm E B Head Segment Tail

N No. and Parameter by Commend O C
Q T C

A Station Comm Proces E B

C No. and sing T C
Head Segment Tail K Result X C

Response Frame

[Structure of general Tx/Rx frame]

- Head: ASCII value indicating frame start.

- Tail: ASCII value indicating frame end.
- BCC (Block Check Character)
 Check data for Tx/Rx frame
 Used to inspect reliability of data with such various methods as ADD, OR, Exclusive OR, MULTPLY, etc

(16) Reset
This function is used to initialize the communication module with errors.
Use XG-PD to select [On-Line] → [Reset] so to execute Reset, which will restart PLC.

1-12
 System
Chapter 1 Introduction

1.2.3 Ethernet term

This chapter describes about the general terminology of FEnet I/F module. For more detail, refer to professional book on the
Ethernet

(1) IEEE 802.3

IEEE 802.3 specifies standards for CSMA/CD based Ethernet. Exactly it is a LAN based on CSMA/CD (Carrier
Sense Multiple Access with Collision Detection) Ethernet designed by IEEE 802.3 group, which is classified into
detailed projects as specified below;

A) IEEE P802.3 - 10G Base T study Group

B) IEEE P802.3ah - Ethernet in the First Mile Task Force
C) IEEE P802.3ak - 10G Base-CX4 Task Force
※ Ethernet and IEEE 802.3 are standardized at RFC894 and RFC1042 so each should process another frame.

(2) ARP (Address Resolution Protocol)

Protocol to search for MAC address by means of correspondent IP address on the Ethernet LAN

(3) Bridge
A device used to connect two networks so to be operated as one network. Bridge is used not only to connect two
different types of networks but also to divide one big network into two small networks in order to increase the
performance

(4) Client
A user of the network service, or a computer or program (mainly the one requesting services) using other
computer’s resource.

(5) CSMA/CD(Carrier Sense Multiple Access with Collision Detection)

Each client checks if there is any sign prior to transmission of data to the network (Carrier Sense) and then sends
its data when the network is empty. At this time, all the clients have the equal right to send (Multiple Access). If two
or more clients send data, collision may occur. The client who detects the collision tries to send again in a specific
time.

(6) DNS (Domain Name System)

A method used to convert alphabetic Domain Name on the Internet to its identical Internet number (namely, IP
address)

(7) Dot Address

Shows IP address of ‘[Link]’, where each figure is displayed in decimal with 1 byte occupied
respectively for 4 bytes in total.

1-13
System

Chapter 1 Introduction

(8) E-mail Address

The address of the user with login account for the specific machine connected via the Internet. Usually user’s ID @
domain name (machine name) is assigned. In other words, it will be like hjjee@[Link], where @ is called
as ‘at’ displayed with shift+2 pressed on the keyboard. The letters at the back of @ are for the domain name of
specific company (school, institute,..) connected with the Internet, and the letters in front of @ are for the user ID
registered in the machine. The last letters of the domain name are for the highest level. USA generally uses the
following abbreviation as specified below, and Korea uses .kr to stand for Korea. .com : usually for companies)
/ .edu : usually for educational organizations such as universities. / .ac(academy) is mostly used in Korea / .gov : for
governmental organizations. For example, [Link] is for NASA (government) / .mil : military related sites. For
example, [Link] is for USA air force (military)/ .org : private organizations / .au : Australia / .uk : the United Kingdom
/ .ca : Canada / .kr : Korea / .jp : Japan / .fr : France / .tw : Taiwan, etc.

(9) Ethernet
A representative LAN connection system (IEEE 802.3) developed by Xerox, Intel and DEC of America which can
send about 10Mbps and use the packet of 1.5kB. Since Ethernet can allow various types of computers to be
connected as one via the network, it has been called a pronoun of LAN as a universal standard with various
products available, not limited to some specific companies.

(10) FTP (File Transfer Protocol)

An application program used to transfer files between computers among application programs providing TCP/IP
protocol. If an account is allowed to the computer to log in, fast log in the computer is available wherever the
computer is so to copy files.

(11) Gateway
Software/Hardware used to translate for two different protocols to work together, which is equivalent to the
gateway necessary to exchange information with the different system.

(12) Header
Part of the packet including self station number, correspondent station number and error checking area.

(13) HTML
Hypertext Markup Language, standard language of WWW. In other words, it is a language system to prepare
Hypertext documents. The document made of HTML can be viewed through the web browser

(14) HTTP
Hypertext Transfer Protocol, standard protocol of WWW. It is a protocol supporting the hypermedia system.

(15) ICMP (Internet Control Message Protocol)

An extended protocol of IP address used to create error messages and test packets to control the Internet.

(16) IP (Internet Protocol)

Protocol of network layers for the Internet

1-14
 System
Chapter 1 Introduction

(17) IP Address
Address of respective computers on the Internet made of figures binary of 32 bits (4 bytes) to distinguish the
applicable machine on the Internet. Classified into 2 sections, network distinguishing address and host
distinguishing address. The network address and the host address is respectively divided into class A, B and C
based on the bits allotted. IP address since it shall be unique all over the world, shall be decided not optionally but
as assigned by NIC(Network Information Center) of the applicable district when joining the Internet. In Korea,
KRNIC(Korea Network Information Center) is in charge of this work. Ex.) [Link]

(18) ISO (International Organization for Standardization)

A subsidiary organization of UN establishing and managing the international standards

(19) LAN (Local Area Network)

Called also as local area communication network or district information communication network, which allows lots
of computers to exchange data with each other as connected though communication cable within a limited area
such as in an office or a building

(20) MAC (Medium Access Control)

A method used to decide which device should use the network during given time on the broadcast network

(21) Node
Each computer connected with the network is called Node

(22) Packet
A package of data which is the basic unit used to send through the network. Usually the package is made of
several tens or hundreds of bytes with the header attached in front to which its destination and other necessary
information are added

(23) PORT number

Used to classify the applications on TCP/UDP.
Ex.) 21/tcp : Telet

(24) PPP (Point-to-Point Protocol)

Phone communication protocol which allows packet transmission in connecting with the Internet. In other words,
normal phone cable and modem can be used for the computer to connect through TCP/IP with this most general
Internet protocol.
Similar to SLIP, however with modern communication protocol factors such as error detection and data
compression, it demonstrates more excellent performance than SLIP.

(25) Protocol
Contains regulations related with mutual information transmission method between computers connected with
each other through the network. The protocol may specify detailed interface between machines in Low level (for

1-15
System

Chapter 1 Introduction

example, which bit/byte should go out through the line) or high level of message exchange regulations as files are
transferred through the Internet.

(26) Router
A device used to transfer the data packet between the networks. It sends the data packet to its final destination,
waits if the network is congested, or decides which LAN is good to connect to at the LAN junction. Namely, it is a
special computer/software used to control the two or more networks connected.

(27) Server
The side which passively responds to the client’s request and shares its resources.

(28) TCP (Transmission Control Protocol)

A transport layer protocol for the Internet
- Data Tx/Rx through connection
- Multiplexing
- Transmission reliable
- Emergent data transmission supported

(29) TCP/IP (Transmission Control Protocol/Internet Protocol)

Transmission protocol used for communication among different kinds of computers, which makes the
communication available between general PC and medium host, IBM PC and MAC, and medium or large-sized
different types of computer. It is also used as a general term for information transmission protocol between
computer networks including FTP, Telnet, SMTP, etc. TCP divides data into packets to send through IP and the
packets sent will be united back together through TCP.

(30) Telnet
It means remote login via Internet. To login to remote host via TELNET, account of that host is necessary.
But for some hosts providing public service, you can connect without account

1-16
 System
Chapter 1 Introduction

(31) Token Ring

As short-distance network using Token to connect to network having physical ring structure, one of the
Node connection methods at network. If node sending data gets Token, then node gets right to send
message packet. Realistically structured examples are IEEE 802.5, ProNet-1080 and FDDI. Terms called
Token is used as IEEE 802.5

Token passing

Token
Ring

Dual Token passing

(32) UDP(User Datagram Protocol)

A transport layer protocol for the Internet
- High speed communication because of communication without connection
- Multiplexing
- Lower reliability than TCP in transmission (Tough data doesn’t arrive, it doesn’t send data again)

(33) Auto-NegotiationFDDI(Fiber Distributed Data Interface)

Based on optical cable, provides 100Mbps, Shared Media Network as Dual Ring method, Token Passing
is done in two-way.
Max 200Km distance for entire network, Max 2Km between Nodes, Max 500 nodes. Generally, this used
as Backbone Network.

(35) Reset
This is function used when you want to initialize the communication module to clear the error
Select [Online]  [Rest] in the XG-PD
If you execute this function, PLC will restart.

1-17
 System
Chapter 2 System Configuration

Chapter 2 System Congifuration

You can configure various systems by using the XGB ‘U’ Type basic unit and expansion·special communication I/F modules. This
chapter describes how to configure the system through the the XGB ‘U’ Type basic unit

2.1 Table of Products Configuration

The available configurations of for the high performance small-sized PLC system are as below table.
Types Model Description Remark

XEC-DN32U AC100-220V power supply, DC24V input 16 point, Transistor output 16 point(sink)
Basic
XEC-DN32U AC100-220V power supply, DC24V input 16 point, Transistor output 16 point(source)
type
XEC-DR28U AC100-220V power supply, DC24V input 16 point, Relay output 12 point
XEC-DN32U/DC DC24V power supply, DC24V input 16 point, Transistor output 16 point(sink)
XEC-DN32U/DC DC24V power supply, DC24V input 16 point, Transistor output 16 point(source)
XEC-DR28U/DC DC24V power supply, DC24V input 16 point, Relay output 12 point
AC100-220V power supply, DC24V input 16 point, Transistor output 16 point( sink)
XEC-DN32UP
Positioining 4axis
AC100-220V power supply, DC24V input 16 point, Transistor output 16 point(source)
XEC-DN32UP
Positioining 4axis
AC100-220V power supply, DC24V input 16 point, Relay output 12 point
XEC-DR28UP
Positioining 4axis Positioning
DC24V power supply, DC24V input 16 point, Transistor output 16 point( sink)
XEC-DN32UP/DC type
Main Unit

Positioining 4axis
DC24V power supply, DC24V input 16 point, Transistor output 16 point(source)
XEC-DN32UP/DC
Positioining 4axis
DC24V power supply, DC24V input 16 point, Relay output 12 point
XEC-DR28UP/DC
Positioining 4axis
AC100-220V power supply, DC24V input 16 point, Transistor output 16 point (sink)
XEC-DN32UA
Analog 8 Channel
AC100-220V power supply, DC24V input 16 point, Transistor output 16 point(source)
XEC-DN32UA
Analog 8 Channel
AC100-220V power supply, DC24V input 16 point, Relay output 12 point
XEC-DR28UA
Analog 8 Channel Analog
DC24V power supply, DC24V input 16 point, Transistor output 16 point (sink)
XEC-DN32UA/DC type
Analog 8 Channel
DC24V power supply, DC24V input 16 point, Transistor output 16 point(source)
XEC-DN32UA/DC
Analog 8 Channel
DC24V power supply, DC24V input 16 point, Relay output 12 point
XEC-DR28UA/DC
Analog 8 Channel
XBE-DC08A DC24V Input 8 point
XBE-DC16A/B DC24V Input 16 point
Input
XBE-DC32A DC24V Input 32 point
XBE-AC08A AC 110V Input 8 point
Expansion Unit

XBE-RY08A Relay output 8 point

XBE-RY08B Relay output 8 point(isolated ouput)
XBE-RY16A Relay output 16 point
Output
XBE-TN08A Transistor output 8 point (sink type)
XBE-TN16A Transistor output 16 point (sink type)
XBE-TN32A Transistor output 32 point (sink type)

2-1
System

Chapter 2 System Configuration

Types Model Description Remark

XBE-TP08A Transistor output 8 point (source type)
XBE-TP16A Transistor output 16 point (source type)
XBE-TP32A Transistor output 32 point (source type)
XBE-DR16A DC24V Input 8 point, Relay output 8 point
In/Output
XBE-DN32A DC24V Input 16 point, Transistor output 16 point (sink type)
XBF-AD04A Current/Voltage input 4 channel, 1/4000 resolution
XBF-AD04C Current/Voltage input 4 channell, 1/16000 resolution
Special Module

XBF-AD08A Current/Voltage input 8 channel, 1/4000 resolution

XBF-DC04A Current output 4 channell, 1/4000 resolution Analog
XBF-DC04C Current output 4 channel, High resolutionl, 1/16000 resolution ln/Out

XBF-DV04A Voltage output 4 channell, 1/4000 resolution

XBF-DV04C Voltage output 4 channel, 1/16000 resolution
XBF-AH04A Current/Voltage input 2 channel, Current/Voltage output 2 channel, 1/4000 resolution
XBF-AH04A Current/Voltage input 2 channel, Current/Voltage output 2 channel, 1/4000 resolution
XBF-RD04A RTD (Resistance Temperature Detector) input 4 channel, Pt100, Jpt100
Temperature
XBF-RD01A RTD (Resistance Temperature Detector) input 1 channel, Pt100, Jpt100

XBF-TC04S TC (Thermocouple) input 4 channel

Special Module

XBF-PD02A Position 2Axis, Line Drive type, Max 2Mpps Positioning

XBF-HD02A High Speed Counter 2 channel, Line Drive Type

Counter
XBF-HO02A High Speed Counter 2 channel, Open Collector Type

XBF-TC04RT Temperature controller module (RTD input, 4 roof) -

XBF-TC04TT Temperature controller module (TC input, 4 roof) -

XBF-PN08B Network position (Open type Ethercat ) 8 Axis -

XBF-LD02S Loadcell input, insulation type

XBL-C21A Cnet (RS-232C/Modem) I/F -

XBL-C41A Cnet (RS-422/485) I/F -

XBL-EMTA Enet I/F -

XBL-EIMT/F/H RAPIEnet I/F 2 UTP cable -

Communication

XBL-EIPT EtherNet I/P Module -

Module

XBL-CMEA CANopen MasterI/F -

XBL-CSEA CANopen Slave I/F -

XBL-PMEC Profibus-DP, Master -

XBL-PSEA Profibus-DP, Slave

XBL-DSEA DeviceNet, Slave

USB-301A Connection cable (PC to PLC), USB --

2-2
 System
Chapter 2 System Configuration

Notice
(1) LS INDUSTRIAL SYSTEM CO., LTD. has consistently developed and launched new products. For new products that
are not included to this manual, please contact a nearby exclusive agency.
(2) Use USB cable within 3m length and use shield cable like USB-301A.
(3) Because some PCs are weak to noise, we recommend using a USB hub.

2.2 Classification and Type of Product Name

2.2.1 Classification and type of basic unit

Standard (S)
Name of basic unit is classified as follows.
Standard with usb loader (S)
High-end type (H)
X E C - D N 32 UP
Ultimate Performance type (U)
Ultimate Analog type (UA)
Ultimate Positioning type (UP)

XGB PLC

No. of I/O point

MK language supported (B)
IEC language supported (E)
Relay output (R)
Sink type transistor output (N)
Module type basic unit (M) Source type transistor output (P)
Compact type basic unit(C)

DC input

Classification Name DC input Relay output Transistor output Power

XEC-DN32U 16 point None 16 point
XEC-DP32U 16 point None 16 point
XEC-DR28U 16 point 12 point None
XEC-DN32UP 16 point None 16 point
XEC-DP32UP 16 point None 16 point AC110V-220V
XEC-DR28UP 16 point 12 point None
XEC-DN32UA 16 point None 16 point
XEC-DP32UA 16 point None 16 point
Compact type XEC-DR28UA 16 point 12 point None
basic unit XEC-DN32U/DC 16 point None 16 point
XEC-DP32U/DC 16 point None 16 point
XEC-DR28U/DC 16 point 12 point None
XEC-DN32UP/DC 16 point None 16 point
XEC-DP32UP/DC 16 point None 16 point DC24V
XEC-DR28UP/DC 16 point 12 point None
XEC-DN32UA/DC 16 point None 16 point
XEC-DP32UA/DC 16 point None 16 point
XEC-DR28UA/DC 16 point 12 point None

2-3
System

Chapter 2 System Configuration

2.2.2 Classification and type of expansion module

Name of expansion module is classified as follows.

X B E - DC XX A

XGB series No. of I/O point

Relay output(RY)
Transistor output (TN/TP)
I/O expansion module(E)
Digital input (DC)
Expansion special module(F)
Digital input+ sink type transistor output (DN)
Expansion communication
Digital input+ source type transistor output (DP)
module(L)
Digital input+ Relay output (DR)

Name DC input Relay output Transistor output Reference

XBE-DC08A 8 point None None

XBE-DC16A/B 16 point None None

Input
XBE-DC32A 32 point None None

XBE-AC08A 8 point (AC) None None

XBE-RY08A/B None 8 point None

Relay Output
XBE-RY16A None 16 point None
8 point
XBE-TN08A None None
(sink type)
16 point
XBE-TN16A None None Sink type Output
(sink type)
32 point
XBE-TN32A None None
(sink type)
8 point
XBE-TP08A None None
(source type)
16 point
XBE-TP16A None None Source type Output
(source type)
32 point
XBE-TP32A None None
(source type)
XBE-DR16A 8 point 8 point None
16 point In/Output
XBE-DN32A 16 point None
(sink type)

2-4
 System
Chapter 2 System Configuration

2.2.3 Classification and type of special module

Special module is classified as follows.

X B F - AD XX A

Non-insulation type (A)

Insulation type (S)
XGB series
RTD input (RT)
TC input(TT)

No. of IO point

Analog input (AD)

Analog voltage output (DC)
I/O expansion module(E) Analog current output (DV)
Expansion special module(F) RTD input (RD)
Expansion communication Thermocouple input (TC)
module(L) Positioning Module(PD)
High Speed Counter(HD/HO)

No. of input No. of output

Classification Name Input type Output type
ch. ch.
XBF-AD04A/C 4 Voltage/Current None -
Analog input
XBF-AD08A 8 Voltage/Current None
XBF-DC04A/C None - 4 Current
Analog output
XBF-DV04A/C None - 4 Voltage
XBF-RD04A 4 PT100/JPT100 None -
RTD input
XBF-RD01A 1 PT100/JPT100 None -
XBF-TC04S 4 K, J, T, R None -
TC input XBF-TC04RT 4 PT100/JPT100 4 Transister
XBF-TC04TT 4 K, J, T, R 4 Transister
XBF-PD02A - Line Driver 2 Voltage
Positioning
XBF-PN08B - Line Driver 8 EtherCAT
XBF-HD02A 2 Line Driver - Voltage
High Speed Counter
XBF-HO02A 2 Open Collector - Voltage
Loadcell XBF-LD02S 2 Voltage

2-5
System

Chapter 2 System Configuration

2.2.4 Classification and type of communication module

Name of communication module is classified as follows.

X B L - C21A

Cnet 1 channel (RS-232C): C21A

XGB series Cnet 1 channel (RS-422/485): C41A
FEnet 1 channel: EMTA
RAPIEnet 1 channel: EIMT

I/O expansion module(E)

Expansion special module(F)
Expansion communication
module(L)

Classification Name Type

XBL-C21A RS-232C, 1 channel

Cnet Comm. Module
XBL-C41A RS-422/485, 1 channel
FEnet Comm. Module XBL-EMTA Electricity, open type Ethernet
XBL- Comm. Module between PLCs, electric media,
RAPIEnet Comm. Module
EIMT/EIMF/EIMH 100 Mbps industrial Ethernet supported

EtherNet Comm. Module XBL-EIPT Open EtherNet I/P

XBL-CMEA CANopen Master

CANopen Comm. Module
XBL-CSEA CANopen Slave

XBL-PMEC Profibus-DP Master

Pnet Comm. Module
XBL-PSEA Profibus-DP Slave

DeviceNet Comm. Module XBL-DSEA DeviceNet Slave

2-6
 System
Chapter 2 System Configuration

2.3 XGB ‘U’ Type’s System Configuration

2.3.1 How to configure the System
You can configure thesystem by using the high performance XGB PLC as below.
You can connect to the expansion modules up to 10EA.

Basic unit I/O module Special module Communication

Items Description
• XEC-DN32U(/DC), XEC-DN32UP(/DC), XEC-DN32UA(/DC)
:32 points ~ 352 points
• XEC-DP32U(/DC), XEC-DP32UP(/DC), XEC-DP32UA(/DC)
Number of I/O configuration points
:32 points ~ 352 points
• XEC-DR28U(/DC), XEC- DR28UP(/DC), XEC- DR28UA(/DC)
:28 points ~ 348 points
Digital I/O module • Up to 10 EA
Number of Special module • Up to 10 EA
accessible Communication module • Up to 2 EA
expansion High speed expansion
• Up to 2 EA (Can be expanded for 2 slots just behind the basic unit)
modules module
Option module • Cannot be installed.
Basic type • XEC-DN32U(/DC) • XEC-DP32U(/DC) • XEC-DR28U(/DC)
Unit
Basic

Positioning type • XEC-DN32UP(/DC) • XEC-DP32UP(/DC) • XEC-DR28UP(/DC)

Analog type • XEC-DN32UA(/DC) • XEC-DP32UA(/DC) • XEC-DR28UA(/DC)
•XBE-DC08/16/32A • XBE-TN08/16/32A •XBE-RY08/16A
Expansion module

Digital I/O
•XBE-DC16B • XBE-TP08/16/32A •XBE-RY08B
Configuration of products

module
•XBE-AC08A • XBE-DR16A
• XBF-AD04A • XBF-DC04A • XBF-HO02A
• XBF-AD04C • XBF-DC04C • XBF-HD02A
• XBF-AD08A • XBF-DV04A • XBF-TC04RT
Special module
• XBF-AH04A • XBF-DV04C • XBF-TC04TT
• XBF-RD04A • XBF-TC04S • XBF-LD02S
• XBF-RD01A • XBF-PD02A
• XBL-C41A • XBL-C21A • XBL-PSEA
Communication module • XBL-EMTA • XBL-EIMT/F/H • XBL-CMEA/CSEA
• XBL-PMEC • XBL-EIPT • XBL-DSEA
High speed I/F module • XBF-PN08B

2-7
System

Chapter 2 System Configuration

2.3.2 Instructions for System Configuration

(1) high speed expansion I/F module
The XGB ‘U’ Type PLC supports the high speed expansion I/F to enhance the expansion module processing
speed.
This section describes the instructions to configure the system by using the high speed expansion I/F modules
and the existing expansion modules.

- The existing XGB expansion· communication· special modules can be commonly used and the high speed
expansion I/F module that cannot be supported by the XGB basic unit are available.
- In the case of expansion communication modules, a total of 4 expansion communication modules can be
mounted in the order of installation; 2EA of high speed I/F communication modules, 2EA of the existing
communication I/F modules.
- In the case of the high speed expansion module, it acts as the high speed expansion I/ only when it is installed
in 1-stage or 2-stage.
- When more than two high speed expansion modules are installed, only the modules mounted in 1-stage, 2-
stage act as the high speed I/F; for the modules mounted in 3-stage or more, they works equally to the
existing expansion modules or does not work depending on the corresponding modules.
- The high speed expansion I/F modules cannot be installed behind the normal expansion modules. Accordingly,
when using the high speed expansion modules and the existing normal expansion modules by mixture, the
existing ones should be installed behind the high speed ones.
- The below table represents the example of the system configuration using the high speed expansion modules
and the existing normal expansion modules.

(◎ : High speed expansion communication modules, ○: Existing communication modules,

◈ : High speed expansion special, I/O modules, ◇ : Existing special, I/O modules)

Expansion modules
1-
Basic Unit 2- 3- 4- 5- Definitions of Operations Remarks
stag
stage stage stage stage
e
1,2-stage : Using the high speed I/F, 3~5-stage : 3 communication
◎ ◎ ◈ ○ ◇
Using the existing I/F modules works
1,2-stage : Using the high speed I/F, 3~5-stage : 4 communication
◎ ◎ ○ ○ ◇
Using the existing I/F modules works
1-stage : Using the high speed I/F, 2~5-stage : 2 communication
◈ ○ ○ ◇ ◇
Using the existing I/F modules works

XGB ‘U’ Type ◇ ◎ ◈ ◇ ◇ System Configuration is impossible.

(The high speed expansion modules cannot be
◈ ◎ ◇ ◈ ◇ applied to the further stage of the existing
expansion modules)
1,2 -stage : Using the high speed I/F, 3~5-stage : 3 communication
◎ ◎ ◎ ◇ ◇
Using the existing I/F modules works
Using 10-stage of the existing expansion
◇ ◇ ◇ ◇ ◇
modules
2 communication
Existing XGB ◎ ◎ ◇ ◇ ◇ 1~5-stage: Operated by the existing I/F
modules works

2-8
 System
Chapter 2 System Configuration

2 communication
◎ ◎ ◈ ◇ ◇
modules works
System Configuration is impossible. (The
◎ ◎ ○ ◇ ◇
number of communication modules is exceeded)
System Configuration is impossible. (The high
speed expansion modules cannot be applied to
○ ◈ ◈ ◇ ◇
the further stage of the existing expansion
modules)

(2) How to allocate slots for expansion modules

-In the case of the high performance XGB PLC, the embedded special functions (built-in positioning or analog)
occupies No.1 slot. Accordingly, No.2 slot is allocated for the first expansion module.
-In the case of the high performance XGB basic type(XEC-DN32U/DR28U) that cannot support the embedded
special functions, the empty slot is allocated for No.1.

2-9
System

Chapter 2 System Configuration

2.3.3 Embedded Communication System Configuration

[Link] Embedded Cnet I/F System Configuration
The Cnet I/F system is the system to transmit·receive external devices including PC and data through RS-232C/RS-
422 I/F. In the case of the high performance XGB PLC, RS-232C and RS-485 communication I/F are respectively
embedded. Moreover, you can additionally install the Cnet I/F module (XBL-C21A) for RS-232C only that is the
expansion module and Cnet I/F module (XBL-C41A) for 485 only so it is possible to build up various communication
systems for the purposes.
Some examples of communication systems are represented here, which can be configured by the Cnet I/F
embedded in the high performance XGB basic unit.
(1) 1:1 connection with the HMI by using the basic unit’s embedded RS-232C or RS-485 port

XEC-DN32U

HMI

RS-232C / RS-485

(2) Communication with the other PLC through the basic unit’s embedded RS-485 port/ 1:1 connection with the HMI
through the embedded RS-232C port

2-10
 System
Chapter 2 System Configuration

(3) Configuring 1:N communication system with the maximum 32 stations by using the basic unit’s embedded RS-
485port

Notice

For detailed specificaitons of the high performance XGB’s embedded Cnet communication, refer to Chap.5 Embedded
Communication of this manual.
For detailed specificaitons of the expansion Cnet communication module, refer to “XGB Cnet I/F” of the manual.

2-11
System

Chapter 2 System Configuration

[Link] Embedded Ethernet I/F System Configuration

The Ethernet is the typical LAN interface (IEEE802.3) developed commonly by Xerox, Intel, DEC of U.S.A. It is the
network connection system with the transfer capacity of 100Mbps and packets of 1.5kB. The Ethernet can integrate
different types of computers through network so it is regarded as the representative LAN interface. It is not the standard
for a specific company but the common standard so you can find various products. In addition, it can control
communication through CSMA/CD and builds up the network easily, furthermore, can collect high-capacity data.

(1) Ethernet system’s block diagram

Notice

For more details on how to the above LSIS’s network system configuration and Enet system configuration, refer to
Chap.5 Embedded Communication and “XGB FEnet I/F ” of this manual.

2-12
 System
Chapter 3 Specifications

Chapter 3 Specifications
3.1 Names and Functions of Each Part
3.1.1 Basic Type

⑥ ①
XBC-DN32U ⑦ ⑤

③ ④

⑩ ⑪ ⑨
No Names Purposes
① LED for displaying input, output ■ Displays the On/Off status of input, output contacts
② Connector for PADT ■ Connector(USB 1channel) to access to XG5000
③ Input connector ■ Terminal block receiving the actual input signal
④ Output connector ■ Terminal block outputting the actual output signal
■ Sets the basic unit’s operation mode.
• STOP → RUN : Program’s operation is executed.
⑤ RUN/STOP mode switch
• RUN → STOP : Program’s operation is stopped.
(In case of STOP, the remote operation is available.)
■ Displays the basic unit’s operation status.
• PWR(Red light On) : The power is supplied.
• RUN(Green light On) : During RUN mode
⑥ Status display LED • ERR(Flickering red light) : Occurrence of errors during operation
• STATE(Red light On/flickering Red light): When the SD card is installed, the
red light is turned On; when the SD card error occurs, the red light is flickering.
• RD/WR(Flickering red light) : During SD card Write
⑦ SD card connector ■ Connector with the SD memory card
connector for the
⑧ embedded ■ Terminal block for the embedded Enet communication
Enet communication
connector for the embedded ■ Terminal block(lower part of the product) for the embedded RS-232C/485
⑨
communication communication
⑩ Power terminal block ■ Terminal block (AC 100 ~ 240V or DC24V) for power supply
⑪ 24V output ■ Terminal block with DC 24V output(Not supported on DC type)
⑫ Battery holder ■ Battery holder(upper part of the product)

3-1
System

Chapter 2 System Configuration

3.1.2 Analog Type

No Names Purposes
① LED for displaying input, output ■ Displays the On/Off status of input, output contacts
② Connector for PADT ■ Connector(USB 1channel) to access to XG5000
③ Input terminal block ■ Terminal block receiving the actual input signal
④ Output terminal block ■ Terminal block outputting the actual output signal
■ Sets the basic unit’s operation mode.
• STOP → RUN : Program’s operation is executed.
⑤ RUN/STOP mode switch
• RUN → STOP : Program’s operation is stopped.
(In case of STOP, the remote operation is available.)
■ Displays the basic unit’s operation status.
• PWR(Red light On) : The power is supplied.
• RUN(Green light On) : During RUN mode
• ERR(Flickering red light) : Occurrence of errors during operation
⑥ Status display LED
• STATE(Red light On/flickering Red light): When the SD card is
installed, the red light is turned On; when the SD card error occurs, the red
light is flickering.
• RD/WR(Flickering red light) : During SD card Write
⑦ SD card connector ■ Connector with the SD memory card
Terminal block for the embedded
⑧ ■ Terminal block for the embedded Enet communication
Enet communication
Terminal block for the ■ Terminal block(lower part of the product) for the embedded RS-
⑨
embedded communication 232C/485 communication
⑩ Power terminal block ■ Terminal block (AC 100 ~ 240V or DC24V) for power supply
⑪ 24V output ■ Terminal block with DC 24V output(Not supported on DC type)
⑫ Battery holder ■ Battery holder(upper part of the product)
■ Displays the operation status of analog input/output.
• Red light On : During normal operation
⑬ Analog display LED
• Flickering red light : Occurrence of errors
• Red light Off : Power OFF or module errors
⑭ AD terminal block ■ Analog input terminal block
⑮ DA terminal block ■ Analog output terminal block

3-2
 System
Chapter 3 Specifications

3.1.3 Positioning Type

⑥ ① ⑬

⑦ ⑤

③ ④ ⑭ ⑮

⑩ ⑪ ⑨

No Names Purposes
LED for displaying input,
■ Displays the On/Off status of input, output contacts
output
② Connector for PADT ■ Connector(USB 1channel) to access to XG5000
③ Input terminal block ■ Terminal block receiving the actual input signal
④ Output terminal block ■ Terminal block outputting the actual output signal
■ Sets the basic unit’s operation mode.
• STOP → RUN : Program’s operation is executed.
⑤ RUN/STOP mode switch
• RUN → STOP : Program’s operation is stopped.
(In case of STOP, the remote operation is available.)
■Displays the basic unit’s operation status.
• PWR(Red light On) : The power is supplied.
• RUN(Green light On) : During RUN mode
⑥ Status display LED • ERR(Flickering red light) : Occurrence of errors during operation
• STATE(Red light On/flickering Red light): When the SD card is installed, the
red light is turned On; when the SD card error occurs, the red light is flickering.
• RD/WR(Flickering red light) : During SD card Write
⑦ SD card connector ■ Connector with the SD memory card
Terminal block for the
⑧ embedded ■ Terminal block for the embedded Enet communication
Enet communication
Terminal block for ■ Terminal block(lower part of the product) for the embedded RS-232C/485
⑨
The embedded communication communication
⑩ Power terminal block ■ Terminal block (AC 100 ~ 240V or DC24V) for power supply
⑪ 24V output ■ Terminal block with DC 24V output(Not supported on DC type)
⑫ Battery holder ■ Battery holder(upper part of the product)
■Displays the operation status by positioning axes.
• Green light On: During the corresponding axial operation
LED displaying axial
⑬ • Green light Off: Stop of the corresponding axial operation
operation
• Flickering red light: Occurrence of errors from the corresponding axial
operation
⑭ I/O connector ■ Connector for external wiring of 3, 4-axis
⑮ I/O connector ■ Connector for external wiring of 1, 2-axis

3-3
System

Chapter 2 System Configuration

3.2 General Specifications

No. Items Specification Reference
1 Ambient Temp. 0 ~ 55 °C
2 Storage Temp. −25 ~ +70 °C
3 Ambient humidity 5 ~ 95%RH (Non-condensing) -
4 Storage humidity 5 ~ 95%RH (Non-condensing)
Occasional vibration -
Frequency Acceleration Pulse width Times
5≤f< 8.4㎐ − 3.5mm
8.4≤f≤150㎐ 9.8m/s2(1G) −
5 Vibration 10 times each
Continuous vibration
direction
Frequency Acceleration Pulse width
(X,Y and Z) IEC61131-2
5≤f< 8.4㎐ − 1.75mm
8.4≤f≤150㎐ 4.9m/s2(0.5G) −
• Peak acceleration : 147 m/s2(15G)
6 Shocks • Duration : 11ms
• Pulse wave type : Half-sine (3 times each direction per each axis)
Square wave AC: ±1,500 V
LSIS standard
impulse noise DC: ±900 V
Electrostatic IEC61131-2
Voltage: 4kV (Contact discharge)
discharge IEC61000-4-2
Radiated
7 Impulse noise IEC61131-2,
electromagnetic field 80 ~ 1,000MHz, 10 V/m
IEC61000-4-3
noise
Classifi- Power Digital/Analog Input/Output,
Fast transient IEC61131-2
cation supply Communication Interface
/Burst noise IEC61000-4-4
Voltage 2kV 1kV
8 Operation ambience Free from corrosive gases and excessive dust
9 Altitude Less than 2,000m
-
10 Pollution degree Less than 2
11 Cooling method Air-cooling

Notice

1) IEC (International Electrotechnical Commission)

: An international civil community that promotes international cooperation for standardization of electric/ electro
technology, publishes international standard and operates suitability assessment system related to the above.
2) Pollution Degree
: An index to indicate the pollution degree of used environment that determines the insulation performance of the device.
For example, pollution degree 2 means the state to occur the pollution of non-electric conductivity generally, but the state
to occur temporary electric conduction according to the formation of dew.

3-4
 System
Chapter 3 Specifications

3.3 Power specifications

This section describes the high performance XGB PLC basic unit’s power specifications.
Specification
Items
AC power DC power
Input volatage
AC85V ~ AC264V DC24V
range
Rated input
AC100V ~ AC240V DC19.2~28.8V
voltage
Input frequency 50/60 ± 3 ㎐(47 ~ 63 ㎐) -
1.2A or less
input current 1.6A or less
Input 0.6A or less
Inrush current 120Apeak or less 100 Apeak or less
eakage current 1㎃ or less 3㎃ or less
Efficiency 65% or more 65% or more
Permitted
momentary 10ms or less 7ms or less
power failure
Output voltage Output voltage
voltage current current
Ripple rate Ripple rate
Output voltage
+5V 4.90~5.15V 5A 4.90~5.15V 5A
+24V 21.1~26.9V 0.4A - -
Ouput voltage ripple noise ripple noise
Ripple&
+5V 100㎷pp or lese 200㎷pp or less 100㎷pp or lese 200㎷pp or less
Noise
+24V 400㎷pp or less -
Protecting +5V 5.5A or more 5.5A or more
overcurrent +24V 0.44A or more -
* For protection of the power supply, you are recommended to use the power supply with the maximum of 4A fuse.

Notice

(1) Allowable instantaneous interruption time

It is the time to maintain the normal output voltage(normal operation) on the condition that the input voltage of
AC110/220V is lower than the rating (AC85/170V).
(2) Over-current Protection
(a) When the voltage exceeding the standard is applied to the circuit of DC5V, DC24V, over-current protection device
interrupts the circuit and stops the system.
(b) If over-current occurs, after removing the causes such as shortage of current capacity, short circuit, etc., restart the
system.
(3) Over-voltage Protection
When the voltage exceeding the standard is applied to the circuit of DC5V, over-voltage protection device interrupts the
circuit and stops the system.
(4) Use a UL certified product for the power supply.
Use a power supply that meets Class 2 or LVLC (Limited voltage Limited circuit).

3-5
System

Chapter 2 System Configuration

3.3.1 Consumption current

Type Model Consumption current (Unit : ㎃)

XEC-DN32U(/DC) 700
XEC-DR28U(/DC) 990
XEC-DN32UP(/DC) 1250
Main unit
XEC-DR28UP(/DC) 1550
XEC-DN32UA(/DC) 780
XEC-DR28UA(/DC) 1040
XBE-DC32A 50
XBE-DC16A/B 40
XBE-DC08A 20
XBE-RY16A 440
Expansion I/O module
XBE-RY08A/B 240
XBE-TN32/16/08A 80/50/40
XBE-DR16A 250
XBE-TP32/16/08A 80/50/40
XBF-AD04A 120
XBF-AD08A 105
XBF-AH04A 120
XBF-DV04A 110
XBF-DC04A 110
XBF-RD04A 100
XBF-RD01A 100
XBF-TC04S 100
Expansion Special module XBF-PD02A 500
XBF-HO02A 270
XBF-HD02A 330
XBF-AD04C 105
XBF-DC04C 70
XBF-DV04C 70
XBF-TC04RT 120
XBF-TC04TT 120
XBF-LD02S 110
XBL-C21A 110
XBL-C41A 110
XBL-EMTA 190
XBL-EIMT/F/H 280/670/480
XBL-EIPT 400
Expansion Communication module
XBL-CMEA 150
XBL-CSEA 150
XBL-PMEC 300
XBL-PSEA 230
XBL-DSEA 100

3-6
 System
Chapter 3 Specifications

3.3.2 Calculation Example of Consumption Current/Voltage

Calculate the consumption current and configure the system not to exceed the output current capacity of main unit.
Refer to 3.3.1 for each module’s consumption current

(1) XGB PLC configuration example 1

Consumption of current/voltage is calculated as follows.
Internal 5V
consumption
Type Model Unit No. Remark
current
(Unit : ㎃)
Main unit XEC-DN32U 1 700
In case all contact points are On.
XBE-DC32A 2 50
(Maximum consumption current)
XBE-TN32A 2 80
Expansion module XBF-AD04A 1 120
All channel is used.
XBF-DC04A 1 110
(Maximum consumption current)
XBL-C21A 1 110
Consumption
1,300㎃ -
current
Consumption
6.5W 1.3A ⅹ 5V = 6.5W
voltage

In case system is configured as above, since 5V consumption current is total 1,300 mA and 5V output of XGB 32 points main unit
is maximum 5A, normal system configuration is available.

(2) XGB PLC configuration example 2

Internal 5V
consumption
Type Model Unit No. Remark
current
(Unit : ㎃)
Main unit XEC-DN32U 1 700
In case all contact points are On.
XBE-DR16A 2 250
(Maximum consumption current)
XBE-RY16A 2 440
Expansion module
XBF-AD04A 2 120 All channel is used.
XBL-C21A 1 110 (Maximum consumption current)
Consumption
2,430mA -
current
Consumption
12.15W 2.43 * 5V = 12.15W
voltage

In case system is configured as above, since 5V consumption current is total 2,430 mA and 5V output of XGB 32 points main unit
is maximum 5A, normal system configuration is available.

3-7
System

Chapter 2 System Configuration

3.4 Battery
3.4.1 Battery specifications
Items Specifications
Nominal voltage / current DC 3.6V / 800 mAh
Warranty term 3 years(at room temperature)
Purpose Program and data backup, RTC operation during the blackout
Backup time 3years
Specifications Lithium battery, 3.6V
Appearance Size (mm) φ14.5 X 26 mm

3.4.2 Instruction for Use

(1) Do not apply heat or solder electrode (It may cause a battery’s life-shortening)
(2) Do not measure voltage with a tester or short-circuit (It may be the cause of a fire.)
(3) Do not disassemble the battery.

3.4.2 Battery Life

A battery’s life may be different depending on the conditions of blackout time, service temperature, etc.
When the voltage of a battery gets lower, the basic unit sends ‘Warning on Battery’s Voltage Drop’. The situation also can
be checked through the basic unit’s error LED and XG5000’s error message.
(Warning on a battery’s voltage drop occurs within 10 second after detaching the battery)
In the system with routine inspection, you can take measures after the fact since the battery works normally for substantial
amount of time even after the warning on a battery’s voltage drop occurred.

3-8
 System
Chapter 3 Specifications

3.4.3 How to replace a battery

The battery used for backup in case of power failure of programs and data requires the periodic replacement.
Although the battery is removed, the program and data electrostatic holding data are maintained by the Super
Capacitor for about 30 minutes, however, it should be replaced as soon as possible.

The procedures to replace the battery are as below.

Start of battery change

Open battery cover

Pick up using battery from holder and

disassemble the connector

Insert new battery and connect to connector

with proper direction

Check the LED whether ERR LED is off

Yes
ERR LED off?

No
Complete
Battery malfunction

3-9
System

Chapter 2 System Configuration

3.5 Performance specifications

3.5.1 Common performance specifications for CPU
The high performance XGB basic unit’s common performance specifications for CPU are as below.
Specifications
Items XEC-DN(P) XEC-DR XEC-DN XEC-DR XEC-DN XEC-DR Remark
32U(/DC) 28U(/DC) 32UA(/DC) 28UA(/DC) 32UP(/DC) 28UP(/DC)
Cyclic execution of stored program, Time-driven interrupt,
Program control metho
Process-driven interrupt
Batch processing by simultaneous scan (Refresh method),
I/O control method
Directed by program instruction
Program language Ladder Diagram, Instruction List
Operator 18
Basic function 136＋Floating-point Arithmetic Functions
No. of Basic function
43
instruction block
Special function
Each special module has own special function blocks
block
Processing speed
60㎱/step
(Basic instruction)
Program memory 384KB
main + 10
Max. I/O points 352points 348points 352points 348points 352points 348points
expansions
Symbolic variable(A) 64KB (Retain setting available)
Input variable(I) 2KB
Output variable(Q) 2KB
M 32KB (Retain setting available) -
R 32KB * 2blocks -
Direct variable
Data area

Same area
W 64KB
with R
F 4KB System flag
K 16KB Keep relay
L 8KB Link relay
Flag variable
Analog data
U 768 Byte
refresh area
N 20KB P2P parameter
Flash area 4blocks (128Kbyte) Using R device
Timer No limit in points (Time range: 0.001~ 4,294,967.295 s)
Counter No limit in points (Counter range: 64 bit range)
Total program 256
Initial task 1
Cyclic task Max 16
Initial task

I/O task Max 8

Internal device task Max 16
High Speed
Max 8
Counter task
Operation mode RUN, STOP, DEBUG
Self-diagnosis function Detects errors of scan time, memory, I/O and power supply
Program port USB 1 channel
Back-up method Latch area setting in basic parameter
Internal consumption current 700㎃ 990㎃ 780㎃ 1,040㎃ 1,250㎃ 1,550㎃
Weight 571g 630g 683g 732g 673g 722g

3-10
 System
Chapter 3 Specifications

Specifications
Items XEC-DN XEC-DR XEC-DN XEC-DR XEC-DN XEC-DR
Note
32U(/DC) 28U(/DC) 32UA(/DC) 28UA(/DC) 32UP(/DC) 28UP(/DC)
Control by instruction, auto-tunning,
PWM output, Forced output,
Operation scan time setting,
PID control
Antiwindup, Delta MV, PV tracking,
Hybrid operation,
Cascade operation
Dedicated protocol,
Modbus protocol
Protocol Embedded00
Serial

User defined protocol ,

P2P:01
LS bus(inverter protocol)
Channel RS-232C 1 port and RS-485 1 port
Cable: 100Base-TX
Transfer Speed: 100Mbps
spec Auto-MDIX*1
Built –in function

IEEE 802.3
Topology Line, star
Ethernet

Diagnosis Module information, service condition

XGT dedicated
Embedded01
Protocol Modbus TCP/IP
P2P:02
user define frame
High-speed
P2P, High Speed link,
Service link:01
Remote connection
Group Max 10 group
Data set 32 per group
Extension csv file
File size Max 16Mbyte
Datalog

SD memory SD,SDHC type

type (Recommand: SanDisk,Transcend)
Memory
Max 16GB
size
File systemFAT32
1-phase : 100 ㎑ 8 channels
Performance
2-phase : 50 ㎑ 4 channels
High Speed Counter

4 counter modes are supported based on input pulse and INC/DEC method
• 1 pulse operation Mode : INC/DEC count by program
Counter
• 1 pulse operation Mode : INC/DEC count by phase B pulse input
Built –in function

mode
• 2 pulse operation Mode : INC/DEC count by input pulse
• 2 pulse operation Mode : INC/DEC count by difference of phase
• Internal/external preset • Latch counter
Function
• Compare output • No. of rotation per unit time
Pulse catch 50㎲ 8point(%IX0.0.8 ~ %IX0.0.15)
External point
50㎲ 8point(%IX0.0.8 ~ %IX0.0.15)
Interrupt
Input filter 1,3,5,10,20,70,100㎳
*1 Auto-MDIX(Automatic medium-dependent interface crossover) : It is the function to automatically detect whether the cable connected
to the Ethernet port is peer-to-peer(straight) or cross cable

Notice
Even in the same program, there may be a difference in the amount of memory used depending on the base unit
MPU chip performance and compilation method.

3-11
System

Chapter 2 System Configuration

3.5.2 Specifications for Embeded Positioning

The specifications for Embeded Positioning are as below.

Items Specifications Remark

No. of control axi: 4axis
Control Method:Position, Speed, Speed/Position,
Feed Control
Control Unit: Pulse ,mm, inch, degree
Basic Function
Positioning Data: Each axis can have up to 400 data
(Step number:1~400)
Operation pattern: End, Keep, Continuous
Operation method: Singular, Repeat
2/3/4 axis linear interpolation
interpolation 2 axis circular interpolation
Built –in function

Positioning

3 axis helical interpolation Available

Method: Absolute/Incremental method On
Address range: 2,147,483,648~2,147,483,647 UP type
Positioning
Speed: Max 2Mpps(1~2,000,000pps)
Acc /Dec process: Trapezoid type, S-type
DOG+HOME(Off),
Homing DOG+HOME(On),
method Upper limit + HOME,DOG, High speed,
Upper/Lower limit, HOME
Manual Jog operation, MPG operation,
operation Inching operation
Encoder Line drive(RS-422A) input
input 1Channel(Max 200kpps)

3-12
 System
Chapter 3 Specifications

3.5.3 Specifications for Embeded Analog

The specifications for Embeded Anlalog are as below.

Items Specifications Remark

Channels 4channels (current/voltage)
Voltage: 1~5V, 0~5V, 0~10V, -10~10V
Current: 4~20㎃,0~20㎃
Input Range
Current input or Voltage input can be selected through
the external terminal wiring setting.
Analog input

Input
1㏁ or more(voltage input), 250Ω (current iput)
resistance
Specification 1/16000
0.250㎷ (1 ~ 5V) 1.0㎂ (4 ~ 20㎃)
[Link] 0.3125㎷ (0 ~ 5V) 1.25㎂ (0 ~ 20㎃)
0.625㎷ (0 ~ 10V)
1.250㎷ (±10V)
Built –in function

±0.2% or less (When ambient temperature is 25℃)

Accuracy Available
Analog

±0.3% or less (When ambient temperature is 0 ~ 55℃)

On
Channels Voltage 2 channels ,Current 2 channels
Analog
Voltage: 1~5V, 0~5V, 0~10V, -10~10V
Current: 4~20㎃, 0~20㎃
Output Range
Output ranges are set in user program or I/O parameter per
each channel.
Analog output

Load 1㏁ or more(voltage output),

resistance 600Ω or less(current output)
Specification 1/16000
0.250㎷ (1 ~ 5V) 1.0㎂ (4 ~ 20㎃)
[Link] 0.3125㎷ (0 ~ 5V) 1.25㎂ (0 ~ 20㎃)
0.625㎷ (0 ~ 10V)
1.250㎷ (±10V)
±0.2% or less (When ambient temperature is 25℃)
Accuracy
±0.3% or less (When ambient temperature is 0 ~ 55℃)

3-13
 System
Chapter 4 Installation and wiring

Chapter 4 Installation and wiring

4.1 Parameter & Operation data

Danger
 Please design protection circuit at the external of PLC for entire system to operate safely because an abnormal

output or an malfunction may cause accident when any error of external power or malfunction of PLC module.

(1) It should be installed at the external side of PLC to emergency stop circuit, protection circuit, interlock circuit of

opposition action such as forward /reverse operation and interlock circuit for protecting machine damage such as

upper/lower limit of positioning.

(2) If PLC detects the following error, all operation stops and all output is off.

(Available to hold output according to parameter setting)

(a) When over current protection equipment or over voltage protection operates

(b) When self diagnosis function error such as WDT error in PLC CPU occurs

 When error about IO control part that is not detected by PLC CPU, all output is off.

Design Fail Safe circuit at the external of PLC for machine to operate safely. Refer to 4.1.1 Fail Safe circuit.

(1) Because of error of output device, Relay, TR, etc., output may not be normal. About output signal that may cause

the heavy accident, design supervisory circuit to external.

When load current is more than rating or over current by load short flows continuously, danger of heat, fire may occur

so design safety circuit to external such as fuse.

Design for external power supply to be done first after PLC power supply is done. If external power supply is done

first, it may cause accident by misoutput, misoperation.

In case communication error occurs, for operation status of each station, refer to each communication manual.

In case of controlling the PLC while peripheral is connected to CPU module, configure the interlock circuit for system

to operate safely. During operation, in case of executing program change, operation status change, familiarize the

manual and check the safety status. Especially, in case of controlling long distance PLC, user may not response to

error of PLC promptly because of communication error or etc.

Limit how to take action in case of data communication error between PLC CPU and external device adding installing

interlock circuit at the PLC program.

4-1
System

Chapter 4 Installation and wiring

Danger

Don’t close the control line or communication cable to main circuit or power line. Distance should be more than 100mm.

It may cause malfunction by noise.

In case of controlling lamp load, heater, solenoid valve, etc. in case of Off -> On, large current (10 times of normal

current) may flows, so consider changing the module to module that has margin at rated current.

Process output may not work properly according to difference of delay of PLC main power and external power for

process (especially DC in case of PLC power On-Off and of start time.

For example, in case of turning on PLC main power after supplying external power for process, DC output module may

malfunction when PLC is on, so configure the circuit to turn on the PLC main power first

Or in case of external power error or PLC error, it may cause the malfunction.

Not to lead above error to entire system, part causing breakdown of machine or accident should be configured at the

external of PLC

4-2
 System
Chapter 4 Installation and wiring

4.1.1 fail safe circuit

(1) example of system design (When ERR contact point of power module is not used)

In case of AC In case of AC . DC
Power

Power

Check direct Trans Trans

Trans
current Fuse Fuse
Fuse
Signal input

DC power
F0045
Pm
Pm
Fuse
F009C
F009C Pm Timer setting
Pm

Start
PLC RUN output Pm which DC input
Program
switch
Start available as RA1 Tm signal is
configured.
Stop
SW Input module
Start Program
switch

Output module Stop Voltage relay

SW
Output for warning equipped
Pm
(Lamp or buzzer)

Pn
RUN by F009C Pm

Power off to output

Output module device Output module Output for warning
(Lamp or buzzer)

Run by F009C
Emergency stop,
Stop by limit
Output module
Configure part that lead
opposite operation or
breakdown such as Power Off to
interlock circuit forward, output device
reverse revolution by (Emergency stop,
external interlock circuit stop by limit
Start sequence of power. In case of AC switch)
(1) Turn on power
(2) Run CPU.
(3) Turn on start switch
Start sequence of power. In case of AC DC
(4) Output device runs by program through
(1) Run CPU after power is on
magnetic contactor (MC) [On]
(2) Turn on RA2 as DC power on
(3) Turn on timer after DC power is stable.
(4) Turn on start switch
(5) Output device runs by program through magnetic contactor (MC) [On] 4-3
System

Chapter 4 Installation and wiring

(2) Fail Safe Measures in case of PLC failures

Failures of the PLC CPU and memory are detected by self-diagnosis but if there are some problems with I/O control part,
etc, the failure may not be detected from the CPU. In this case, it can be different depending on the failure status, all
contacts may be On or Off so normal operation or safety of the controlled subject cannot be guaranteed.
We have done our best to assure quality but in case there are some problems with the PLC, please configure the fail safe
circuit on the outside to prevent damage of the equipment or accident due to some cause. The below is the example of
system configuration with the fail sage circuit.

<System example>

Slot No. 0 1 2 3 4 5

t t
u u
t t p p
t u
6 t u
6 t tu
6 t tu
6
1 p
in 1 p
in 1 O
in 1 O
in
o In o In o o
p p p p

P Area 00~3F 40~7F 80~11F 120~15F 160~19F 200~23F

Output module for fail safe

* Equip output module for fail safe to last slot of system.

[Fail safe circuit example]

On delay timer

P200 T1
F0093 Off delay timer
P200 T2
External load MC
P201 L
~
P20F L
P200
24V

- +
0.5s 0.5s 0V
T1 T2 DC24V

MC
CPU unit Output module

Since P200 turn on/off every 0.5s, use TR output.

4-4
 System
Chapter 4 Installation and wiring

4.1.2 PLC heat calculation

(1) Power consumption of each part

(a) Power consumption of module

The power conversion efficiency of power module is about 70% and the other 30% is gone with heat; 3/7 of the output power
is the pure power consumption. Therefore, the calculation is as follows.
• Wpw = 3/7 {(I5V X 5) + (I24V X 24)} (W)
I5V : power consumption of each module DC5V circuit(internal current consumption)
I24V: the average current consumption of DC24V used for output module
(current consumption of simultaneous On point)
If DC24V is externally supplied or a power module without DC24V is used, it is not applicable.

(b) Sum of DC5V circuit current consumption

The DC5V output circuit power of the power module is the sum of power consumption used by each module.
• W5V = I5V X 5 (W)

(c) DC24V average power consumption(power consumption of simultaneous On point)

The DC24V output circuit’s average power of the power module is the sum of power consumption used by each module.
• W24V = I24V X 24 (W)

(d) Average power consumption by output voltage drop of the output module(power consumption of simultaneous On point)
• Wout = Iout X Vdrop X output point X simultaneous On rate (W)
Iout : output current (actually used current) (A)
Vdrop: voltage drop of each output module (V)

I24V

DC24V
Main unit Comm. Comm. output input Special input
AC power
100V~240V DC5V I5V
constant
Voltage
transformer
Iout Iin

load
AC power
DC 100V~240V
power
24V

4-5
System

Chapter 4 Installation and wiring

(e) Input average power consumption of input module

(power consumption of simultaneous On point)
• Win = lin X E X input point X simultaneous On rate (W)
Iin: input current (root mean square value in case of AC) (A)
E : input voltage (actually used voltage) (V)

(f) Power consumption of special module power assembly

• WS = I5V X 5 + I24V X 24 + I100V X 100 (W)
The sum of power consumption calculated by each block is the power consumption of the entire PLC system.
• W = WPW + W5V + W24V + Wout + Win + Ws (W)
Calculate the heats according to the entire power consumption(W) and review the temperature increase within the control
panel.

The calculation of temperature rise within the control panel is displayed as follows.
T = W / UA [°C]
W : power consumption of the entire PLC system (the above calculated value)
A : surface area of control panel [m2]
U : if equalizing the temperature of the control panel by using a fan and others : 6
If the air inside the panel is not ventilated : 4

If installing the PLC in an air-tight control panel, it needs heat-protective(control) design considering the heat from the PLC as well
as other devices. If ventilating by vent or fan, inflow of dust or gas may affect the performance of the PLC system.

2 기본 파라미

4-6
 System
Chapter 4 Installation and wiring

4.2 Attachment/Detachment of Modules

Here describes about basic parameter of embedded positioning.

4.2.1 Attachment/Detachment of modules

Caution in handling
Use PLC in the range of general specification specified by manual.
In case of usage out of range, it may cause electric shock, fire, malfunction, damage of product.

Remark
 Module must be mounted to hook for fixation properly before its fixation.
The module may be damaged from over-applied force. If module is not mounted properly, it may cause malfunction.

 Do not drop or impact the module case, terminal block connector.

 Do not separate PCB from case.

(1) Equipment of module

• Eliminate the Extension Cover at the product.
• Push the product and connect it in agreement with Hook For Fixation of four edges and Hook For Connection at the bottom.
• After connection, push down the Hook For Fixation and fix it completely.

Boss for fixation

Extension cover

Hook for fixation

Boss for connection

(2) Detachment of module

•Push up the Hook For Disconnection, and then detach the product with two hands.
(Do not detach the product by force)

Remark
 When separating module, do not apply excessive force. If so, hook may be damaged.

4-7
System

Chapter 4 Installation and wiring

(3) Installation of module

XGB PLC has a hook for DIN rail (rail width: 35mm) so that cab be installed at DIN rail.

(a) In case of installing at DIN rail

• Pull the hook as shown below for DIN rail at the bottom of module and install it at DIN rail
• Push the hook to fix the module at DIN rail after installing module at DIN rail
• Install a stopper at both ends of the product to prevent damage to the product due to vibration.

(b) In case of installing at panel

• You can install XGB compact type main unit onto a panel directly using screw hole
• Use M4 type screw to install the product onto a panel.

Panel

2-Ø4.5 screw hole

4-8
 System
Chapter 4 Installation and wiring

(4) Module equipment location

Keep the following distance between module and structure or part for ventilation, easy detachment and attachment.

30㎜ or above *1

Panel
PLC

20㎜or above*3

30㎜or above*1

5㎜ or above*1 5㎜ or above

*1 : In case height of wiring duct is less than 50 mm (except this 40mm or more)
*2 : In case of equipping cable without removing near module, 20mm or more
*3 : In case of connector type, 20mm or above

(5) Module equipment direction

(a) For easy ventilation, install as shown below.

(b) Don’t install as shown below.

4-9
System

Chapter 4 Installation and wiring

(6) Distance with other device

To avoid radiation noise or heat, keep the distance between PLC and device (connector and relay) as far as the following figure.
Device installed in front of PLC: 100 ㎜ or more
Device installed beside PLC: 50 ㎜ or more

100mm or above

50mm or above

50mm or above

4-10
 System
Chapter 4 Installation and wiring

4.2.2 Caution in handling

Here describes caution from open to install

• Don’t drop or impact product.
• Don’t disassemble the PCB from case. It may cause an error.
• In case of wiring, make sure foreign substance not to enter upper part of module. If it enters, eliminate it.

(1) Caution in handling IO module

It describes caution in handling IO module.

(a) Recheck of IO module specification

For input module, be cautious about input voltage, for output module, if voltage that exceeds the max. open/close voltage is
induced, it may cause the malfunction, breakdown or fire.

(b) Used wire

When selecting wire, consider ambient temp, allowed current and minimum size of wire is AWG22(0.3mm2) or above.

(c) Environment
In case of wiring IO module, if device or material that induce high heat is too close or oil contacts wire too long time, it may
cause short, malfunction or error.

(d) Polarity
Before supplying power of module which has terminal block, check the polarity.

(e) Wiring
• In case of wiring IO with high voltage line or power line, induced obstacle may cause error.
• Let no cable pass the IO operation indication part (LED).
(You can’t discriminate the IO indication.)
• In case induced load is connected with output module, connect the surge killer or diode load in parallel. Connect cathode of
diode to + side of power.

OUT Induced load

Output module
Surge killer
COM

OUT Induced load

+
Output module
-
Diode
COM

(f) Terminal block

Check close adhesion status. Let no foreign material enter into PLC when wring terminal block or processing screw hole as it
may cause malfunction, it may cause malfunction.

(g) Don’t impact IO module or don’t disassemble the PCB from case.

4-11
System

Chapter 4 Installation and wiring

4.3 Wire
In case using system, it describes caution about wiring.

Danger
When wiring, cut off the external power.
If all power is cut, it may cause electric shock or damage of product.
In case of flowing electric or testing after wiring, equip terminal cover included in product. It not, it may cause electric shock.

Remark
 Do D type ground (type 3 ground) or above dedicated for PLC for FG and LG terminal. It may cause electric shock or malfunction.
 When wiring module, check the rated voltage and terminal array and do properly.
If rating is different, it may cause fire, malfunction.
 For external connecting connector, use designated device and solder.
If connecting is not safe, it may cause short, fire, malfunction.
For screwing, use designated torque range. If it is not fit, it may cause short, fire, malfunction.
Let no foreign material enter such as garbage or disconnection part into module. It may cause fire, malfunction, error.

4.3.1 Power wiring

(1) In case voltage regulation is larger than specified, connect constant voltage transformer.

AC power
100V~240V AC power
Constant AC100-240V
voltage
transformer

(2) Connect noise that include small noise between line and earth.
(When there are much noise, connect insulated transformer.)

4-12
 System
Chapter 4 Installation and wiring

(3) Isolate the PLC power, I/O devices and power devices as follows.

Main unit
Main PLC
power power Constant
AC220V Voltage
Transformer AC100-240V

IO power

Main circuit device

(4) If using DC24V of the main unit

(a) Do not connect DC24V of several power modules in parallel. It may cause the destruction of a module.
(b) If a power module can not meet the DC24V output capacity, supply DC24V externally as presented below.

DC 24V Output

DC 24V
SMPS

(5) AC110V/AC220V/DC24V cables should be compactly twisted and connected in the shortest distance.

(6) AC110V/AC220V cable should be as thick as possible(2mm2) to reduce voltage drop.

(7) AC110V/ DC24V cables should not be installed close to main circuit cable(high voltage/high current) and I/O signal cable. They
should be 100mm away from such cables

4-13
System

Chapter 4 Installation and wiring

(8) To prevent surge from lightning, use the lightning surge absorber as presented below.

(9) Wiring of each input power should be twisted as short as possible and the wiring of shielding transformer or noise filter should not
be arranged via a duct.

(10)To prevent surge from lightning, use the lightning surge absorber as presented below.

PLC
I/O device

E1 E2
Surge absorber to prevent lighting

Remark
(1) Isolate the grounding(E1) of lightning surge absorber from the grounding(E2) of the PLC.
(2) Select a lightning surge absorber type so that the max. voltage may not the specified allowable voltage
of the absorber.

4-14
 System
Chapter 4 Installation and wiring

4.3.2 I/O Device wiring

(1) The size of I/O device cable is limited to 0.3~2 mm2 but it is recommended to select a size(0.3 mm2) to use conveniently.

(2) Please isolate input signal line from output signal line.

(3) I/O signal lines should be wired 100mm and more away from high voltage/high current main circuit cable.

(4) Batch shield cable should be used and the PLC side should be grounded unless the main circuit cable and power cable can not
be isolated.

PLC Shield cable

Input
RA

Output DC

(5) When applying pipe-wiring, make sure to firmly ground the piping.

4-15
System

Chapter 4 Installation and wiring

(6) Example of input module.

(7) Example of output module.

4-16
 System
Chapter 4 Installation and wiring

4.3.3 Grounding wiring

(1) The PLC contains a proper noise measure, so it can be used without any separate grounding if there is a large noise. However, if
grounding is required, please refer to the followings.

(2) For grounding, please make sure to use the exclusive grounding.
For grounding construction, apply type 3 grounding(grounding resistance lower than 100 Ω)

(3) If the exclusive grounding is not possible, use the common grounding as presented in B) of the figure below.

PLC Otherdevices PLC Otherdevices PLC Otherdevices

Type 3 Grounding Type 3 Grounding

A) Exclusive grounding : best B) common grounding : good C) common grounding: defective

(4) Use the grounding cable more than 2 mm2. To shorten the length of the grounding cable, place the grounding point as close to
the PLC as possible.

(5) If any malfunction from grounding is detected, separate the FG of the base from the grounding.

4.3.4 Specifications of wiring cable

The specifications of cable used for wiring are as follows.

Types of external Cable specification (mm2)

connection Lower limit Upper limit
Digital input 0.18 (AWG24) 1.5 (AWG16)
Digital output 0.18 (AWG24) 2.0 (AWG14)
Analogue I/O 0.18 (AWG24) 1.5 (AWG16)
Communication 0.18 (AWG24) 1.5 (AWG16)
Main power 1.5 (AWG16) 2.5 (AWG12)
Protective grounding 1.5 (AWG16) 2.5 (AWG12)

4-17
 System
Chapter 5 Maintenance

Chapter 5 Maintenance
Be sure to perform daily and periodic maintenance and inspection in order to maintain the PLC in the best conditions.

5.1 Maintenance and Inspection

The I/O module mainly consist of semiconductor devices and its service life is semi-permanent. However, periodic inspection is
requested for ambient environment may cause damage to the devices. When inspecting one or two times per six months, check
the following items.
Check Items Judgment Corrective Actions

Within change rate of input

Change rate of input voltage Hold it with the allowable range.
voltage
Input/Output specification of each
Power supply for input/output Hold it with the allowable range of each module.
module
Temperature 0 ~ + 55℃ Adjust the operating temperature and humidity with the defined
Ambient Humidity 5 ~ 95%RH range.
environment
Use vibration resisting rubber or the vibration prevention
Vibration No vibration
method.
Play of modules No play allowed Securely enrage the hook.
Connecting conditions of
No loose allowed Retighten terminal screws.
terminal screws
Check the number of
Spare parts Spare parts and their Cover the shortage and improve the conditions.
Store conditions

5-1
System

Chapter 5 Installation and wiring

5.2 Daily Inspection

The following table shows the inspection and items which are to be checked daily.
Corrective
Check Items Check Points Judgment
Actions
Connection conditions of Retighten
Check the screws. Screws should not be loose.
base Screws.
Connection conditions of Check the connecting screws Retighten
Screws should not be loose.
Input/Output module Check module cover. Screws.
Retighten
Check for loose mounting screws. Screws should not be loose.
Connecting conditions of Screws.
terminal block or extension Check the distance between solderless Proper clearance should be
Correct.
cable terminals. provided.
Connecting of expansion cable. Connector should not be loose. Correct.
PWR LED Check that the LED is On. On (Off indicates an error)
On (flickering or On indicates an
Run LED Check that the LED is On during Run.
error)
LED ERR LED Check that the LED is Off during Run. Flickering indicates an error
indicator On when input is On,
Input LED Check that the LED turns On and Off.
Off when input is off.
On when output is On,
Output LED Check that the LED turns On and Off
Off when output is off

5.3 Periodic Inspection

Check the following items once or twice every six months, and perform corrective actions as needed.
Check Items Checking Methods Judgment Corrective Actions
Ambient Adjust to general
0 ~ 55 °C
temperature -. Measure with thermometer and standard
Ambient
Ambient Humidity hygrometer 5 ~ 95%RH (Internal environmental
environment
Ambient pollution -. measure corrosive gas There should be no standard of control
level corrosive gases section)
Looseness, The module should be move The module should be
PLC Ingress the unit mounted securely.
Retighten screws
Conditions dust or foreign
Visual check No dust or foreign material
material
Loose terminal
Re-tighten screws Screws should not be loose Retighten
screws
Distance between
Connecting Visual check Proper clearance Correct
terminals
conditions
Retighten connector
Connectors should not be
Loose connectors Visual check mounting
loose.
screws
Measure voltage between
Line voltage check 3.3 Power specifications Change supply power
input terminals

5-2
 System
Chapter 6 Troubleshooting

Chapter 6 Troubleshooting
The following explains contents, diagnosis and corrective actions for various errors that can occur during system operation.

6.1 Basic Procedure of Troubleshooting

System reliability not only depends on reliable equipment but also on short downtimes in the event of fault. The short discovery and corrective
action are needed for speedy operation of system. The following shows the basic instructions for troubleshooting.

(1) Visual checks

Check the following points.
• Machine operating condition (in stop and operation status)
• Power On/Off
• Status of I/O devices
• Condition of wiring (I/O wires, extension and communications cables)
• Display states of various indicators (such as POWER LED, RUN LED, ERR LED and I/O LED)
After checking them, connect peripheral devices and check the operation status of the PLC and the program contents.

(2) Trouble Check

Observe any change in the error conditions during the following.
• Switch to the STOP position, and then turn the power on and off.

(3) Narrow down the possible causes of the trouble where the fault lies, i.e.:
• Inside or outside of the PLC ?
• I/O module or another module?
• PLC program?

6.2 Troubleshooting
This section explains the procedure for determining the cause of troubles as well as the errors and corrective actions.

Symptoms

Is the power LED turned Flowchart used when the POWER LED is turned Off.
Off ?

Is the ERR LED flickering ? Flowchart used when the ERR LED is flickering.

Are the RUN LED turned Flowchart used when the RUN turned Off.
Off ?

I/O module doesn’t operate Flowchart used when the output load of the output module doesn’t
properly. turn on.

Program cannot be written. Flowchart used when a program can’t be written to the PLC.

6-1
System

Chapter 6 Trouble Shooting

6.2.1 Troubleshooting flowchart used when the PWR (Power) LED turns Off
The following flowchart explains corrective action procedure used when the power is supplied or the power
LED turns Off during operation.

Power LED is turned Off.

Is the power supply No

operating? Supply the power.

No Yes
Yes Does the power LED
turns On?

No
Is the voltage within the rated Supply the power properly.
power?

Yes

Yes Yes
Does the power LED
turns On?

Over current protection

device activated?

1) Eliminate the excess current

2) Switch the input power Off then On.

No

No Yes
Does the power LED
turns On?

Write down the troubleshooting

Questionnaire and contact
the nearest service center.

Complete

6-2
 System
Chapter 6 Troubleshooting

6.2.2 Troubleshooting flowchart used with when the ERR (Error) LED is flickering
The following flowchart explains corrective action procedure used when the power is supplied starts or the ERR LED
is flickering during operation.

STOP LED goes flickering

Check the error code, with

connected XG5000.

No

See Appendix 1 Flag list and

Warning error?
remove the cause of the
error.
Yes

No
Is ERR LED still
flicking ?

Complete Yes

Write down the Troubleshooting

Questionnaires and contact the nearest
service center.

Warning
Though warning error appears, PLC system doesn’t stop but corrective action is needed promptly. If not, it
may cause the system failure.

6-3
System

Chapter 6 Trouble Shooting

6.2.3 Troubleshooting flowchart used with when the RUN , STOP LED turns Off.

The following flowchart explains corrective action procedure to treat the lights-out of RUN LED when the
power is supplied, operation starts or is in the process.

RUN, STOP LED is Off.

Turn the power unit Off and On.

No
Is RUN/ STOP LED Off?

Yes

Write down the Troubleshooting

Questionnaires and contact the nearest Complete
service center.

6-4
 System
Chapter 6 Troubleshooting

6.2.4 Troubleshooting flowchart used when the I/O part doesn’t operate normally.
The following flowchart explains corrective action procedure used when the I/O module doesn’t operate normally.

When the I/O module doesn’t work normally.

No
Is the output LED of SOL1
On?

Yes

Measure the voltage of Correct wiring. Replace the connector of Check the status of SOL1
the terminal block.
terminal in SOL1 by Tester. by XG5000.

No No

Is the No
Yes Yes
Is the output terminal connector Is it normal condition?
Is the measured value
normal? wiring correct? appropriate?
Yes
Yes
Yes

Separate the external

wiring than check the
condition of output Continue
module.

Yes No
Is it normal condition?

Check the status of Replace the Unit

SOL1.

6-5
System

Chapter 6 Trouble Shooting

Continue

No
Are the indicator LED of the
switch 1 and 2 on?

Yes

Check voltage of switch 1,2 by Check voltage of switch 1,2 by

tester tester

Yes Is the
Is the measured value Is the measured value terminal screw tighten
normal? No normal? No securely?
Yes No Yes

Is the condition
Yes
Is input wiring correct? of the terminal board connector
appropriate?

Separate the external No No

wiring witch then check
the status by forced
i t

Correct wiring Retighten the Replace the

Is the measured value terminal screw. Terminal board
No normal? connector.
Yes

Input unit Check the status of the Check from the beginning. Input unit
replacement is switch 1 and 2. replacement is
Needed. Needed.

6-6
 System
Chapter 6 Troubleshooting

6.3 Troubleshooting Questionnaire

If any problem occurs during the operation of XGB series, please write down this Questionnaires and contact the service center via telephone or
facsimile.
 For errors relating to special or communication modules, use the questionnaire included in the User’s manual of the unit.

1. Telephone & FAX No

Tell) FAX)
2. Using equipment model:

3. Details of using equipment

CPU model: ( ) OS version No.: ( ) Serial No. ( )
XG5000 (for program compile) version No.: ( )

[Link] description of the device or system used as the control object:

5. The kind of the base unit:

− Operation by the mode setting switch ( ),
− Operation by the XG5000 or communications ( ),
− External memory module operation ( ),

6. Is the ERR. LED of the CPU module turned On ? Yes ( ), No ( )

7. XG5000 error message:

8. History of corrective actions for the error message in the article 7:

9. Other tried corrective actions:

10. Characteristics of the error

 Repetitive ( ): Periodic ( ), Related to a particular sequence ( ), Related to environment ( )
 Sometimes ( ): General error interval:

11. Detailed Description of error contents:

12. Configuration diagram for the applied system:

6-7
System

Chapter 6 Trouble Shooting

6.4 Troubleshooting Examples

Possible troubles with various circuits and their corrective actions are explained.

6.4.1 Input circuit troubles and corrective actions

The followings describe possible troubles with input circuits, as well as corrective actions.

Condition Cause Corrective Actions

Leakage current of external device  Connect an appropriate register and capacity,
Input signal (Such as a drive by non-contact switch) which will make the voltage lower across the
doesn’t turn off. terminals of the input module.
AC input
C Leakage current AC input
R
C
~
External device R
~
Input signal Leakage current of external device
doesn’t turn off. (Drive by a limit switch with neon lamp)  CR values are determined by the leakage
(Neon lamp current value.
may be still on) AC input − Recommended value C : 0.1 ~ 0.47㎌
C Leakage current R: 47 ~ 120 Ω (1/2W)
R
Or make up another independent display circuit.
~
External device

Input signal Leakage current due to line capacity of wiring cable.

doesn’t turn off.  Locate the power supply on the external device side
as shown below.
AC input AC input
Leakage current

~ ~
External device External device

 Connect an appropriate register, which will make the

Input signal Leakage current of external device (Drive by switch voltage higher than the OFF voltage across the input module
doesn’t turn off. with LED indicator) terminal and common terminal.

DC input
DC input
Leakage current
R R

External device

6-8
 System
Chapter 6 Troubleshooting

 Use only one power supply.

Input signal  Sneak current due to the use of two different power  Connect a sneak current prevention diode.
doesn’t turn off. supplies.
DC input
DC input
E L
L E1 E
E

 E1 > E2, sneaked.

6.4.2 Output circuit and corrective actions

The following describes possible troubles with output circuits, as well as their corrective actions.
Condition Cause Corrective Action
When the output Load is half-wave rectified inside (in some cases, it  Connect registers of tens to hundreds KΩ across the
is off, excessive is true of a solenoid) load in parallel.
voltage is applie When the polarity of the power supply is as shown in
R
d to the load. ①, C is charged. W hen the polarity is as shown in ②,
the voltage charged in C plus the line voltage are
D
applied across D. Max. voltage is approx. 2√2.
C
R ~
Load
←
C D
~
R Load
↑

*) If a resistor is used in this way, it does not pose a

problem to the output element. But it may make the
performance of the diode (D), which is built in the
load, drop to cause problems.
The load doesn’t  Leakage current by surge absorbing circuit, which is  Connect C and R across the load, which are of
turn off. connected to output element in parallel. registers of tens KΩ. When the wiring distance from the
output module to the load is long, there may be a
Output Load
leakage current due to the line capacity.
C C
R Leakage current ~ R R

Load Load

6-9
System

Chapter 6 Trouble Shooting

When the load is  Leakage current by surge absorbing circuit, which is  Drive the relay using a contact and drive the C-R type
C-R type timer, connected to output element in parallel. timer using the since contact.
time  Use other timer than the C−R contact some timers
Output
constant have half-ware rectified internal circuits therefore, be
Load
fluctuates. C cautious. Timer
R ~ T
Leakage current

Output X
~

The load does not  Sneak current due to the use of two different power  Use only one power supply.
turn off. supplies.  Connect a sneak current prevention diode.

Output Output

Load
Load
E1 E
E2 E

If the load is the relay, etc, connect a counter-

E1<E2, sneaks. E1 is off (E2 is on), sneaks. electromotive voltage absorbing code as shown by the
dot line.

Output circuit troubles and corrective actions (continued).

Condition Cause Corrective actions
The load off  Over current at off state [The large solenoid  Insert a small L/R magnetic contact and drive the
response current fluidic load (L/R is large) such as is load using the same contact.
time is long. directly driven with the transistor output.

Output Output
Off current

Load
E1 Load

 The off response time can be delayed by one or

more second as some loads make the current
flow across the diode at the off time of the

6-10
 System
Chapter 6 Troubleshooting

transistor output.
Output Surge current of the white lamp on.  To suppress the surge current make the dark
transistor is current of 1/3 to 1/5 rated current flow.
destroyed.
Output

Output

R E

E1

Sink type transistor output

Output
A surge current of 10 times or more when turned
on. R

Source type transistor

output

6-11
System

Chapter 6 Trouble Shooting

6.5 Error Code List

Error
code Action Operation LED Diagnosis
Error cause
(restart mode after taking an action) status status point
(Dec)
Program to execute is 0.5 second
23 Start after reloading the program Warning RUN mode
abnormal Flicker
Start after reloading I/O parameter,
Reset
Battery change if battery has a problem. 0.5 second
24 I/O parameter error Warning RUN mode
Check the preservation status after I/O parameter Flicker
switching
reloading and if error occurs, change the unit.
Start after reloading Basic parameter,
Change battery if it has a problem. Reset
0.5 second
25 Basic parameter error Check the preservation status after Basic Warning RUN mode
Flicker
parameter reloading and if error occurs, change switching
the unit.

0.1 RUN
26 Compile error exceed Reduce the program and down. Heavy
second mode
error
Flicker switching

0.1 second RUN

27 Compile error Check the program Heavy error
Flicker mode
switching
Module set in parameter
0.5 second RUN mode
30 and the installed module modify the module or parameter and then restart. Warning
Flicker switching
does not match
Module falling during After checking the position of
0.1 second
31 operation or additional attachment/detachment of expansion module Warning Every scan
Flicker
setup during Run mode

Data of I/O module does After checking the position of slot where the
0.1 second
33 not access normally during access error occurs by XG5000, change the Heavy error Scan end
Flicker
operation. module and restar ([Link] parameter.)

Normal access of
After checking the position of slot that access error
special/link module 0.1 second
34 occurred by XG5000, change the module and Heavy error Scan end
data during operation not Flicker
restart ([Link] parameter).
available

Extension Extension module is attached over 10 slot or 0.1 second RUN

38 Heavy error
Module exceed communication module is attached over 3 slot Flicker mode
switching
Abnormal system end by noise or hard ware error.
1) If it occurs repeatedly when power
Abnormal stop of 0.1 second Ordinary
39 reinput, request service center Heavy error
CPU or malfunction Flicker time
2) Noise measures

6-12
 System
Chapter 6 Troubleshooting

Error
code Action Operation LED Diagnosis
Error cause
(restart mode after taking an action) status status point
(Dec)
Scan time of program
during operation
After checking the scan watchdog time designated While
exceeds the scan 0.5 second
40 by parameter, modify the parameter or the Warning running the
watchdog time Flicker
program and then restart. program
designated by
parameter.
Operation error
Remove operation error → reload the program While
occurs while 0.5 second
41 and restart. Warning running the
running the user Flicker
program
program.
Timer index user After reloading a timer index program modification, 0.5 second
44 Warning Scan end
error start Flicker

Heavy error of Refer to Heavy error detection flag and modifies 1 second
50 Heavy error Scan end
external device the device and restart. (Acc. Parameter) Flicker

0.5second
55 Task confliction Check task occurrence Heavy error Every time
Flicker

While
E_STOP function After removing error causes which starts E_STOP 1 second
60 Heavy error running the
executed function in program, power reinput Flicker
program

Error Action Operation LED Diagnosis

Error cause
code (restart mode after taking an action) status status point
Data memory backup not If not error in battery, power reinput 1 second
500 Warning Reset
possible Remote mode is switched to STOP mode. Flicker
0.1 second Ordinary
501 Abnormal clock data Setting the time by XG5000 if there is no error Warning
Flicker time
0.1 second Ordinary
502 Battery voltage falling Battery change at power On status Warning
Flicker time

6-13
 Chapter 7 EMC Standard

Chapter 7 EMC Standard

The following explains contents, diagnosis and corrective actions for various errors that can occur during system operation.

7.1 Requirements for Conformance to EMC Directive

The EMC Directive specifies the products must “be so constructed that they do not cause excessive electromagnetic
interference (emissions) and are not unduly affected by electromagnetic interference (immunity)”. The applicable products
are requested to meet these requirements.
This section summarizes the precautions on conformance to the EMC Directive of the machinery assembled using PLC
XGB series. The details of these precautions are based on the requirements and the applicable standards control.
However, LSIS will not guarantee that the overall machinery manufactured according to the these details conforms to the
below-described directives. The method of conformance to the EMC directive and the judgment on whether or not the
machinery conforms to the EMC Directive must be determined finally by the manufacturer of the machinery.

7.1.1 EMC Standard

The standards applicable to the EMC Directive are listed below.

Table13-1

Specification Test item Test details Standard value

EN50081-2 EN55011 Electromagnetic emissions from the 30~230 ㎒ QP : 50 ㏈㎶/m ＊1
Radiated noise product are measured 230~1000 ㎒ QP : 57 ㏈㎶/m
＊2
EN55011 Electromagnetic emissions from the 150~500 ㎑ QP : 79 ㏈ Mean: 66 ㏈
Conducted noise product to the power line is measured 500~230 ㎒ QP : 73 ㏈ Mean: 60 ㏈
EN61131-2 EN61000-4-2 Immunity test in which static electricity is 15 ㎸ Aerial discharge
Electrostatic applied to the case of the equipment 8 ㎸ Contact discharge
immunity
EN61000-4-4 Immunity test in which burst noise is Power line: 2 ㎸
Fast transient applied to the power line and signal lines Digital /O : 1 ㎸
burst noise Analog I/O, signal lines: 1 ㎸
EN61000-4-3 Immunity test in which field is irradiated to 10Vm,26~1000 ㎒
Radiated field AM the product 80%AM modulation@ 1 ㎑
modulation
EN61000-4-12 Immunity test in which a damped Power line: 1 ㎸
Damped oscillatory oscillatory wave is superimposed on the Digital I/O (24V or higher): 1 ㎸
wave immunity power line

＊1) QP: Quasi-peak value, Mean: Average value

＊2) The PLC is an open type device (device installed to another device) and must be installed in a conductive control
panel. The tests for the corresponding items were performed while the PLC was installed inside a control panel.

7-1
Chapter 7 EMC Standard

7.1.2 Control Panel

The PLC is an open type device (device installed to another device) and must be installed in a control panel. This is
needed to prevent electric shock by touching XGB PLC and reduce the PLC-generated noise. Install the XGB PLC
in a metallic panel to reduce PLC-generated EMI (Electro-magnetic interference),
The specifications for the control panel are as follows:

(1) Control panel

The PLC control panel must have the following features:

(a) Use SPCC (Cold Rolled Mild Steel) for the control panel.
(b) The steel plate should be thicker than 1.6mm.
(c) Use isolating transformers to protect the power supply from external surge voltage.
(d) The control panel must have a structure which the radio waves does not leak out.

For example, make the door as a box-structure so that the panel body and the door are overlapped each other. This
structure reduces the surge voltage generate by PLC.
Panel body

Door

Seal

(e) To ensure good electrical contact with the control panel or base plate, mask painting and weld so that good
surface contact can be made between the panel and plate.

7-2
 System
Chapter 7 EMC Standard

(2) Connection of power and earth wires

Earthing and power supply wires for the PLC system must be connected as described below.

ferrite core

(a) Earth the control panel with a thick wire so that a low impedance connection to ground can be ensured even at high frequencies.
(b) The function of LG (Line Ground) and FG (Frame Ground) terminals is to pass the noise generated in the PLC system to the ground,
so an impedance that is as low as possible must be ensured.
(c) The earthing wire itself can generate the noise, so wire as short and thick to prevent from acting as an antenna.
(d) Attach ferrite core under the power cable to satisfy CE specification.

[ferrite core]
External Dimension (mm) maximum
cable
manufacture name address
A B C D diameter
(mm)
Laird 28A3851-0A2 30.00 13.00 33.70 30.00 12.85 [Link]
Laird 28A5776-0A2 29.20 20.00 42.00 42.00 19.40 [Link]
Coilmaster C2L RU130B 31.50 13.00 33.00 31.50 13.00 [Link]
TDK ZCAT3035-1330 30.00 13.00 34.00 30.00 13.00 [Link]

7-3
System

Chapter 7 EMC Standard

7.2 Requirement to Conform to the Low-voltage Directive

The low-voltage directive requires each device that operates with the power supply ranging from 50V to 1000VAC and 75V to 1500VDC to satisfy
the safety requirements. Cautions and installation and wiring of the PLC XGB series to conform to the low-voltage directive are described in this
section.
The described contents in this manual are based on the requirements and the applicable standards control. However, LSIS will not guarantee
that the overall machinery manufactured according to the these details conforms to the above regulation. The method of conformance to the
EMC directive and the judgment on whether or not the machinery conforms to the EMC Directive must be determined finally by the manufacturer
of the machinery.

7.2.1 Standard Applied for XGB Series

The XGB series follow EN6100-1 (safety of devices used in measurement rooms, control rooms, or laboratories). And the XGB series
modules which operate at the rated voltage of AC50V/DC75V or above are also developed to conform the above standard.

7.2.2 XGB Series PLC Selection

(1) Power and CPU
There are dangerous voltages (voltages higher than 42.4V peak) inside the power supply modules of the AC110/220V rated I/O
voltages. Therefore, the CE mark-compliant models are enhanced in insulation internally between the primary and secondary.
(2) I/O module
There are dangerous voltages (voltages higher than 42.4V peak) inside the I/O modules of the
AC110/220V rated I/O voltages. Therefore, the CE mark-compliant models are enhanced in insulation internally between the primary and
secondary.
The I/O modules of DC24V or less rating are out of the low-voltage directive application range.

(3) Special module, Communication module

The special module and communication modules are DC24V or less in rated voltage, therefore they are out of the low-voltage directive
application range.

7-4
 FUEL OIL PUMP

INSTALLATION OPERATION
AND MAINTENANCE INSTRUCTION

3. FUEL OIL PUMP

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
 Installation, Maintenance and
Operation Instruction

Industrial pump series - VB

11/2004

hp-TE CHNIK GmbH Indus t ri epumpen -För deragg re gate un d An l agenb au

Gablonzer Straße 21 D-76185 Karlsruhe Germany Tel.: 0721/ 9 56 18 – 0
Postfach 21 10 10 D-76160 Karlsruhe Germany FAX: 0721/ 9 56 18 – 28
home: [Link] |: info@[Link]
Contents

1 General Safety Notes..................................................................................................................... 3

1.1 Intended Use.......................................................................................................................... 3

2 General Information...................................................................................................................... 3

2.1 hp-Industrepumpe VB-Baureihe ............................................................................................ 3

2.2 Operational Limits .................................................................................................................. 4

2.3 Materials used ........................................................................................................................ 4

2.4 Mechanical seal ...................................................................................................................... 4

3 Installation .................................................................................................................................... 5
4 Commissioning .............................................................................................................................. 6

5 Accessories .................................................................................................................................... 7

5.1 hp-Electrical standby and companion heater ........................................................................ 7

6 Operation....................................................................................................................................... 7

6.1 Inspection and Maintenance.................................................................................................. 7

6.1.1 hp-Electrical standby and companion heaters ................................................................ 7

6.1.2 Oil filter ........................................................................................................................... 7

6.2 Preservation ........................................................................................................................... 7

6.3 Troubleshooting ..................................................................................................................... 8

7 Environment .................................................................................................................................. 8
8 General Information...................................................................................................................... 9

8.1 Application Risk ..................................................................................................................... 9

8.2 Usable fuel ............................................................................................................................. 9

8.3 Painting .................................................................................................................................. 9

8.4 Directives ............................................................................................................................... 9

8.5 Documentation....................................................................................................................... 9

9 Dimensional drawing VB – Industrial pump ............................................................................... 10

10 Flow characteristics for hp-pumps series VB .............................................................................. 11
 ----
1 General Safety Notes

Indicates a potentially dangerous situation. If this is not avoided, small or

light injury may result.

Indicates general information on a danger of property damage.

Indicates general information on a danger of personal injury.

The notes for installation and maintenance are intended for a specialist!

Pursuant to DIN EN 12514-1 section 4.3.3., the operator of the complete system must provide a
pressure controller, e.g. a pressure control device.

The operator shall responsible for complying with general accident prevention, safety and
operating provisions.
1.1 Intended Use

In spite of careful safety optimization being performed, there is still some residual danger from operating the
pump. The safety notes explained above and in the following must be observed under any case to prevent
personal injury and / or damage to the pump. By complying with the instructions at all times, you will increase
your pump's service life and retain full warranty claims towards the manufacturer in the case of damage.
Any pumps are subjected to a performance test after manufacture and are equipped with a test card.

2 General Information

2.1 hp-Industrial pump series VB

The VB series pumps are internal gear pumps. They have an integrated overflow valve. The flow rate for normal
fuel oil at 20 °C (6 cSt) and motor speed of 1400/2800 min -1 (depending on on pump size) is 6700 l/h at 40 bar.
The pressure range where the pump works depends on the chosen pressure stage (see Chapter 4). It ranges
between 0,5 – 40 bar.
An internal geared rotor drives an excentric mounted outer geared pinion. The pumping medium will conveyed
between the tooth gaps of the two gears. For this purpose the conveyor rooms are sealed by a cap with an
integrated crescent.
The VB series pumps are intended for transporting heating oils (see Kap. 8.2). Where other media has to be
transported, this must be verified by the manufacturer. Otherwise, the pump's service life may be decreased.
10/2014

Fig. 1. (Excample for direction of rotation „I“)

3
 ----
For use with pre-heated media - which have a higher viscosity when cooled - the manufacturer recommends the
use of an electrical standby and companion heating system H1 without thermostat (see Fig. 3). It is available as
an accessory.

The following information is engraved into the pump body:

• Exact description of the pump type

• manufacturing date – MM/YY
• Rotational direction arrow (corresponding to order)
• Manufacturer's pump number
• The side for suction connection will be marked with „A“
• The side for delivery connection will be marked with „S“.

2.2 Operational Limits

Flow max. 6700 l/h

Max. pressure (adjustable with integrated overflow valve) 40 bar
Min. permitted pre-pressure - 0,6 bar CAUTION! Gas secretions arise already
at -0,4 bar.
Max. permitted pre-pressure 5,0 bar
Max. allowed pump RPM 2800 min -1 at 50 Hz
Temperature Up to 150 °C
Permitted test pressure for approvals Max. 60 bar with removed mech. seal
(Sealing area closed by jack)
2.3 Materials used

Pump housing EN-GJL-250

Rotor EGT 88
Pinion gear 16MnCr5
Lower bearing EN-GJL-250
Mechanical seal Carbon/ SiC- Viton – CrNiMo-steel
Valve parts Spring wire steel, 11SMnPb30+C, 16MnCrS5
2.4 Mechanical seal

1. Pump housing
2. Union nut
3a. O-Ring
3. Tapet
4a. O-Ring
4. Counter ring
5. Spring
X Installation size*
* - In case of replacement can be found in the
documents accompanying the valid installation
dimension
Item no. for shaft Ø12: 0190015
Item no. for shaft Ø18: 0190016
Item no. for shaft Ø22: 0190017

Fig. 2.
10/2014

4
 ----
All hp pumps are equipped with axial
25
face seals. They are temperature-

Max. pressure (bar)

resistant up to 150°C.
20

m ax. D ruck (bar)

These axial face seals are relieved at the
pump's suction side.
15
Maximum pressure load on the GLRD,
i.e. suction side, against temperature 10
(see adjacent figure).
5
For a new pump a max. leakage of
1 cm3/day is regular. 0
25 50 75 100 125 150
Temperatur °C

3 Installation

x Installation must be performed so that the pump shaft and drive shaft are perfectly aligned in axial
direction and so that there is no radia force. Furthermore, a coupling appropriate for the pump shaft in
size and weight and not transferring any imbalances to the pump must be used.
x The axial clearance between the coupling halves should be max. 1,5 mm. Rotation coupling parts must
not touch any fixed pump or engine parts axially!
x Before connecting the lines, all plastic caps must be removed.
x All connections and lines must be installed free of tension and tight. We recommend only using sealing
rings made of copper, aluminium or plastics. Never use hemp or similar materials. The pipes must be
cleaned from any dirt and metal particles before the pump is connected.
x The suction connection (see Fig. 1) of the pump is filled with oil. Then the suction line is connected to
thread connection „A“.
x The pressure/delivery line connect to thread connection „S“. (Fig. 1)
x Remove the screw plug for connecting the manometer 1 / vacuum gauge (Fig. 1). The pressure gauge
connected to port „A“ it shows the suction pressure and the pressure gauge connected to port „S“ it
shows the delivery pressure. Observe using manometers with the right pressure range (according to the
pump's pressure range).
x Before switching on the pump, check that all locking valves in the pipes and check whether the pump has
sufficient medium is available.
x Ensure that the pump is operated in the intended rotational direction (engraved arrow). Connect the
motor according to the information on the type plate and switch it on. Preventively provide a motor
protection switch with overload function!
x The pump shaft is sealed to the outside with a mechanical seal made of the materials carbon / SiC and
Viton elastomer.
Pumps must never be used as a fix point for the connected pipes. Any forces and moments appearing, e.g.
x Tensions
x Expansion of pipe lines due to temperature influence or reaction forces must be avoided.
x To prevent possible heat expansion of pipe lines, we recommend installing compensators.
x The suction line must be designed so that the flow speed is between 0.5 und max. 1.0 m/sec.
x The pressure line must only reach a maximum of 2 – 2.5 m/sec.
x The suction line must be vacuum-tight and placed in a rising fashion.
x Ensure that the pump and pipe system is not contaminated, e.g. by purging.
10/2014

x When testing the pipe system for tightness, the max. permissible shaft sealing supply pressure must not
be exceeded.

5
 ----
Never use water as purging liquid!
Danger of corrosion!

4 Commissioning

Ensure that the pump does not start up dry. It must be filled with oil.

Mechanically abrasive and chemically aggressive components in the

medium reduce the pump service life.
Clear your pipe lines from any dirt or metal particles
before connecting it to the pump.
Ensure correct rotational direction (see engraved arrow).
Only perform the basic settings or adjustment of the
pump pressure when the pressure line is closed.
Before installation, ensure that the pump and drive shafts correspond
exactly in axial direction. There must not be any radial force.
Use a coupling suitable for the pump shaft in respect of size
and weight. This way, you can avoid transferring imbalances onto the
pump shaft.

x Before switching on the pump, check that all locking valves in the pipes and check whether the pump has
sufficient medium is available.
x For pressure regulation, the plug screw (see Fig. 1) must be removed.
x After removing the cover screw, the pressure regulating screw with hexagon socket (6mm size) is visible.
Use a hexagon wrench to:
- Turn the setting screw to the right (clockwise) to increase the pressure
- Turn the setting screw to the left (counterclockwise) to decrease the pressure
x When adjusting the desired operational pressure, observe that it may only be set within the permissible
pressure range of the included pressure spring (pressure level 0 to 4).

Pressure level Pressure range Factory settings

0 from 0,5 - 1,5 bar 1 bar
1 from 1 - 4 bar 2 bar
2 from 2 - 9 bar 6 bar
3 from 6 - 25 bar 15 bar
4 from 15 - 40 bar 15 bar
Attention! Setting an operational pressure exceeding the pressure range will cause the spring
to lock and lead to pressure surges and thus to pump outage after a short time.
For oil-burning applications, close the burner’s solenoid valve before setting or resetting pump pressure.
x When the pressure is set, the pressure adjustment cover screw and its sealing must be replaced oil-tight.

Non-compliance with the max. pressure range may cause spring blockage.
These in turn causes pressure surges and thus pump outage after a short
time.
If the medium rotates within the pump for too long, this may cause
damage to the valve, overheating and, as a result, mechanical damage.
For highly viscous media, a pump heating is prerequisite. To avoid
cavitations and damage to the shaft sealings, the heating times must be
10/2014

observed under any circumstances (abaut 30min starting from 20°C).

Because of heat expansion, all valves must be open when heating.

6
 ----
5 Accessories

5.1 hp-Electrical standby and companion heater

hp- Electrical standby and companion heaters

All hp-Pump models can be equipped with electrical heating
system without thermostat at the factory.
Using this option is strictly recommend for using the
pumps with "heavy fuel oil"!

Fig. 3.

6 Operation

6.1 Inspection and Maintenance

6.1.1 hp-Electrical standby and companion heaters

When replacing a defect electrical heater it is strongly recommended to insert only electrical heaters designed by
the manufacturer. Otherwise:
x the medium can be heated to excessively high temperatures. Consequence thereof is e.g. gas
release of the medium.
x The required operating temperature cannot be reached. Consequence thereof is e.g. the required
engine power is greater than the available maximum engine power.
x Result of the too low or too high a temperature is, e.g. outage of the mechanical seal after a
shorter time.
6.1.2 Oil filter
The pump is provided with a suction filter integrated in the suction line. The filter must be checked for dirt
regularly and replaced if required. The mesh width of the filter element depends on the viscosity of the
transported medium. Transported media with a high viscosity (heavy heating oil) require a filter element with a
mesh width of 500 µm and alternative for media with a low viscosity a filter element with mesh width 100 µm is
recommend. The pump supply must be within a pressure range of -0.4 to 5 bar.

Filter elements must be disposed of under environmental considerations.

6.2 Preservation

After the test run, testing oil remains in the pump to preserve it. The parts not treated ex works must be re-
treated by the operator according to the local conditions.
If the pump is inactive for an extended period or stored, it must be preserved with acid-free non-resinous oil
and stored dryly.
10/2014

7
 ----
6.3 Troubleshooting

Errors appearing Possible cause

The pump does not prime 1, 2, 3, 4, 5, 12

The pump does not work at full capacity 3, 4, 5, 8, 9, 10, 11, 17, 18
The pump is operating noisily 3, 4, 5, 6, 7, 10, 11, 13, 17
The motor heats up 9, 10, 13
Uneven transport 3, 5, 8, 10, 11
Shaft seal is not tight 7, 10, 14, 15, 16
No. Possible cause Removal
1. No medium in the pump Fill pump with medium
2. Pump has the wrong rotational direction Set rotational direction according to the engraved
arrow
3. Filter element, valve or lines are clogged Check and clean parts
4. Suction line or shaft seal are leaking Check suction line, connection points and valves or
shaft face seal
5. Suction head too large - Decrease height difference
- Shorten line
- Increase line diameter
- Decrease medium viscosity by
heating
6. Axis error Pump, coupling and motor:
- Align shaft end precisely
- Balance coupling
7. Vibrations and pulsations in the system - Use elastic bearings for the aggregate
- Use hoses for connections
8. The overflow valve is jammed or set too Check or adjust valve
low
9. Wrong speed - Check motor speed and power
consumption
- Compare voltage and frequency to the
type plate
10. Medium too viscous - Increase medium temperature
- Lower speed
11. Air inclusions or gas formation in the - Remove leakages
medium - Decrease suction height
- Increase feed pressure
12. Pump does not vent Vent pressure line at the highest point
13. Motor bearing damaged Renew motor bearings
14. Shaft seal damaged Replace shaft seal
15. Feed pressure too high or too low - Decrease feed pressure in the system
- Insert check valve on the pressure side
16. Cold start when transporting heavy oil Install pump heating and observe pre -heating time
17. Overflow valve fluttering Set opening pressure higher by turning the setting
screw clockwise.
18. Overflow valve leaking Clean overflow valve

For economic reasons, we recommend providing a reserve pump right

at the burner.

7 Environment
10/2014

Of course, hp-TECHNIK focuses on Environmental protection for its development work! To ensure that the
environment does not take damage from our products - caused, e.g. by environmentally harmful media escaping
unnoticed - we will even increase our efforts for the further development of our hp- Program.

8
 ----
We are continuously working to decrease effects on the environment as well as energy and resource
consumption - far exceeding the measure required for compliance with environmental protection laws and
regulations.
Environmentally compatible actions are not only a task for each and every employee, but must also be
supported continuously by the management. We ensure that our environmental policy is effectively
implemented. The technical and organizational procedures required for this are inspected regularly and
continuously developed.
We support our customers in the environmentally compatible use of our products.

8 General Information

8.1 Application Risk

In case of failure or leakage may occur hazards to humans and the environment.
8.2 Usable fuel

Liquid fuels, mainly fuel oils derived from crude oil distillation, qualities according to DIN 51603 Part 1 – 5.
FAME – mix with fuel oil according to DIN 51603 Part 6 (FAME = Fatty Acid Methyl Ester)
FAME 100% DIN EN 14214 respectively EN 14213
Crude oils (max. fluid temperature 90°C)
Marine fuel ISO 8217 (HFO, MDF Kategorie ISO-F-DMX, DMA, DMB)
Cold-pressed bio fuel according to DIN V 51605
Characteristics for different fuels (reference value)
Fuel Density Kin. viscosity Max. temperature
(at 20 °C) (at 40°C) at spraying viscosity *)
Unit [kg/m3] [mm2/s] [°C]
Fuel oil (DIN 51603-1) max. 856 max. 3,6 15
Havy fuel oil (DIN 51603-3) max. 1150 160
Re – raffinate (DIN 51603-4) <45 90
Fuel oil (DIN 51603-6) max. 860 max. 3,6 15
Marine Fuels (ISO 8217) 890 (15°C) min: 1,4; max. 11 80
RME (DIN EN 14213) 856,6-896,6 3,5 – 5,0 28
Rape oil (DIN V 51605) 896,6-926,6 max. 36,0 85
Ecoil (Basis Rapsöl) 923,3 39,3 85 – 90
Palm oil 947,6 85,9 100 – 105
*) temperature values are approximate
Chemical resistance of all parts for specified types of fuel. Non-standard fuels are excluded from the warranty.
8.3 Painting

black RAL 9005.

temperature resistant to 150 °C, coating thickness min. 2µm
According to the requisitions, the executed painting may vary from the standard paint.
8.4 Directives

PED 97/23/EG
MD 2006/42/EG
EMC 2004/108/EG (89/336/EWG)
LVD 2006/95/EG (73/23/EWG)
ROHS 2000/53/EG
EU MEPS
WEEE 2002/95/EC
Observe the relevant national regulations.
8.5 Documentation

Test report on leak and functional testing

10/2014

Installation, maintenance and operating instructions with dimensional drawing and flow characteristics

9
 ----
9 Dimensional drawing VB – Industrial pump

Pipe connections
pipe thread DIN ISO 228-1

Manometer connection G ¼”
10/2014

10
 ----
10 Flow characteristics for hp-pumps series VB

Flow characteristics VB for fuel oil L/EL

Gear rotor Ø25

Gear rotor Ø38

10/2014

11
 10/2014
----

12
 ROTOR

INSTALLATION OPERATION
AND MAINTENANCE INSTRUCTION

4. ROTOR

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
Rotor
assembly instructions

(Original instructions)
 Table of contents

1 Important user information ___________________ 5

1.1 Purpose of this document ______________________________ 5
1.2 Read this before use __________________________________ 5
1.3 Safety notices _______________________________________ 5

2 Safety instructions __________________________ 7

2.1 Safety precautions____________________________________ 7
2.1.1 About this chapter _______________________________ 7

3 Scope and layout ___________________________ 9

3.1 Scope______________________________________________ 9
3.2 Layout ____________________________________________ 10
3.2.1 Rotor face ____________________________________ 10
3.2.2 Rotor cross section _____________________________ 10
3.2.3 Rim joint _____________________________________ 11

4 Rotor assembly ___________________________ 13

4.1 General information __________________________________ 13
4.1.1 Tools ________________________________________ 13
4.1.2 Assembly equipment ____________________________ 13
4.1.3 Inspection ____________________________________ 13
4.2 Assembly instructions ________________________________ 14
4.2.1 Attaching spokes to the hub plate __________________ 14
4.2.2 Mounting of rotor segments outside cassette _________ 16
4.2.3 Mounting of rotor segments inside cassette __________ 19
4.2.4 Tightening of spoke plates________________________ 23
4.2.5 Rotor tightening________________________________ 23
4.2.6 Gap filling ____________________________________ 24
4.2.7 Mounting the hub cover plates (rotors Ø>2 m) _______ 25

5 Troubleshooting ___________________________ 27

6 Reference information ______________________ 29

6.1 Documents ________________________________________ 29

7 Index ___________________________________ 31

Rotor assembly instructions © 2012 3

ProFlute, [Link], April 2012
1 Important user information

1.1 Purpose of this document

This document contains assembly instructions for rotors delivered from
ProFlute AB.

1.2 Read this before use

WARNING! Before installing, operating and maintaining the

rotor, all users must read and understand the entire contents of
this manual, to become aware of the hazards involved.
Failure to do this may cause human injury or death, or damage to
the equipment.

WARNING! Do not assemble or operate the product in any

other way than described in the user documentation, delivered
with the product.

1.3 Safety notices

The user documentation contains warnings, caution, notes, and tips
concerning the safe use of the product. See definitions below.

WARNING! A warning indicates a hazardous situation which, if

not avoided, could result in death or serious injury. It is important
not to proceed until all stated conditions are met and clearly
understood.

CAUTION! A caution indicates instructions that must be

followed to avoid damage to the product or any other equipment.

Note! A note is used to indicate information that is important for trouble-free

and optimal use of the product.

Tip: A tip contains useful information that can improve or optimize your
procedures.

Rotor assembly instructions © 2012 5

ProFlute, [Link], April 2012
2 Safety instructions

WARNING! Before installing, operating and maintaining the

rotor, all users must read and understand the entire contents of
this manual, to become aware of the hazards involved.
Failure to do this may cause human injury or death, or damage to
the equipment.

CAUTION! The surface of the rotor is fragile and should be

handled with care!

2.1 Safety precautions

2.1.1 About this chapter

Read and understand the warnings in this chapter before starting to
assemble the rotor.

Warnings

WARNING! Crush hazard! The rotor must be secured in both

directions of rotation during assembly! Otherwise the rotor might
spontaneously rotate. A rotating rotor may cause serious crush
injuries.

WARNING! Crush hazard! Ensure that the rotor is securely

fixed during assembly. An overturning rotor may cause serious
crush injuries.

Cautions

CAUTION! Do not drill new holes for the pop rivets! The
spokes will be damaged! If the holes do not fit, contact ProFlute.

Rotor assembly instructions © 2012 7

ProFlute, [Link], April 2012
3 Scope and layout

3.1 Scope
These assembly instructions apply to rotor sizes Ø>1.4 m.

Rotors up to Ø2 m are normally delivered fully assembled from ProFlute.

Rotor assembly instructions © 2012 9

ProFlute, [Link], April 2012
3.2 Layout

3.2.1 Rotor face

5
00 001

This is an illustration of a rotor with Ø>1.6 m

No Part
1 Rim segment
2 Rotor segment/sector
3 Spoke
4 Hub plate
5 Rim joint

3.2.2 Rotor cross section

00 002

Rotor depth Rotor depth

200 mm 400 mm

10 Rotor assembly instructions © 2012

ProFlute, [Link], April 2012
3.2.3 Rim joint
Note! This is an illustration of a 400 mm depth rotor rim joint. The layout is
slightly different for 200 mm depth rotor rim joints, which only have one
clamp bolt.

00 003

1 2 3 4 5 6

No Part
1 Spoke plate bolt (M12)
2 Clamp bolt (M12)
3 Spoke plate
4 Rim segment
5 Rim clamp
6 Rim bolt (M8)

Rotor assembly instructions © 2012 11

ProFlute, [Link], April 2012
4 Rotor assembly

4.1 General information

WARNING! Crush hazard! The rotor must be secured in both

directions of rotation during assembly! Otherwise the rotor might
spontaneously rotate. A rotating rotor may cause serious crush
injuries.

WARNING! Crush hazard! Ensure that the rotor is securely

fixed during assembly. An overturning rotor may cause serious
crush injuries.

CAUTION! Do not drill new holes for the pop rivets! The
spokes will be damaged! If the holes do not fit, contact ProFlute.

4.1.1 Tools
No special tools are required for assembly.

4.1.2 Assembly equipment

Bolts, pop rivets and adhesive are included in the assembly kit.

4.1.3 Inspection

Inspection interval
2-3 months after commissioning
Once a year

Check if the rotor segments have compressed and the outer rim
segments need to be tightened. See Rotor Tightening Instruction.

Rotor assembly instructions © 2012 13

ProFlute, [Link], April 2012
4.2 Assembly instructions

4.2.1 Attaching spokes to the hub plate

The layout of the hub plates differs according to size.

Hub plate Ø 1100-1599 Hub plate Ø 1600 - 1999

Hub plate Ø 2000-2999 Hub plate Ø >3000

No Part
a Spoke ledge
b Hub plate
c Hub plate spoke slot
d Rivet openings

14 Rotor assembly instructions © 2012

ProFlute, [Link], April 2012
 1. Slide the first spoke into one of the hub plate spoke slots.

2. Ensure that the spoke ledges are fitted on both sides of the hub
plate.

Note! When the spoke is fitted properly the spoke ledge rivet openings are
aligned with the corresponding hub plate openings.

3. Place the hub plate with the inserted spoke on a piece of cardboard
or equivalent in order not to damage the components while
performing the riveting.

Pop rivets inserted into the rivet openings in the spoke ledge and hub plate

4. Insert pop rivets into the spoke ledge rivet openings and through
the corresponding openings in the hub plate.

Note! Make sure that all pop rivets are inserted before starting to rivet!
Otherwise the spokes will be damaged!

5. Rivet the spoke to the hub plate.

6. Rivet the opposite side of the spoke to the hub plate.

All spokes mounted on the hub plate

7. Place the hub plate in the cassette or on a scaffold for support.

8. Continue to pop rivet all spokes to the hub plate in a crosswise

manner.

Rotor assembly instructions © 2012 15

ProFlute, [Link], April 2012
4.2.2 Mounting of rotor segments outside cassette
One-piece rotor segments

For some rotors the segments may be delivered as multiple-piece split

rotor segments, see “Multiple-piece rotor segments” on page 18.

b b

No Part
a First rotor segment to be mounted
b Supporting bars

Note! The rotor must be secured in both directions of rotation during

assembly!

1. Secure the rotor in both directions using supporting bars. Place one
bar under the lower of the two spokes between which the first rotor
segment will be mounted.

2. Insert the first rotor segment between the spokes.

No Part
a Spoke plate No. 1
b Spoke plate No. 2

16 Rotor assembly instructions © 2012

ProFlute, [Link], April 2012
 3. Secure the rotor segment by attaching spoke plates to the two
spokes which the segment has been fitted between.

Note! Do not tighten the spoke plate bolts! The spoke plate should have a
loose fit and only hold the rotor segment in place.

b
a

No Part
a Rim segment
b Rim bolts (2 pcs)

4. Mount the rim segment and secure it on both spoke plates with the
rim bolts.

Note! Do not tighten the rim bolts! The rim bolts shall only hold the rim
segment in place.

5. Carefully remove the supporting bar while holding on to the rotor.

6. Rotate the rotor for mounting of the next rotor segment.

No Part
a Repositioned supporting bar

Rotor assembly instructions © 2012 17

ProFlute, [Link], April 2012
 7. Reposition the supporting bar to achieve support for mounting of
the next rotor segment.

8. Repeat step 2 to step 6 until all but the final segment have been
mounted.

Note! Do not mount the spoke plate next to the last sector on the second to
last rotor segment.

Note! To mount the final rotor segment the spoke plates next to the sector
must not be mounted!

9. Remove the spoke plate from the last sector.

a
a

No Part
a No spoke plate

10. Insert the final rotor segment.

11. Mount the final spoke plates.

12. Mount and secure the final rim segment.

Multiple-piece rotor segments

For multiple-piece rotor segments mounting is performed according to

the following instructions:

1. Insert the first part of the rotor segment into the first rotor sector.

2. Coat the inner segment surface with an abundant amount of

adhesive.

Note! Be careful not to put any adhesive on the surface close to the rotor face
in order to avoid that adhesive is pressed out onto the rotor face when
the outer rotor segment is mounted.

3. Insert the outer segment.

4. If required, fill gaps between the segment parts with a sealant. See
Gap filling” on page 24.

18 Rotor assembly instructions © 2012

ProFlute, [Link], April 2012
4.2.3 Mounting of rotor segments inside cassette
One-piece rotor segments

For multiple-piece split rotor segments, See Multiple-piece rotor

segments” on page 18

1. Secure the rotor using a wooden board. Place the board under the
lower of the two spokes between which the first rotor segment will
be mounted.

Spoke secured with a wooden board

2. Insert the first rotor segment between the spokes.

3. Secure the rotor segment by attaching spoke plates to the two

spokes which the segment has been fitted between.

Note! Do not tighten the spoke plate bolts! The spoke plate should have a
loose fit and only hold the rotor segment in place.

4. Mount the rim segment and secure it on both spoke plates with the
rim bolts.

Note! Do not tighten the rim bolts! The rim bolts shall only hold the rim
segment in place.

Chain fall securing the rotor

Rotor assembly instructions © 2012 19

ProFlute, [Link], April 2012
 5. Position the rotor for mounting of the second rotor segment. Use a
chain fall to position the rotor on the wooden supports.

No Part
a Wooden supports

6. Use the chain fall to position the rotor for mounting of the third
segment.

7. Secure the rotor with a wooden board.

Rotor secured with a wooden board

20 Rotor assembly instructions © 2012

ProFlute, [Link], April 2012
 8. Use the chain fall to position the rotor on wooden supports for
mounting of the fourth segment.

Rotor positioned on wooden supports

Note! When half the rotor has been assembled the rotor must be secured in
both directions of rotation!

9. Use two chain falls to secure the rotor. One from the top and one
from the bottom.

10. Mount next segment.

Two chain falls securing the rotor in both directions

Rotor assembly instructions © 2012 21

ProFlute, [Link], April 2012
 11. Repeat step 8 and 9 until all but the final segment have been
mounted.

Note! Do not mount the spoke plate next to the last sector on the second to
last rotor segment.

Note! To mount the final rotor segment the spoke plates next to the sector
must not be mounted!

12. Remove the spoke plate from the last sector.

No Part
a No spoke plate

13. Insert the final rotor segment.

14. Mount the final spoke plates.

15. Mount and secure the final rim segment.

22 Rotor assembly instructions © 2012

ProFlute, [Link], April 2012
4.2.4 Tightening of spoke plates

Correctly positioned spoke plate

Note the countersunk position of the spoke plate into the rim of the
rotor sections.

1. Tighten all spoke plate bolts so that the plate surface facing the
spoke is positioned in line with the top of the spoke.

Note! If required the clamp bolt can be used to get the rotor segment into
position. Then the spoke plate bolts and the clamp bolt should be
tightened in alternating sequence.

4.2.5 Rotor tightening

See separate document for instructions: Rotor tightening instruction.

Finished rotor tightening

Rotor assembly instructions © 2012 23

ProFlute, [Link], April 2012
4.2.6 Gap filling
If required, fill gaps between rim and rotor media with a sealant that
can withstand temperatures >150 °C.

No Part
a Gaps
b Gaps filled with sealant

24 Rotor assembly instructions © 2012

ProFlute, [Link], April 2012
4.2.7 Mounting the hub cover plates (rotors Ø>2 m)
Note! If the rotor is assembled with the rotor in the air handling box it is
important that the hub cover plate is fitted at the same time as the hub
is mounted in the air handling box.

The layout of the hub cover plates differs according to size and use.

Hub cover plate Ø 2000-2999

1/2 Hub cover plate Ø >3000 Hub cover plate Ø >3000

1. Mount the hub cover plate with pop rivets. One on each side of the
rotor.

Rotor assembly instructions © 2012 25

ProFlute, [Link], April 2012
5 Troubleshooting

Problem Action
The last rotor segment does Loosen the rim segments as much as possible. They should
not fit have a loose fit.

The rotor is unbalanced The segments have absorbed different amounts of moist. Run
the rotor as normal, after 1 hour the rotor will be in balance. If
not contact ProFlute.

Rotor assembly instructions © 2012 27

ProFlute, [Link], April 2012
Cassette
installation, operation and
maintenance instructions
(Original instructions)
 Table of contents

1 Important user information ___________________ 5

1.1 Purpose of this document ______________________________ 5
1.2 Read this before use __________________________________ 5
1.3 Safety notices _______________________________________ 5

2 Safety instructions __________________________ 7

2.1 Safety precautions____________________________________ 7
2.1.1 About this chapter _______________________________ 7
2.2 Recycling ___________________________________________ 8
2.3 Storage ____________________________________________ 8

3 Scope and layout ___________________________ 9

3.1 Scope______________________________________________ 9

4 Product description ________________________ 11

4.1 Components _______________________________________ 11
4.1.1 Desiccant rotor ________________________________ 11
4.1.2 Cassette frame ________________________________ 11
4.1.3 Drive system __________________________________ 12
4.1.4 Air seals ______________________________________ 12

5 Installation ______________________________ 13
5.1 About this chapter ___________________________________ 13
5.2 Instructions ________________________________________ 14
5.2.1 Location ______________________________________ 14
5.2.2 Installation area _______________________________ 14
5.2.3 Guidelines ____________________________________ 14
5.2.4 Install rotor ___________________________________ 15
5.2.5 Install air seals ________________________________ 15
5.2.6 Install drive system _____________________________ 18

6 Operation ________________________________ 19
6.1 About this chapter ___________________________________ 19
6.2 Start-up ___________________________________________ 19
6.2.1 Check points at start-up _________________________ 19

Cassette installation, operation and maintenance instructions © 2012 3

ProFlute, [Link], April 2012
 6.3 Process principle ____________________________________ 20
6.4 Measurement of performance __________________________ 20
6.5 Troubleshooting _____________________________________ 22

7 Maintenance ______________________________ 23
7.1 About this chapter ___________________________________ 23
7.2 Regular maintenance _________________________________ 23
7.2.1 Maintenance schedule ___________________________ 23
7.2.2 Inspect seals __________________________________ 24
7.2.3 Change seals __________________________________ 24
7.2.4 Inspect drive system ____________________________ 24
7.3 Replace drive system_________________________________ 24
7.4 Replace rotor _______________________________________ 25
7.5 Rotor alignment _____________________________________ 26

8 Reference information ______________________ 27

8.1 Documents ________________________________________ 27

9 Index ___________________________________ 29

4 Cassette installation, operation and maintenance instructions © 2012

ProFlute, [Link], April 2012
1 Important user information

1.1 Purpose of this document

This document contains instructions for installation, operation and
maintenance for casettes delivered from ProFlute.

1.2 Read this before use

WARNING! Before installing, operating and maintaining the

casette all users must read and understand the entire contents of
this manual, to become aware of the hazards involved.
Failure to do this may cause human injury or death, or damage to
the equipment.

WARNING! Do not use or operate the product in any other

way than described in the user documentation, delivered with the
product.

1.3 Safety notices

The user documentation contains warnings, cautions, notes, and tips
concerning the safe use of the product. See definitions below.

WARNING! A warning indicates a hazardous situation which, if

not avoided, could result in death or serious injury. It is important
not to proceed until all stated conditions are met and clearly
understood.

CAUTION! A caution indicates instructions that must be

followed to avoid damage to the product or any other equipment.

Note! A note is used to indicate information that is important for trouble-free

and optimal use of the product.

Tip: A tip contains useful information that can improve or optimize your
procedures.

Cassette installation, operation and maintenance instructions © 2012 5

ProFlute, [Link], April 2012
2 Safety instructions

WARNING! Before installing, operating and maintaining the

casette, all users must read and understand the entire contents of
this manual, to become aware of the hazards involved.
Failure to do this may cause human injury or death, or damage to
the equipment.

CAUTION! The surface of the rotor is fragile and should be

handled with care!

2.1 Safety precautions

2.1.1 About this chapter

This chapter contains a list of all warnings and cautions in this manual.

Warnings

WARNING! Installation should be performed by qualified

service personnel.

WARNING! Maintenance should be performed by qualified

service personnel.

WARNING! Crush hazard! The rotor is very heavy. Be careful

when replacing!

Cassette installation, operation and maintenance instructions © 2012 7

ProFlute, [Link], April 2012
 Cautions

CAUTION! If welding, make sure that seals and rotating parts

are protected from the heat. Weld in locations away from selas
and moving parts.

CAUTION! The cassette must be installed with care! Be careful

not to damage rotor seals, rotor face or rotating parts.

CAUTION! At start-up all check points should be performed to

ensure that the cassette is working properly.

2.2 Recycling
Note! Product not classified as harmful to the environment.

When taking the product out of service, the different materials must be
separated and recycled according to national and local environmental
regulations. Cover the material to avoid blowing of dust.

2.3 Storage
If the product is not used for a longer time period.
Store in:

• room temperature,

• a dry and particle free environment.

8 Cassette installation, operation and maintenance instructions © 2012

ProFlute, [Link], April 2012
3 Scope and layout

3.1 Scope
These instructions apply to rotor sizes Ø<3 m.

For rotors larger than 3 m contact ProFlute.

Cassette installation, operation and maintenance instructions © 2012 9

ProFlute, [Link], April 2012
4 Product description
Cassette
frame

Circumference
seal

Radial seal

Rotor

Direction
00 026

Drive and
of rotation
belt

4.1 Components

4.1.1 Desiccant rotor

The desiccant rotor is a high capacity desiccant media captivated in a
circumference rim with radial spokes. The spokes attach to a central hub
with integral sealed ball bearings. The sealed bearings ride on a solid
center shaft. The rotor is held in place with a lock ring on each side.

For more information about rotors see document: Rotor specifications

and maintenance.

4.1.2 Cassette frame

The cassette frame is made of stainless, galvanized or painted steel.
It securely support the rotor and minimize rotor movement along the
shaft.

Cassette installation, operation and maintenance instructions © 2012 11

ProFlute, [Link], April 2012
4.1.3 Drive system
The drive system is the most critical component in the casette. Damaged
media and seals will still allow for some moisture removal, however
if the drive system is not properly maintained and fails the desiccant
media will no longer remove moisture.

The cassettes use a pulley and a belt driven by an electrical motor

with a gearbox. A self tensioning pivot arm ensures that the belt is
sufficiently tensioned around the circumference of the rotor.

4.1.4 Air seals

The seals are made of high temperature low friction rubber and designed
to provide a long service life.

• The circumference seals are intended to seal the circumference of

the rotor on both sides.

• The radial seals contact the face of the desiccant media and seal
between the process and reactivation areas.

Circumference
seal
00 038

Radial seal

12 Cassette installation, operation and maintenance instructions © 2012

ProFlute, [Link], April 2012
5 Installation

5.1 About this chapter

Proper installation is important for safe and trouble-free operation of the
casette. This chapter provides instructions for installation.

WARNING! Installation should be performed by qualified

service personnel.

CAUTION! If welding, make sure that seals and rotating parts

are protected from the heat. Weld in locations away from selas
and moving parts.

CAUTION! The cassette must be installed with care! Be careful

not to damage rotor seals, rotor face or rotating parts.

Note! Distortion of the cassette from improper installation may result in

substantially unequal clearance between the rotor face and the cassette.
This can cause excessive drive torque requirement (reducing the life of
the drive), uneven seal wear and reduced seal or media life!

Cassette installation, operation and maintenance instructions © 2012 13

ProFlute, [Link], April 2012
5.2 Instructions

5.2.1 Location
• Verify heat source (gas and electric) is a minimum of 1 rotor
diameter (or 60 cm) from the rotor face.

• Provide clearance to adjacent walls or equipment to provide enough

space to replace the whole rotor or rotor segments.

• Access doors should be provided to allow for maintenance and

rotor removal. At a minimum, the full height of the drive end of the
cassette.

5.2.2 Installation area

The installation area must give sufficient structure to adequately support
the cassette from distorting during transit or operation.

The cassette may be installed:

• within a customer supplied air handler

• within a ducted system or machinery room

• as a stand alone component with proper exterior covers, insulation

and weatherproofing

5.2.3 Guidelines
• The cassette structure should be insulated to prevent condensation
on the metal surfaces of the cassette.

• Installed ducting/partitions must not block rotor shaft bolts!

• All attachment within the air handler should be additionally sealed

to prevent loss of dry air from the process air stream or leakage of
moist air from the reactivation air steam.

• Leave adequate space around the cassette to allow for thermal

movement.

• All ducting used within customer supplied air handlers or to casette

as a stand alone component should be vapor tight, insulated and
sealed.

14 Cassette installation, operation and maintenance instructions © 2012

ProFlute, [Link], April 2012
5.2.4 Install rotor
Rotor sizes Ø ≤ 2940 mm

The cassette is delivered with the rotor installed.

Rotor sizes Ø > 2940 mm

1. Install the cassette frame.

2. See document: Rotor assembly instructions.

5.2.5 Install air seals

Circumference
seal
00 038

Radial seal

Radial seals

Note! Seals are fitted on both sides of the 90° reactivator sector.

1. Measure and cut the seal to fit the sector. This sector is insulated.

2. Compress the bulb on the seal between the rotor face and cassette
frame. When the rotor rotates the bulb shall be compressed
between the rotor and the frame.

Cassette installation, operation and maintenance instructions © 2012 15

ProFlute, [Link], April 2012
 3. Drill and pop rivet a mounting bracket on top of the seal.

16 Cassette installation, operation and maintenance instructions © 2012

ProFlute, [Link], April 2012
 Circumference seals

Note! Seals are fitted on both sides of the rotor.

1. Fasten double sided adhesive tape, edge to edge on the rotor rim.

2. Attach the flat circumference seal on to the tape (grey side down).
50% of the seal width on the rotor and 50% of the width tailing up
on the cassette side.

3. Attach a hose clamp on top of the seal to fixate it.

Cassette installation, operation and maintenance instructions © 2012 17

ProFlute, [Link], April 2012
5.2.6 Install drive system
Note! The drive system is self tensioning. It is important that the drive motor
turns in the correct direction. With reference to the drive motor corner
the rotor must turn upwards. See illustration below.

Motor
00 028

Kidney shaped
V-belt opening

1. Fit the motor and bracket into the cassette.

2. Cut the V-belt so that the motor is positioned 1/3 from the top in
the kidney shaped opening.

3. Connect the electrical wiring.

Rotor size Connection diagram, 3-phase

> 800 mm
00 044

up to 800 mm 1
white L3

green/
yellow

blue red
3 2
00 045

L2 L1

4. Check the direction of rotation.

5. Run the drive system for 1-2 hours.

6. If the drive motor is below the centre of the kidney shaped area go
back to step 2 and shorten the V-belt.

18 Cassette installation, operation and maintenance instructions © 2012

ProFlute, [Link], April 2012
6 Operation

6.1 About this chapter

This chapter provides instructions for start-up and operation.

6.2 Start-up

CAUTION! At start-up all check points should be performed to

ensure that the cassette is working properly.

Start-up consists of having both the proper balanced flow and

temperature through both process and reactivation air streams, as well
as rotation of the rotor.

6.2.1 Check points at start-up

Component Check that:

Rotor the rotor can rotate freely

the rotor face is parallel to the cassette frame and face

panels.

the rotor is correctly aligned in the casette

the rotor rotates in correct direction

Cassette the cassette is secured

the seals are correctly mounted

Drive system the drive system operates correctly

the drive belt is properly tensioned

Cassette installation, operation and maintenance instructions © 2012 19

ProFlute, [Link], April 2012
6.3 Process principle
Reactivation
air outlet

Heater

Reactivation
Process
air inlet
air inlet

Process
00 025

air outlet

Air flow through a cassette in operation

Air volume flow (standard 75% dry air flow and 25% reactivation air
flow) are for two air streams in counter-flow directions.

Process air passes through the cassette, where the desiccant media
removes moisture to dry the air stream. Simultaneously heated
reactivation air drives moisture from the desiccant media, where it is
subsequently exhausted to an ambient location.

The drive system rotates the rotor at pre-determined speed to provide

for a continuous process.

Seals seal the cassette to ensure that the dried process air and moisture
laden reactivation air remain separated.

6.4 Measurement of performance

Note! If possible use a chilled mirror dew point sensor for all dew point
readings.

1. Measure dry bulb temperature, dew point and air volume flow at:

- Entering process air inlet, leaving process air outlet.

- Entering reactivation air inlet, leaving reactivation air outlet.

2. Measure dry bulb temperature at the reactivation heater outlet.

3. Time rotor speed of rotation.

4. Measure process and reactivation air pressure drop and drive motor
amperage.

20 Cassette installation, operation and maintenance instructions © 2012

ProFlute, [Link], April 2012
 Compare all measurements against the data provided from ProFlute. The
result should agree within a few percent of graph. In event of substantial
(>5%) difference between measured and predicted results, re-perform
measurements.

Common measurement and calculation errors are:

• process leaving dew point is inaccurately determined by measuring

wet bulb (or RH) and calculating dew point. In many cases, the
leaving process air is so dry that even slight measurement errors in
dew point (or RH) will have significant results.

• Uneven temperature and flow in air streams causes variance in all

readings. Take an average reading in transverse across the face of
the rotor in order to minimize variance.

• Heat and mass transferred do not balance. The amount of heat

gain in kWh on the process side must match the heat loss in kWh
on the reactivation side. Also, the amount of moisture removed on
the process side must match the amount of moisture gained on the
reactivation side.

If mass and heat transfer do balance, it is likely that the readings

obtained are correct. See “Troubleshooting” on page 22 for additional
actions.

Cassette installation, operation and maintenance instructions © 2012 21

ProFlute, [Link], April 2012
6.5 Troubleshooting
Note! For problems not covered in the chart below or problems not solved,
contact ProFlute!

Problem Inspection Action

Rotor does not Power not on Energize
rotate Check direction of rotation Change direction
Check that the rotor is free to Determine cause and remove
rotate obstacles
Check the operation of the drive Replace drive motor
motor
Check wiring and capacitor
Check seal clearance Check rotor alignment

Adjust or replace seals

Check that the bearings are free to Replace bearing
rotate
Check engagement of the rotor in Adjust or replace
the pulley
Check drive belt tension Adjust tension
Rotor rotates but Make measurement of Determine cause
drying performance performance
is poor Check seal clearance Adjust or replace seals
High process outlet Check seal clearance Check rotor alignment
temperature
Adjust or replace seals
Check rotor speed Contact ProFlute
Low reactivation Check seal clearance Check rotor alignment
outlet temperature
Adjust or replace seals
Check rotor speed Contact ProFlute
Check heated temperature Adjust to set point

22 Cassette installation, operation and maintenance instructions © 2012

ProFlute, [Link], April 2012
7 Maintenance

7.1 About this chapter

Regular maintenance is important for safe and trouble-free operation of
the casette. This chapter provides instructions for maintenance.

WARNING! Maintenance should be performed by qualified

service personnel.

7.2 Regular maintenance

Note! The casette requires very little routine maintenance. Following the
maintenance intervals will result in years of trouble free operation.

The drive system is designed for long life and minimum maintenance.

7.2.1 Maintenance schedule

Note! For rotor maintenance instructions see document: Rotor specifications
and maintenance.

Interval Maintenance
At start-up Check for gaps *
Inspect on seals
Inspect drive system
2-3 months after commissioning Inspect rotor face for shrinkage *
Inspect seals
Inspect drive system
Yearly Inspect rotor face for shrinkage *
Check and clean rotor face *
Inspect filters *
Inspect seals
Inspect drive system
Pressure drop > 1.25 x new Clean rotor *
Performance <95% of new Make measurement of
performance and troubleshoot.

See “Measurement of
performance” on page 20.

Instructions for maintenance marked with * in the table above are found in: Rotor
specifications and maintenance.

Cassette installation, operation and maintenance instructions © 2012 23

ProFlute, [Link], April 2012
7.2.2 Inspect seals
Inspect the condition of the seals between the rotor and the metallic
frame structure. The seals should be pliable and intact. They shall lightly
contact the rotor.

A small amount of residue will occur after extended use, it is completely

normal. If large amounts of residue occurs, closely inspect the seals
for excessive wear, especially the radial seals between process and
reactivation. If excessive wear is evident the seals shall be replaced.

Inspect to ensure a good seal exists between the metallic structure of

the cassette and interconnecting ductwork. Any significant leakage in
these areas affects overall performance and should be sealed.

Change seals if necessary see “Change seals” on page 24

7.2.3 Change seals

Radial seals

1. Remove the mounting bracket attaching the seal and remove from
the cassette.

2. Install new seals according to: “Install air seals” on page 15.

Circumference seals

1. Pull the seals from the rotor edge.

2. Clean up any residual adhesive tape from the rotor edge.

3. Install new seals according to: “Install air seals” on page 15.

7.2.4 Inspect drive system

• Inspect the condition of the drive belt. Replace if necessary.

7.3 Replace drive system

1. Remove electrical connections from the drive motor.

2. Unwrap belt from gear motor drive wheel.

3. Remove the motor bracket bolts.

4. Pull the drive system out of the cassette.

5. Replace the drive system using the reverse procedure.

24 Cassette installation, operation and maintenance instructions © 2012

ProFlute, [Link], April 2012
7.4 Replace rotor
Rotors up to 1400 mm

WARNING! Crush hazard! The rotor is very heavy. Be careful

when replacing!

1. Secure the air handler and observe applicable safety precautions

regarding confined space entry and electrical tag out.

2. Determine if the rotor will be removed from the drive side of the
cassette (requires drive system removal, see “Replace drive system”
on page 24) or the opposite side of the cassette.

3. Remove the circumference seals if they are to be re-used.

4. Place a suitable wooden beam under the rotor.

Wooden
beam
00 046

5. Loosen and remove both shaft bolts at the centre shaft of the rotor.

6. Slide the shaft out of the rotor. Use the wooden beam as a lever to
keep the rotor in place.

7. Gently roll the rotor out of the cassette using the wooden beam.

8. Replace the rotor using the reverse procedure.

Rotors larger than 1400 mm

1. Replace rotor sector by sector. See document: Rotor assembly

instructions.

Cassette installation, operation and maintenance instructions © 2012 25

ProFlute, [Link], April 2012
7.5 Rotor alignment
Alignment of the rotor is maintained by the rotor shaft position (vertical
and horizontal) within the cassette.

Adjust the position:

1. Loosen the center shaft bolts.

2. Align the rotor to desired position. Small wooden wedges inserted

between the rotor circumference and rotor seal are sufficient to
align the rotor.

3. Re-tighten the shaft bolts.

26 Cassette installation, operation and maintenance instructions © 2012

ProFlute, [Link], April 2012
 CHILLER UNIT

INSTALLATION OPERATION
AND MAINTENANCE INSTRUCTION

5. CHILLER UNIT

____________________________________
KANGRIM HEAVY INDUSTRIES CO., LTD.
CONTROL PHILOSOPHY AND
OPERATING MANUAL
 TABLE OF CONTENTS

1. CONTROL PHILOSOPHY ........................................................................................................... 1

1.1 GENERAL ............................................................................................................................................................. 2

1.1.1 CHILLED WATER PUMP ....................................................................................................................................................... 3

1.1.2 EVAPORATOR .......................................................................................................................................................................... 3
1.1.3 CONDENSOR ........................................................................................................................................................................... 3

1.2 BASIC OPERATION SEQUENCE........................................................................................................................ 2

1.1.1 CHILLED WATER PUMP ....................................................................................................................................................... 3

2. OPERATING MANUAL (HMI)................................................................................................... 4

2.1 MAIN SCREEN .................................................................................................................................................... 5

2.1.1 BASIC BUTTON DESCRIPTION .......................................................................................................................................... 6
2.1.2 LOG-IN........................................................................................................................................................................................ 6
2.1.3 PRODUCT INFORMATION .................................................................................................................................................. 6

2.2 COMPRESSOR OPERATING SCREEN .............................................................................................................. 5

2.2.1 COMPRESSOR STATUS PAGE 1........................................................................................................................................ 6
2.2.2 COMPRESSOR STATUS PAGE 2........................................................................................................................................ 6
2.2.3 COMPRESSOR SETTING PAGE 1 ...................................................................................................................................... 6
2.2.4 COMPRESSOR SETTING PAGE 2 ...................................................................................................................................... 6
2.2.5 COMPRESSOR SETTING PAGE 3 ...................................................................................................................................... 6

2.3 CHILLER OPERATING SCREEN ......................................................................................................................... 5

2.3.1 CHILLER STATUS PAGE 1 .................................................................................................................................................... 6
2.3.2 CHILLER SETTING PAGE 1................................................................................................................................................... 6
2.3.3 CHILLER SETTING PAGE 2................................................................................................................................................... 6
2.3.4 CHILLER SETTING PAGE 3................................................................................................................................................... 6

2.4 ALARM LIST ........................................................................................................................................................ 5

2.4.1 ALARM LIST PAGE.................................................................................................................................................................. 6
2.4.2 ALARM HISTORY PAGE........................................................................................................................................................ 6

-2-
1 IGG CHILLER CONTROL PHILOSOPHY

1.1 GENERAL

Chiller unit shall be provided with all necessary control and monitoring instrumentation for automatic
operation.

Chiller unit shall be provided with control and power switchboard on the chiller unit to perform chiller system
related controls and monitoring.

1.1.1 CHILLED WATER PUMP

One (1) constant flow chilled water circulation pump shall be provided for chiller unit. (1X100%)

Chilled water pump shall be powered from Chiller unit power switchboard, 440V-3Ph-60Hz.

The chilled water pump shall start before starting the chiller unit and shall stop after stopping of chiller. This
operation shall be carried out by operator on the chiller unit control switchboard.

1.1.2 EVAPORATOR

Chiller unit shall provide one (1) evaporator mounted in chiller unit.

Two temperature sensor (TS) shall be installed at the chilled water inlet and outlet of evaporator for
monitoring of temperature by chiller unit control switchboard. Chilled water supply temperature shall be
maintained at 0℃.

1.1.3 CONDENSOR

Chiller unit shall provide one (1) condenser mounted in chiller unit.

One pressure sensor (PS) shall be installed at the cooling water outlet of condenser for monitoring of
pressure by chiller unit control switchboard. If cooling water pressure drops below setting pressure, an
alarm will be prompted on HMI of chiller control switchboard.

-3-
1.2 BASIC OPERATION SEQUENCE (AUTO MODE)

 Operator starts chilled water pump by pushing the start push button on the control switchboard and
check running status on the HMI.
 And, the operator activates compressor operating switch ON mounted on the control switchboard.
 Cooling mode starts if chilled water outlet temperature rises above 1℃
(Cooling mode inhibits to start if chilled water outlet temperature drops below -2℃.)
 Compressor shall be ordered to start if the suction pressure rises above setting value.
 EEV automatically controlled by means of suction superheat of compressor.
 Also, 2-way regulating valve controlled by means of the discharge pressure to maintain 1.85 MPa.(18.5
Bar)
 If capacity of the compressor drops below 75%, the control switchboard opens hot gas bypass valve. In
this low load mode, the 2-way regulating valve shall be controlled to maintain discharge pressure as
1.4 MPa (14.0 Bar).
 Capacity increase solenoid valve shall be ordered to open when the suction pressure rises above the
setting value and chilled water outlet temperature increase above 0.5℃.
 Capacity decrease solenoid valve shall be ordered to open when the suction temperature or pressure
drops below setting value or chilled water outlet temperature drops below 0.5℃.

-4-
2 OPERATING MANUAL (HMI)

2.1 MAIN SCREEN

When the main power is supplied, the touch screen will be displayed. It is indicated most of information
such as present values, set point values and present status of chiller unit.

Press the button to see the status and setting page of compressor. Refer to the next
section 2.2.

Press the botton to see the status and setting page of chiller unit. Refer to the section 2.3.

2.1.1 BASIC BUTTON DESCRIPTION

Back to the main menu.

Returning one menu back.

Review the alarm history.

-5-
2.1.2 LOG-IN

To enter status and setting screen of chiller unit, the operator should enter the ID and password.

 Default ID : HAK
 Default Password : 8888

-6-
2.1.3 PRODUCTS INFORMATION

Press the botton on the main screen. In this screen,

the operator can see major product information and address of HI AIR KOREA briefly.

-7-
 2.2 COMPRESSOR OPERATING SCREEN

2.2.1 COMPRESSOR STATUS PAGE 1

From this screen, the operator can see the values of safety instrument and the condition of compressor. Press

the button to see next status page of the compressor.

 Function Description

1) RUN HOUR TOTAL : Total running hour of the compressor

2) SINCE LAST RUN : Hour counting from the last running status of compressor
3) ANTI-RECYCLE : Delay time count that must pass from one compressor start to the next
4) RESTART DELAY : Delay time count that must pass from on compressor stop to next start
(regardless of ANTI-RECYCLE)
5) CAPACITY : Current capacity of the compressor converted from ampere
6) SUCTION PRESS : Suction pressure of the compressor
7) DISCHARGE PRESS : Discharge pressure of the compressor
8) SUCTION TEMP : Suction temperature of the compressor
9) DISCHARGE TEMP : Discharge temperature of the compressor
10) SUCTION SPHT : Suction superheat

*Note : Pressure unit is MPa.

-8-
 Graphic button description

Press this button to select ‘AUTO’ or ‘MANUAL’ mode of the solenoid valve.
In ‘MANUAL’ mode, operator controls the capacity of the compressor by
pushing the triangular button located below on this page.

Press this button to open the increase solenoid valve increasing the
capacity of the compressor.

Press this button to open the decrease solenoid valve decreasing the
capacity of the compressor.

Press this button to reset motor protection device after

-9-
 2.2.2 COMPRESSOR STATUS PAGE 2

From this screen, the operator can see the status of valves and compressor. Press the
button to see setting screen page. Refer to the next content for page 11.

 Function Description

1) START/STOP : Status of compressor start switch on control switchboard.

2) RUN FEEDBACK : Running feedback of the compressor.
3) MOTOR PROTECTION : Status of motor protection device.
4) UNLOADING : Compressor start signal from control switchboard.
5) INCREASE SOL V/V : Status of capacity increase solenoid valve.
6) DECREASE SOL V/V : Status of capacity decrease solenoid valve.
7) OIL LEVEL S/W : Status of oil level switch.
8) LIQUID INJECTION V/V : Status of liquid injection valve.
9) CHILLED WATER PUMP : Status of chilled water pump.
10) COOLING WATER SWITCH : Status of cooling water switch.

: RED symbol means STOP, ABNORMAL or CLOSED status.

: GREEN symbol means START, NORMAL or OPEN status.

- 10 -
 2.2.3 COMPRESSOR SETTING PAGE 1

The operator selects the setting area on this page then Keypad will be shown. Enter new set point
value what you want to input by pushing buttons.

 Function Description

1) SUCTION PRESSURE
ALARM(Low) : Suction pressure low limit set point for stopping the compressor

2) DISCHARGE PRESSURE
TRIP(High) : Discharge pressure high limit set point for stopping the compressor
WARNING : Discharge pressure high warning set point for controlling the compressor

3) ANTI RECYCLE
DELAY : Delay time of the compressor start from the last compressor start.

4) RESTART (for Motor Protection)

DELAY : Delay time of the compressor start from the last compressor stop.

5) CAPACITY RANGE CALIBRATION

EOCR Max. : EOCR signal maximum ampere set point
COMP. Max. : Compressor capacity maximum ampere set point

*Note : Pressure unit is MPa.

- 11 -
 Graphic button description

Press this button to recover all set point values to default value.

Press this button to recover all time related value to default value.

- 12 -
 2.2.4 COMPRESSOR SETTING PAGE 2

The operator selects the setting area on this page then Keypad will be shown. Enter new set point
value what you want to input by pushing buttons.

 Function Description

1) SUCTION SUPERHEAT
TRIP(Low) : Suction superheat low limit set point for stopping the compressor

2) SUCTION TEMPERATURE
TRIP(Low) : Suction temperature low limit set point for stopping the compressor
DELAY : Suction temperature limit delay time set point when stopping the compressor

3) DISCHARGE TEMPERATURE
TRIP(High) : Discharge temperature high limit set point for stopping the compressor

4) LIQUID INJECTION SOL V/V

CUT IN : Liquid injection solenoid valve open set point regarding discharge temperature
CUT OUT : Liquid injection solenoid close set point regarding discharge temperature

- 13 -
 2.2.5 COMPRESSOR SETTING PAGE 3

The operator selects the setting area on this page then Keypad will be shown. Enter new set point
value what you want to input by pushing buttons.

 Function Description

1) CAPACITY REGULATION
START : Compressor starting set point regarding suction pressure
INCREASE : Compressor capacity increasing set point regarding suction pressure
DECREASE : Compressor capacity decreasing set point regarding suction pressure
DECREASE : Compressor capacity decreasing set point regarding suction temperature

2) INCREASE SOL V/V

OPERATION : Increase solenoid valve operation time set point
CONTROL : Delay time set point for next operation

3) DECREASE SOL V/V

OPERATION : Decrease solenoid valve operation time set point
CONTROL : Delay time set point for next operation

*Note : Pressure unit is MPa.

- 14 -
2.3 CHILLER OPERATING SCREEN

2.3.1 CHILLER STATUS PAGE 1

From this screen, the operator can see the status of valves and compressor. Press the
button to see setting screen page. Refer to the next content for page 18.

 Function Description

1) CHILLED WATER INLET : Chilled water inlet temperature

2) CHILLED WATER OUTLET : Chilled water outlet temperature
3) SUCTION TEMP : Suction temperature
4) SUCTION SPHT : Suction superheat value
5) EEV POS 1 : Electric expansion valve position
6) EEV POS 2 : Electric expansion valve position
7) HOT GAS BYPASS POS 1 : Hot gas bypass position
8) HOT GAS BYPASS POS 2 : Hot gas bypass valve position
9) 2WAY V/V : 2 way water regulating valve position

 Graphic button description

If an operator wants to stop the compressor, must press this button!

So the solenoid valves of the evaporator side close and the compressor will
be stop till reaching the suction pressure alarm set point by running unload
control mode and automatically reset pump down mode. To reset pump down
mode in this process, press this button once more.

- 15 -
 2.3.2 CHILLER SETTING PAGE 1

The operator selects the setting area on this page then Keypad will be shown. Enter new set point
value what you want to input by pushing buttons.

 Function Description

1) CHILLED WATER OUTLET TEMP.

COOLING : Setting value of chilled water outlet temperature for capacity control
2) COOLING (CHILLED WATER OUTLET)
START : Setting value of chilled water outlet temperature for cooling mode start
STOP : Setting value of chilled water outlet temperature for cooling mode stop
3) SUPERHEAT
COOLER : Suction superheat adjusting set point for controlling EEV
4) EEV INITIAL
POSITION : Initial position set point of EEV for starting the compressor
DELAY : Initial position maintaining delay time set point when starting compressor

 Graphic button description

Press this button to recover all setting values to default value on this page

- 16 -
 2.3.3 CHILLER SETTING PAGE 2

The operator selects the setting area on this page then Keypad will be shown. Enter new set point
value what you want to input by pushing buttons.

 Function Description

1) MAXIMUM OPERATION PRESSURE

MOP : This function is operated to close the EEV(=electric expansion valve) for not increasing the
suction pressure of the compressor and the evaporator side.

2) DISCHARGE TEMPERATURE LIMIT

HIL : This function is operated to open the EEV for not increasing the discharge temperature of the
compressor by rising the flow rate of the refrigerant.

3) SUPERHEAT LOW LIMIT

LOL : This function is operated to close the EEV for safety in low heat load condition. So the suction
pressure and superheat of the compressor can be preserved safely.

*Note : Pressure unit is MPa.

- 17 -
 2.3.4 CHILLER SETTING PAGE 3

The operator selects the setting area on this page then Keypad will be shown. Enter new set point
value what you want to input by pushing buttons.

 Function Description

1) EEV MANUAL OPEN

COOLER 1,2 : Position of electric expansion valve

2) HOT GAS BYPASS CONTROL

SET (LP) : Suction pressure adjusting set point for controlling hot gas bypass valve
MANUAL OPEN : Forced opening position of hot gas bypass valve
DELAY : Delay time of controlling hot gas bypass valve from compressor start.
CUT IN : Setting value of compressor capacity when the hot gas bypass valve is ordered to open.
CUT OUT : Setting value of compressor capacity when the hot gas bypass valve is ordered to close.

3) 2 WAY V/V MANUAL OPEN

2 WAY V/V : Position of 2 way regulating valve
HIGH LOAD : Setting value of discharge pressure when the hot gas bypass valve is closed position.
LOW LOAD : Setting value of discharge pressure when the hot gas bypass valve is open position.

*Note : Pressure unit is MPa.

- 18 -
 Graphic button description

Press this button to control EEV position by operator. This manual operation is
only for test. The position will be reset when the compressor starts.

Press this button to recover EEV position to default value.

Press this button to control hot gas bypass valve position by operator. This
manual operation is only for test. The position will be reset when the
compressor starts.

Press this button to recover hot gas bypass valve position to default value.

Press this button to control 2 way valve position by operator.

Press this button to recover 2 way valve position to default value.

- 19 -
2.4 ALARM LIST

2.4.1 ALARM LIST PAGE

 Graphic button description

Press this button to see alarm history. Refer to the next section 2.4.2.

Press this button to acknowledge the alarm displaying on the screen.

- 20 -
2.4.2 ALARM HISTORY PAGE

- 21 -
Appendix
Parameter list
 IGG Chiller Parameter List

PROGRAM DEFAULT ALL SET-POINT Comm.

No. Description UNIT Location
(현재 프로그램) RESET BUTTON Set
1 SUCTION PRESSURE ALARM(low) 1.7 1.7 bar COMPRESSOR SET 1
2 TRIP(high) 23 23 bar COMPRESSOR SET 1
DISCHARGE PRESSURE
3 WARNING 22 22 bar COMPRESSOR SET 1
4 ANTI RECYCLE DELAY 1200 1200 sec COMPRESSOR SET 1
5 RESTART(for motor protection) DELAY 360 360 sec COMPRESSOR SET 1
6 EOCR Max. 300 A PID SETTING
CAPACITY RANGE CALIBRATION
7 COMP. Max. 170 A PID SETTING
SUCTION SUPERHEAT TRIP(low) 1.5 1.5 K COMPRESSOR SET 2
8
SUCTION SUPERHEAT DELAY SETTING 60 60 sec COMPRESSOR SET 2
9 TRIP(low) -10 -10 ℃ COMPRESSOR SET 2
SUCTION TEMPERATURE
10 DELAY 10 10 sec COMPRESSOR SET 2
11 DISCHARGE TEMPERATURE TRIP(High) 120 120 ℃ COMPRESSOR SET 2
12 CUT IN 95 95 ℃ COMPRESSOR SET 2
LIQUID INJECTION SOL V/V
13 CUT OUT 90 90 ℃ COMPRESSOR SET 2
14 START 2.5 2.5 bar COMPRESSOR SET 3
15 INCREASE 2.4 2.4 bar COMPRESSOR SET 3
CAPACITY REGULATION
16 DECREASE 2.0 2.0 bar COMPRESSOR SET 3
17 DECREASE 0.0 0.0 ℃ COMPRESSOR SET 3
18 OPERATION 0.7 0.7 sec COMPRESSOR SET 3
INCREASE SOL V/V
19 CONTROL 5.0 5.0 sec COMPRESSOR SET 3
20 OPERATION 0.8 0.8 sec COMPRESSOR SET 3
DECREASE SOL V/V
21 CONTROL 3.0 3.0 sec COMPRESSOR SET 3
22 CHILLED WATER OUTLET TEMP. COOLING 0.0 0.0 ℃ CHILLER SET 1
23 START 1.0 1.0 ℃ CHILLER SET 1
COOLING(CHILLED WATER OUT)
24 STOP -2.0 -2.0 ℃ CHILLER SET 1
25 SUPERHEAT COOLER 1,2 5.0 5.0 K CHILLER SET 1
26 POSITION 25.0 25.0 % CHILLER SET 1
EEV INITIAL
27 DELAY 5 5 sec CHILLER SET 1
28 MAXIMUM OPERATION PRESSURE MOP 5.5 5.5 bar CHILLER SET 2
29 DISCHARGE TEMPERATURE LIMIT HIL 115.0 115.0 ℃ CHILLER SET 2
30 SUPERHEAT LOW LIMIT 0.0 K CHILLER SET 2
31 EEV CONTROL MANUAL OPEN % CHILLER SET 3
32 SET(LP) 2.7 2.6 bar CHILLER SET 3
33 MANUAL OPEN % CHILLER SET 3
34 HOT GAS BYPASS CONTROL DELAY 10 sec CHILLER SET 3
35 CUT IN 55 % CHILLER SET 3
36 CUT OUT 65 % CHILLER SET 3
37 MANUAL OPEN % CHILLER SET 3
38 2WAY V/V CONTROL HIGH LOAD 18.5 bar CHILLER SET 3
39 LOW LOAD 14.0 bar CHILLER SET 3
40 P 30 Kp PID SETTING
HOT GAS BYPASS VALVE
41 I 20 Ti PID SETTING
42 P 6 Kp PID SETTING
SUCTION SUPERHEAT
43 I 120 Ti PID SETTING
44 P 30 Kp PID SETTING
MOP
45 I 60 Ti PID SETTING
46 P 10 Kp PID SETTING
HIL
47 I 60 Ti PID SETTING
48 P 10 Kp PID SETTING
LOL
49 I 60 Ti PID SETTING
50 P 18 Kp PID SETTING
SHIFT
51 I 60 Ti PID SETTING
52 P 15 Kp PID SETTING
2 WAY VALVE
53 I 20 Ti PID SETTING
54

OP
Appendix
Alarm & safety list
 Alarm & Safety Table for IGG Chiller
Document name: Alarm &Safety Table Chiller
Document reference: Chiller_Alarm&Safety_Table
Revision no.: R01
Name customer : KANGRIM Heavy Ind.
Order number : TBA
IMO / Hull number : HMD / 8347
Date: 2022-03-04

Chiller water pump stop(by Manual)

Common fault(Chiller failure)

Ref. compreessor stop

Audible Alarm

Time delay
Indicator

Operator

Setpoint
Check
Tag Description Device Range / condition Type:

Attachment chiller unit alarm table

No. Tags from P&ID and Parts list Description of the part from the parts list range/condition of the specific part with the unit
1 EXTERNAL EMERGENCY STOP TRIP Stop A X X X N/A X X N/A N/A
2 INTERNAL CHILLED WATER PUMP STOP TRIP Alarm A N/A
3 PT-02 COMP SUCTION PRESS LOW TRIP -1~9 bar Trip A X X X N/A X X 1.7bar
4 PT-01 DISCHARGE PRESS HIGH WARNING -1~29 bar Warning W 22bar
5 PT-01 DISCHARGE PRESS HIGH TRIP -1~29 bar Trip A X X X N/A X X 23bar
6 TT-03 SUCTION TEMP LOW TRIP -50℃~150℃ Trip A X X X N/A X X -10℃ 10sec
7 TT-04 DISCHARGE TEMP HIGH TRIP -50℃~150℃ Trip A X X X N/A X X 120℃
8 INTERNAL SUPERHEAT LOW TRIP Trip A X X X N/A X X 1.5k 60sec
9 LS-01 OIL LEVEL S/W TRIP Trip A X X X N/A X X 90sec
10 PD-01 MOTOR PROTECTION TRIP Trip A X X X N/A X X
11 INTERNAL COMP OVER CURRENT TRIP 100 - 300 A Trip A X X X N/A X X 170 A
12 INTERNAL CHILLER PUMP OCR TRIP 7 ~ 10A Trip A X X X N/A X X 7.08 A
13 PS-01 COOLING WATER PRESS LOW TRIP -0.2~5 bar Trip A X X X N/A X X 0.4 bar 5sec
14 TT-01 CHILLED WATER INLET TEMP SENSOR FAULT -50℃~150℃ Trip A X X X N/A X X
15 TT02 CHILLED WATER OUTLET TEMP SENSOR FAULT -50℃~150℃ Trip A X X X N/A X X
16 PT-02 SUCTION PRESS SENSOR FAULT -1~9 bar Trip A X X X N/A X X
17 PT-01 DISCHARGE RESS SENSOR FAULT -1~29 bar Trip A X X X N/A X X
18 TT-03 SUCTION TEMP SENSOR FAULT -50℃~150℃ Trip A X X X N/A X X
19 TT-04 DISCHARGE TEMP SENSOR FAULT -50℃~150℃ Trip A X X X N/A X X
20 INTERNAL SENSOR FAULT TRIP Trip A X X X N/A X X
21 INTERNAL COMP RUN FEEDBACK TRIP Trip A X X X N/A X X
22 INTERNAL CHILLED WAER PLANT STOP COMMAND FROM IAS Trip A X X X N/A X X

OR
 Appendix
SD Card PLC Program
download manual

S
SD card PLC Program download

① ② ① Prepare the SD card in which the PLC program

Is stored.

② Turn off the MCCB of the red circle installed

Inside the panel to cut off the power.

③ Insert the prepared SD card into the SD card

Slot of the CPU PLC.

④ Turn on the MCCB of the red circle installed

③ ④ Inside the panel to apply power.

1
SD card PLC Program download

⑤ ⑥ ⑤ After power is supplied, the PLC Lamp is on

before the program is downloaded.
The red lamp is blinking.

⑥ After power on, program download CPU PLC

Lamp is on before completion.
Orange lamp will blink as shown.
After a few seconds, the program download is
Completed.

⑦ PLC lamp is on after program download is

Completed.
Green lamp is blinking.
⑦ ⑧
⑧ CPU PLC Lamp is on after program download
Is completed. The first lamp lights green, and the
Second lamp flashes red.

2
SD card PLC Program download

⑨ ⑩ ⑨ After confirming that the program download

Is complete, turn off the MCCB in the red circle
Installed on the power panel to cut off the power.

⑩ After confirming that the power is off,

Safely remove the SD Card.

⑪ Please be careful not to use the SD CARD

Program on other panels.

3
 Appendix
Refrigerant charging
manual
 REFRIGERANT CHARGING
CAUTION:

 During operation, be sure to wear safety goggles and protective gloves.

 Before charging, all safety procedures indicated in the equipment IOM prior to any maintenance
procedures shall be followed.
 Before connecting any refrigerant hose to a service or tap valve, the hose should be briefly purged
(vented) with refrigerant from the cylinder to ensure that air and moisture does not enter the
system.

1.1 Liquid refrigerant charging

Liquid refrigerant charging is the process of moving liquid refrigerant from the liquid space of the
refrigerant cylinder to the liquid side of the system, as shown here:

Liquid refrigerant charging usually applies to high refrigerant charge systems, like large commercial
systems and systems with liquid receivers. Charging liquid refrigerants always requires skill and caution.

1. One hose is connected to the suction side of the compressor while another hose is connected to
charging valve with the condenser outlet shut‐off and is sensing high side pressure from that
location instead.
Note that the refrigerant cylinder (jug) should be inverted.
 2. Perform “Pump down” procedure according to compressor manufacturer. The pressure reading
on the high side gauge should indicate the same low pressure as the low side gauge. Pump
down will ensure that the pressure in the refrigerant cylinder is higher compared to the liquid
line connection in order to initiate refrigerant flow.

Note that the condenser outlet shut‐off valve prior to the liquid charging valve is closed before
pump down.

3. Start charging. Open the high‐pressure side valve then open refrigerant graduated charging
cylinder valve keeping eye on system pressure and refrigerant weight scale.
4. Notice that the sight glass will start to show liquid, the suction gauge pressure increases and the
high side gauge reflects the pressure from the jug, not from the high side of the system.
Fuller Sight Glass may be achieved but this is not a reflection of system operating conditions.
Due to liquid line isolation valve closed, all the refrigerant you are adding is merely being
relocated into the isolated high side (see section 1.2).
5. Due to the current system configuration it would be difficult to tell whether sufficient
refrigerant has been added. The weight of the jug should be closely monitored to know how
much refrigerant has already been added and periodically closing the high side valve and
opening the condenser outlet shut‐off valve to see how things are progressing. Be cautious not
to overcharge the system using this method.
6. When charging is close to being complete (based on the monitored amount already transferred)
it is recommended that the charging shall be completed by the vapor charging method (see
Section 1) to avoid overcharging.

Caution:

 The suction hand‐valve is to be used carefully to monitor the liquid gauge pressure to not
exceed 140 kPa (approximately 20 psig) above suction pressure; when the blue hose (suction
line) frost is observed close to the hand‐valve, check the suction pressure. Repeat until the
desired charge is obtained.
  If the refrigerant cylinder does not have a dip‐tube, it should be placed in an upside down
position to guarantee liquid flow.
 Bypassing the low‐pressure side control to avoid shutting off during charging

1.2 Charging to sight glass

This method normally applies to larger systems that have a liquid receiver. Refrigerant is charged into
the system, and as it is metered in, the technician observes the sight glass in the liquid line.

Eventually, once no more bubbles can be seen in the sight glass, the charge size has approximately been
achieved, as shown here:

However, as there is always a delay between adding the refrigerant and the effect on the sight glass, the
technician should take extra time to ensure that the correct charge has been added. It should also be
borne in mind that longer delays between adding refrigerant and the response of the sight glass occur
with larger systems. As with all other systems, it is important to consider the ambient temperature and
the possibility of adding a little more refrigerant so that no bubbles appear during warmer/cooler
ambient conditions.

In addition, the refrigerant cylinder(s) should be weighed before and after, and the charged amount
checked against the intended charge.

Reference

 [Link]
ref_manual_servicing_technicians.pdf
 [Link]
 [Link]
[Link]/wrx/STi_Manual/06.%20BODY/01.%20HVAC%20SYSTEM%20(HEATER,%20VENTILAT
OR%20AND%20AC)/04.%20Refrigerant%20Charging%[Link]
Compressor manual

 


     


 
 
 









  
  
  
  

     

        

     
     
     
     

        

        
     
     
     
     
        
        
      
      
      
   
     

        

     

     
        
        
     
     

     

  
   
   

     

  
     

 

     

        

        
     
     
     
     
     
     
        
        
        
     
     

        

        
      
      
       
     
      
     

        

        

        

          

        
        
        

        

        
        
        
        

 

     

  

  
  

  

     
     
  
     

  

     
  
     

  

     
  
     
  
  
  

  

     
  
  
  
     
  

  

  

 

     
  

  

  
  
  
  

 
  
  
  
  
  
  
  
 


 
  
  
  
  
   
 


 
  
  
  
 


  

  
  
  
    
  

 

   
     
    
   
     
   
    

 


 

     
  

  

  
  
  
  
  
  
  
  
 


 
  
  
  
  
  
  
  
  
 
 
  
  

     
  
  
 
 
   
 
 

   
 
 

    
  
  
 
 
 
  
  
  
  
  
  
  
  

     

    
  
  
  
  

 

  
  
   
  
  
  
  
  
  
  
 


 

 
  
  
  
  
  
  
  
  
 
 


     

    
  
  

 

     

     

  

  
  
  
  
  
  
  
  
  
  
  
  
 

 


 

 

 
  
  
  
  
  
  
   
 
 





  

  
  
  
  
  
  
  
  
 

 

  
 

  

  
     
     
     
  
     

  

  
     
  
  
     

  

  
     
     
  
  
     
 

  


   
   
  
  
  
   
    
   
     
     
    
  
  
  
  
  
 
 

  

     
   
  
  
  
     
  
     

 

   
     
  
     
    
   
     

  

     
        
     
  
  
  

  

  

  
     
     
    
   
   
    
 

  


   
   
  
  
    
   
  



  

  

     
  
   
    
  
   
   
  


 

   
     
   
    
   
     
    
     
     
    
    
    
   
  

  

        
     
  
       
  
     
  
     
     
  
     
  
    
     
 


     

  

 

     
  

  

  
  
  
  
  
  
  
  
  
  
  
  
 


 
  
  

 

 
  
   
   
  
  
  
  
  
  

 
 
 

 
 








 

       

   

     

     
     
     
  
     

     

  

 

  
  
   

 

 

 
  
 

 

 

 

 

 

  




     

  

  

  
  
     
    
   
  
  

 
   
  
  
   


 

 

 
  
  
  
 


 

 

 
  
  
  
  
  
  
 




 

    
   
   
   
   
   
   
   
  

     

 
 

 
 

     

 

     

  

  
  
   
  
  
  
  
  
  
  
  
  
  
  
  
  
   
  
  
  
  
  
  
  

     

  

  
  
  
  
  
  

 
  
  
  
  
  
  
 

     

  

  
  
  
  
  
   
  
  
  
 

 

    
  
  
  
  
  
  
  

  
  
  
  
 

 
 
 

         

 
 

 

 












     

     
     

     

  
  
  
  
  
  
 

  

  
  
  
        

  

 


 


 



     

 

   
  
  
  
  
 

   

 
 











   


    


   

   

   
   
   
   
   

   

   
   

   

   
   
   

   

     

  
  
  
  
  

 

  
  
  
  
  
  
  
  
  
  

  

  
  
  
  
  
  
  
  
 

 

  
  
  
  
 
 

  
  
  
  
 
 
    
  
  
  
 
 
    
  
  
  
  
  
  
  
  
  
  
  
    
  
  
   
 
 


 

     


  

  
  
  
  

 
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  

 
  
  
  

 

 
  
  
  
  
  
  
  
  
  
  
  
  
  



 

     

  

  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
   
  
  
 

 

 
 
  
  
  
  
  
   
 
 
  
 

 

  
        
  
  
  
  
  
 
  

 
  
  


        

  
  
  
  
  
  
  
   
  
  
 

 

     

  

  
  
  
  
  
 
 

  

     

     
     
   

   

    
   

      

     


     

  

  
   

  

     
  
     
  
  
  
  
  
     
     
  

   
   
  
  
  
  
  
 
 

  
   
 

 

   
  

 
  
  
  
  
  
  
 


 

     
 

  
  
   
  
  
  
  
  
  
  
  

 
  
  
  
  
  
 


     

  

  
  
  
  
  

 
   
 

  
  
  
 


 
     
   
 

     

 

  
  
  
  
  
  


  

  
  

 


 


 


   
  

  

  
  
  
  


     

  

  
  
 

   


 
  
  
  
  

  
  
  
    
   
   
    
 

  
  
   
  
 

 

  
  
  
 

 

 


 

  
  
  
  
  
  
  
  
  
   
  
  
  
  
 

 

 
 
 
 
 

  
  
 
 




   

     

     
     
     
     
     
     
     
     

     

  


 

   
   
  
  

 
   
     
  
      

  

      
    
  
      
      
 


 
  
  
  
 
 
 


 
 
 


  

  
  
  
  
  
  

  
  


  

 

  
  
  
  
  


  

  
  
  
   
  

 

  
  
     
  
  
  
  


  

  
  
  
  
   
  
  
  
  

 
  
  
  
  
  
 


 
  
  
  
 


 
  
  
 

  

  
  
  
  
    
  
  
  
  
  
    

 

 
  
  
   
  
  
  
  
 

 

  
  
 

 

  
  
  
  
  
 

 


 

 
  
  
  
  
  
 



 
 
 
 
 

 

 

     
  

  

  
  
  
  
  
 

  

  
  
  
  
     
  
  
  
  
  
   
  
     
  
  
  
     
  
  

   

 
   
  



  

  
  
  
  
  
  
  
  
  
  
  
  
  
  
   
  
  
   
 
 

 

  
  

  
   
  
 
 
 

 

 

 

 

  

    

 
 

  
    
  
 
 

  
   
  
 
 
 


  
   
  
 
 
   

 

 

 
 
 

 

 

 

 


 
 




  


  
  
    
  
   
  
  
  
  
  
 


 

  
  
  
  
  
  
  
  
  
  
  
   
   
  
  
   
   
   
     
  
  
  
  
  
  
 

 

  
  
  
  
  
  
  
  
 
 
 

 


   
   
    
 
 
 

 


  
  
 
 

 
 
 


  



  

 

 

 




 
 



 

     
     
  

  

  
  
   
  
   
   
  
  

 
  
  
   
    
   
    
 


 
     
  
    
   
 


 

 
  
  
  
 



  

  
  
   
  
  
  

  

 


 


 


  
  

 

  







     

   
    
  
  


 

  
     
  
  
     
     
  
  
  
  
  
     
  
  
  
   

   
   
  
  


  

     
  

   
   

   
   
    
   
   
   
    
   
   
    
  
 

   

  
  
  
  
  
  

  

  
  
  
  
  
  
  

 

     
     
  

  

  
  
  
  

 
  
  
  
   
    
     
     
    
  


 
 


  

  
  
  
  
  
     
  
  
  
  
  
     
  
  
  
  
  
     
  
  
  
  

  

  
  
  
  
   
  
  
   
  
  
  
 


 

 
 







 



 

 
 

     

  
  
   
   
  
  
  


 

  


     

  
     
  
  
  
  
 
 
 


  
   
  
  
  
  
  
  
  
  
  
  
   
   
   
    
    
   
  
    
   

 

 

 


 
  
  
  
  
 
 
 
 
 
 
 


 

     
  
  

   

   
   
 
    
 
 
    
 

  



     

  
  
  
  
  
   
    
  
   
    
  
   
   
  

   
   
  
  
  
  
  
  

   
   
  



 

  
  
  
  
        




     



 

  
  
  
  
  
     
    

  
  
  
  
     
 
   


 




     

     
     

 

  
  
  
  
  
  
     
    

   
 
  
  
  
  
  
 













        

     



 

     

  

   
  
  
  
  
  
  
  
  
 


 
  
  
  
  
 


 
 


     

  

  
  
  
  
  
  
  
  
  
 

     

  
 

 

  
  

 
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
 

     

  

  

  
  
  
  
   
  
  

     

 

 

  
  
  
 

 

  
  
  
  
  
 


     

  

  

  
  
  
  
  
  
  
  
  
  
  
  











     

  
  
  
 

 

  
  
  
  

 
  
  
  
  
  
  
 


     

  

  

  
  
  
  
 

  
  
  
  
 
 

  

  
  
  

  

  
  
  
  

 
    
     

  

  
  
  
  
  
  
 

 

  
 
 
 

 

     

     

  
  
  
  
     
           
           
           
           
           
           
           
           

     

  
     
  
  
 
     
  
  
  
  
  
  

 
  

  



     

  
  
  
  


 

   
  
    


     
  
  
  
  
     
  
  
  
  
 

     

  

  
  
  
  
  
  

 
  
   
     
     
     
   

  

     
     
  
     
  
 
 
    
  
  
  
 
 
    
  
     
  
    
      
 

     
      
  
  

 

  
  
   
  
     
 

  

     
   
     
   
   
   
   
   
  
  
  
   
   
   
  
  
 
 
    
  
  
  
  
  
  
  
  
  
  
 
 
 


     

  

  
  
  
  
  
  


 

     
  
  

  

  
  
  
  
  
  
 

     
  
 

  

  
  
  
  
  
  
  
  
  


 

     

  

 

     

     

  

  
   
    
     
  
 
 
    
 

  

  
  
     
  
     





     

   
  

   
 

   

  

 
   
 

     

     
     
  
  

 

  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  





        

    

 
   
 
   





   

  



        

     
     
  
  

 

   
  
  
  
  


     


 
  
  

 
  
  
  
  

 
  
   

 
  
  
  
  
 


  

  
  

     

  
  
  


 

  
 

  
 

  

  
  
  


  

  
  
  
  
  
  

  

  
  
  
  
  
  
     
   
     
  

  

  
  
  

  

  
  

  

  

 

   
  
     
  
     

     
   
  
   
  

   
   


  

  
  
  
     
  
  
  
 

  
 


  

  
  
     
     

     

  
  

 

  
  
  
  


  

 
   
  
  
  
  
     
   


 
 
    
  
  
  
 
 

  
   
  
 


  

  
     
  
  
  
  
   

   
     
   
    
    
  
  
 

 

  
  
     
  
  
  
     
  
 
 
    
 
 

  
  



  

     
  
     
  
  
  
     
  
  

  

     
     
  
  
  

  

  
  
 

  
  
  

 

  
  
  
  

 
  
  


     
  
  
     
     
     
        
     
  
     
   
  
   

   
   
  
  
  

   
   
  
  
  


  

  
  
  
  
  
  
  
 
  
  
  


 

  
  
  
  
  
  
  
  
  
  
  
  
  
  
    
  
    
 

 

  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
 

 

 


 

 
  
  
  
  
  
   
  
 

 


 








 

     

  

 
 
 

  

    

    

    

    

  

  
    
 

   

  

  



  

   

  

   

  

   

      

    

  

  

        

  

  
  
  
  
  
  
 


 

  
  
  
   


  





 

 



  

  
  
  
  

 

     
  

  

 

  

 


 


 


  
  
  
  
  
  
  
 

  

  
  
  

  

  
  
 
  
 
 
    
  
  
  
 

  

  
  
  
  
  
  
  
  
  
  
  
  
 

  
  
  
  
  
  
 


 

  
        
   
  

  

     
  
  
  
  
  
  
  
  
  
  
     
  
  
  
  
  

   
   
  
  
  
  
  
  
  


  

  
  

  

     

  
  

   

     

  
  
  


 

  
     
  
  
  
  
  

   
   
  
  
  
   
  
  
  
  
  
  
 
 
    
  
  
  
  
  
 

  
 
 
  

 


 


 


  



 

 
    

  
     
     

    

  
  
  


 

     

  

  
  
  
  
  
   
  
  
  


  

 


 


 


     
     
    
  
  
  
     
  
   
     
  
     
     
     
     
  
     
  
  
  

 

  
 

  
  
  
  
  
 

 

  
  
  
  
  
 

 

 


 
  
 
 
 
 



  

  
  
  
  
  
  
   
 
 
  
   
  
  
  
   
   

 

 
  
 


 

 
  
  
  




 

  

     

     
     
     
     
     
     
     
     
     
     
    
     
 
     
  
     
     
     
     
     
        
     
        
       
     
      
        
     
    
  
     
     
     
     
     
     
  
  
     
     
    
     
     
     
     
     
     
     
     
     

 

     
  
  
  
  
     
  
  

  
  

  

  

  
  
  
  
  
  
  
  
           
           
    

 

 





  

  
  

  

  
  

 







 





  

  

  

  
  

 






 





  

  
  

  

  

  

  
  



  



 





  

  

  

  

  

  
  



  



 
 
 
 
 

     

     
  
  
  
     
     

     
     
  

  

     
     


  

     
  
    



 
 
 
 
 

     

     
  
  
  
     
     
     
     
  

  

     
     


  

     
  


    


 








  

  


  

  

  


  

  
  






 








  

  


  

  
  


  

  





 








  

  
  


  

  
  


  

  
  


  





 








  

  


  

  
  


  

  
  


  





     


 



  
  

   

   
  

   

   

  

  

   

   

   

   

   

   

   

   

   

   

  

   

   

   

   

   

  

  

 
  

 

 
 




 

 
 
 

 
  

   

   

   

   

   

   

   

   

   

   

   

   

   

   

  

  

 

     

  

          
         
    

          
         
     

          
         
      
       

     


   
    

     


   
    

         

         

     

   
     

     

   
     

     

   
     

     

   
      

     

   
     

     

   
    

      
 
 
     

     
 
 
     

     
 
 
      

      

 
 
     

         

     

   
     

     


   
    

     

   
     

     

   
     

     

   
     

         

 

  

          
         
    

          
         
     

          
         
      
       

     

   
     

     

   
     

     

   
     

     

   
     

     

    
     

     

   
      

     

    
      

     

    
     

      

   
      

     

    
     

     

   
     

     

   
     

     

   
     

     

   
     

 

   
  

  

     

     

  

  
  
              
              
              
              
        
        

  

  

  

  
  
  
  
  


        

  
     
    
 

  

  

  

  

     

 

  
     
  
  
     
  
     
     
  
  
  
     
  
  
  
  

  

  
  
  
  
  
  
  
     
  
  
     
     
     
  

 

     

   

   

 
 
 

   

 
 

 

 
 

  
 












 


  


 




 








 




  



















 

     

  

  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
  
   
  


  

  
  
  
  
   
  
  
  
  
  
  
  
  
  
  
  
 

  

   
  
  
  
  
  


  

  
  
  
  
  
     
     

 

    
  
   
  
   
  

 
  
  
  

   
 
 
  
  
 
 
    
  
 
 
    
  
 

 

 
  
  
 

 

 
    
 
   
  
   
      
 

     

  

 

  
 
  
     
      
              
  
        
    
          
          

     

  
  


  

  
  
  
  

  

  
  
  
        
   

  
  
  


       

  

 

     
  

       

    

        


   
   
    
        
          
        
     
       
         
         
          
        
      
        
          
        
 
   
       
   
  
  
  
      
   
       
          
      
               
         


     

  
  

 

     
  
  

      

    

         

     

  
     
         
         
       
      
       
          
       
           
      
        
       
           
       
      
      
  
  
   
  
      
   
       
          
      
               
         


     

  
  
  

 

  
  
      
  
  
  
  
  

  


    
      
   
  
    
     
  
 
      
      
      
               
              
          

     

  
  

 

   
      
       
  
      
         
        
     
  

    
      
     
    

    
   
  

   
      
  
               
              
               

     

  
  
  

 

   
           
  
      
      
       
  
      
          
       
     
  

       
       
   
     
 

       

 
  
        
    
    
   
    
  
    
   
  
   
 
 

           
  


 

     
  

     
       
       
     
 
   
   
            
               
              
     

           
   
  
  

 

   
           
  
      
        
  
      
   

      

    
  
     
     
  
               
              
               
      
         
    
        
  

     

  
  
  

 

     


  
 
 
  












   
   

 

      
   

   
 




 

    
    
 
 
  
  
   
   

     

  

  

  

  

 


 

 
  


 







    
  

 

       
    

    
  




 

   
   
 
 

  
  
   
   

  

  

  

 


 


 
  

    
  

 

       
    

     
   

 

  
  
 
 

  

  

  

 





 







    
  



       
    

    
 





 

   
   
 
 

        
        
         
         
         
         
         

     

  
  
  
  

 



  
 
 
  









   
   

 

     
   

   
 








    
  



  

  

  

 



 

 
  









    
  

 

       
     

   
 








   
 



   
   
    
    

  

  

  

 



 


 
  

    
  

 

      
    

    
  

 

 
 



   
   
    
    

  

  

  

 



  

 







    
  

 

      
    

    
 






 

 
 



         
         
          
          
          
          
          

  

  

  

 

  

     

  
     
  
  
  
  
 

  
 
 

     

     

     
 
     
     
     
  
  
     

     
  
  
     
  
  
     
  
     
     
  
     
     
  
  
     
  
     
  
     
     
  
  


  

  
 

 

     

 
       
 

   
   
   
   
       
   
       
   

   
   
   
   
       
       
       
       
       
       

   

   
   
   
       
       
       
       
       
       

   

       
       
       
       
       
       
       
       
       
       
       
   

  

  

 

   
    
            
  


 SB-170-9

Semi-hermetic compact screw compressors

Translation of the original Operating Instructions
English....................................................................................................................................................... 2

Halbhermetische Kompaktschraubenverdichter
Originalbetriebsanleitung
Deutsch ..................................................................................................................................................... 35

Compresseurs à vis compacts hermétiques accessibles

Traduction des instructions de service d'origine
Français..................................................................................................................................................... 68

CSH6553-35Y .. CSH6593-60Y CSW6583-40Y .. CSW6593-60(Y)

CSH7553-50Y .. CSH7593-110(Y) CSW7571-60Y .. CSW7593-90(Y)
CSH8553-80Y .. CSH8593-180(Y) CSW8573-90Y .. CSW8593-140(Y)
CSH9553-180(Y) .. CSH95113-320Y CSW9563-140Y .. CSW95113-320(Y)
CSW10593-400Y
CSH7673-70Y .. CSH7693-90Y
CSH8673-110Y .. CSH8693-140Y
CSH9663-160Y .. CSH96113-320Y

CSK6151-50 .. CSK6161-60

Document for installers

Dokument für Monteure
Document pour des monteurs

7)4
Table of contents

1 Introduction............................................................................................................................................................ 4
1.1 Also observe the following technical documents .......................................................................................... 4

2 Safety .................................................................................................................................................................... 4
2.1 Authorized staff.............................................................................................................................................. 4
2.2 Residual risks ................................................................................................................................................ 4
2.3 Safety references........................................................................................................................................... 4
2.3.1 General safety references.................................................................................................................. 4

3 Application ranges ................................................................................................................................................. 5

3.1 Economiser and additional cooling ................................................................................................................ 6
3.2 Use of flammable refrigerants of the A2L safety group (e.g. R1234yf).......................................................... 6

4 Mounting................................................................................................................................................................ 6
4.1 Transporting the compressor......................................................................................................................... 6
4.1.1 Centres of gravity and weights........................................................................................................... 7
4.2 Installing the compressor............................................................................................................................... 9
4.2.1 Arranging for removal clearances ...................................................................................................... 9
4.2.2 Marine application.............................................................................................................................. 9
4.2.3 Vibration dampers............................................................................................................................ 10
4.3 Connecting the pipelines ............................................................................................................................. 11
4.3.1 Pipe connections.............................................................................................................................. 11
4.3.2 Shut-off valves ................................................................................................................................. 11
4.3.3 Pipelines .......................................................................................................................................... 11
4.4 Oil connection .............................................................................................................................................. 12
4.5 Capacity control (CR) and start unloading (SU) .......................................................................................... 12
4.5.1 Solenoid valves and control sequences........................................................................................... 13
4.6 Connections and dimensional drawings ...................................................................................................... 14

5 Electrical connection............................................................................................................................................ 23
5.1 Mains connections ....................................................................................................................................... 23
5.2 Motor versions ............................................................................................................................................. 24
5.3 High potential test (insulation strength test)................................................................................................. 24
5.4 Protection devices ....................................................................................................................................... 24
5.4.1 SE-E1............................................................................................................................................... 24
5.4.2 CM-SW-01 ....................................................................................................................................... 25
5.4.3 SE-i1 ................................................................................................................................................ 25
5.4.4 SE-E2............................................................................................................................................... 25
5.4.5 Monitoring of the oil circuit ............................................................................................................... 25
5.4.6 Safety devices for pressure limiting (HP and LP) ............................................................................ 26
5.4.7 Oil heater ......................................................................................................................................... 26

6 Commissioning .................................................................................................................................................... 26
6.1 Checking pressure strength......................................................................................................................... 27
6.2 Checking tightness ...................................................................................................................................... 27
6.3 Evacuation ................................................................................................................................................... 27
6.4 Charging refrigerant..................................................................................................................................... 27
6.5 Checks prior to compressor start................................................................................................................. 28

2 SB-170-9
7)W
 6.6 Compressor start ......................................................................................................................................... 28
6.6.1 Checking the rotation direction ........................................................................................................ 28
6.6.2 Lubrication/oil level monitoring......................................................................................................... 29
6.6.3 Set high pressure and low pressure switches (HP + LP)................................................................. 29
6.6.4 Set the condenser pressure............................................................................................................. 29
6.6.5 Vibrations and frequencies .............................................................................................................. 29
6.6.6 Checking the operating data ............................................................................................................ 29
6.6.7 Control logic requirements ............................................................................................................... 30
6.6.8 Particular notes on safe compressor and system operation ............................................................ 30

7 Operation............................................................................................................................................................. 31
7.1 Regular tests................................................................................................................................................ 31
7.2 Locking the protection and monitoring devices............................................................................................ 31

8 Maintenance ........................................................................................................................................................ 31
8.1 Oil change.................................................................................................................................................... 31
8.2 Replace oil filter (CSW105) ......................................................................................................................... 31
8.3 Integrated pressure relief valve ................................................................................................................... 32
8.4 Integrated check valve................................................................................................................................. 32

9 Decommissioning ................................................................................................................................................ 32
9.1 Standstill ...................................................................................................................................................... 32
9.2 Dismantling the compressor ........................................................................................................................ 32
9.3 Disposing of the compressor ....................................................................................................................... 32

10 Tightening torques for screwed connections ....................................................................................................... 33

10.1 Normal screwed connections....................................................................................................................... 33
10.2 Special screwed connections ...................................................................................................................... 33
10.3 Sight glasses ............................................................................................................................................... 34
10.4 Screwed joints of electrical contacts in the terminal box ............................................................................. 34
10.5 Screws inside the compressor..................................................................................................................... 34

SB-170-9 3
7)ü
1 Introduction 2.3 Safety references
These refrigeration compressors are intended for incor- are instructions intended to prevent hazards. Safety ref-
poration into refrigeration systems in accordance with erences must be stringently observed!
the 2006/42/EC Machinery Directive. They may only be
put into operation if they have been installed in the refri- NOTICE
geration systems according to these Mounting/Operat-
ing Instructions and if the overall system complies with
the applicable legal provisions (applied standards: see
declaration of incorporation).
! Safety reference to avoid situations which may
result in damage to a device or its equipment.

CAUTION
The compressors have been built in accordance with Safety reference to avoid a potentially hazard-
state-of-the-art methods and current regulations. Partic- ous situation which may result in minor or mod-
ular importance was placed on user safety. erate injury.
These Operating Instructions must be kept available
near the refrigeration system during the whole lifetime WARNING
of the compressor. Safety reference to avoid a potentially hazard-
ous situation which could result in death or seri-
ous injury.
1.1 Also observe the following technical documents
SW-170: Checking and replacing intervals in compact DANGER
screw compressors. Safety reference to avoid an imminently hazard-
ous situation which may result in death or seri-
ous injury.

2 Safety 2.3.1 General safety references

2.1 Authorized staff NOTICE

All work done on compressors and refrigeration sys-

tems may only be performed by qualified and author-
ized staff who have been trained and instructed accord-
! Risk of compressor failure!
Operate the compressor only in the intended ro-
tation direction!

ingly. The qualification and expert knowledge of the State of delivery

personnel must correspond to the local regulations and
guidelines. CAUTION
The compressor is filled with a holding charge:
2.2 Residual risks Excess pressure 0.2 .. 0.5 bar.
Risk of injury to skin and eyes.
The compressor may present unavoidable residual Depressurize the compressor!
risks. That is why any person working on this device Wear safety goggles!
must carefully read these Operating Instructions!
The following regulations shall apply:
• relevant safety regulations and standards (e.g.
EN 378, EN 60204 and EN 60335),
• generally accepted safety rules,
• EU directives,
• national regulations.

4 SB-170-9
7)M
For work on the compressor once it has been For work on the electrical and/or electronic system
commissioned
WARNING
WARNING Risk of electric shock!
The compressor is under pressure! Before working on the terminal box, module
Serious injuries are possible. housing and electrical lines: Switch off the main
Depressurize the compressor! switch and secure it against being switched on
Wear safety goggles! again!
Close the terminal box and the module housing
before switching on again!
CAUTION
Surface temperatures of more than 60°C or be- NOTICE
low 0°C.
Risk of burns or frostbite.
Close off accessible areas and mark them.
Before performing any work on the compressor:
! The compressor module may be damaged or
fail!
Never apply any voltage to the terminals of CN7
to CN12 – not even for test purposes!
switch it off and let it cool down. The voltage applied to the terminals of CN13
must not exceed 10 V!
The voltage applied to terminal 3 of CN14 must
not exceed 24 V! Do no apply voltage to the
other terminals!

3 Application ranges

Permitted refrigerants CSH65 .. CSH95, CSW65 .. CSH76 .. CSH96: CSH65 .. CSH95,

(other refrigerants on request) CSW95: R134a, R450A, CSW65 .. CSW95,
R134a, R407C, R450A, R513A, R513A, R1234yf, CSK61:
R1234yf, R1234ze(E) R1234ze(E) R22
CSW105: R134a, R450A,
R513A, R1234yf
Oil charge CSH: BSE170 BSE170L B320SH
CSW: BSE170L
Application limits CSH: see brochure SP-171 and BITZER SOFTWARE
CSW: see brochure SP-172 and BITZER SOFTWARE
Tab. 1: Application ranges of CS. compressors

The use of R404A and R507A and other refrigerant Risk of air penetration during operation in the vacuum
blends requires individual consultation with BITZER. range

Application limit for CSK61 NOTICE

CSK61 compressors are only approved for use with
R22 refrigerant, without ECO and LI. The application
limit goes down to -10°C. Above this value, the applica-
! Potential chemical reactions as well as in-
creased condensing pressure and rise in dis-
charge gas temperature.
Avoid air penetration!
tion limit corresponds to that for CSH65 compressors
with R22 refrigerant.
WARNING
A critical shift of the refrigerant ignition limit is
WARNING
possible.
Risk of bursting due to counterfeit refrigerants!
Avoid air penetration!
Serious injuries are possible!
Purchase refrigerants only from reputable man-
ufacturers and reliable distributors!

SB-170-9 5
7)B
3.1 Economiser and additional cooling R1234yf and R1234ze(E). They are considered as
technically tight. No ignition source assessment is
Compressors of the series CSH65 to CSH95 are
available for other refrigerants of the A2L safety group.
provided with an ECO economiser connection that is
That is why the protection device has to be installed
active in the entire capacity control range. They also
outside the terminal box, for example in the switch cab-
have connections for external oil cooling and LI liquid
inet, until specific approval has been obtained.
injection.
The economiser of the compressor models CSW65 to
Information
CSW105 and CSH76 to CSH96 is only active at full
When using a flammable refrigerant:
load. These compressors have no connections for addi-
Affix the warning sign “Warning: flammable ma-
tional cooling.
terials” (W021 according to ISO7010) well vis-
For production reasons, the CSK6151 and CSK6161
ibly to the compressor. An adhesive label show-
compressors are equipped with connections for ECO
ing this warning sign is enclosed with the Oper-
and LI, which are not approved for use.
ating Instructions.
These connections will no longer be available in the
near future.
Refrigerant burning in the terminal box may only hap-
pen if several very rare errors occur at the same time.
3.2 Use of flammable refrigerants of the A2L safety The probability of this event occurring is extremely low.
group (e.g. R1234yf) When suspecting burnt refrigerant in the terminal box,
wait at least 30 minutes before opening it. According to
Information the present knowledge, this is the time needed for the
The information in this chapter about the use of toxic combustion products to be degraded. It is neces-
refrigerants of the A2L safety group refer to sary to use appropriate, acid-resistant gloves. Do not
European regulations and directives. In regions touch moist residues, but allow them to dry, because
outside the EU, observe the local regulations. they may contain dissolved toxic substances. Never in-
hale evaporation products. Have trained staff clean the
Information parts concerned or, if the parts are corroded, dispose of
For refrigerants of the A3 safety group, e.g. them properly.
R290 propane or R1270 propylene, specific
compressor designs can be delivered upon re-
quest. In this case, also observe the additional
Operating Instructions. 4 Mounting

This chapter describes and gives explanations of addi-

4.1 Transporting the compressor
tional residual risks originating from the compressor
when using refrigerants of the A2L safety group. This Transport the compressor screwed onto the pallet or lift
information helps the manufacturer of the system carry it using the lifting eyes. Lift CS.95, CSH96 and
out a risk assessment. This information may in no way CSW105 with a lifting beam only, see figure 1, page
replace the risk assessment for the system. 7.
Design, maintenance and operation of refrigeration sys- Weight 1200 .. 1900 kg (depending on the model)
tems using refrigerants of the A2L safety group are
subject to particular safety regulations. DANGER
Suspended load!
When installed according to these Operating Instruc-
Do not step under the machine!
tions and in normal operation conditions without mal-
functions, the compressors are free from ignition
sources that could ignite the flammable refrigerants

6 SB-170-9
740
 X

Fig. 1: Lifting the compressor. Left CS.65 .. CS.85, CSH76 and CSH86, right CS.95, CSH96 and CSW105

X (mm) 4.1.1 Centres of gravity and weights

CS.95, CSH96 1150
CSW105 1448

X Y

Fig. 2: Centres of gravity using the example of the CSH85

CSH compressors Weight (kg) Centre of gravity X (mm) Centre of gravity Y (mm)
CSH6553-35Y 314 89 22
CSH6553-50(Y) 322 100 22
CSH6563-40Y 314 107 22
CSH6563-60(Y) 322 120 22
CSH6583-50Y 365 39 22
CSH6593-60(Y) 365 46 22
CSK6151-50 322 100 22
CSK6161-60 322 120 22
CSH7553-50Y 500 95 25
CSH7553-70(Y) 515 126 25
CSH7563-60Y 510 113 25
CSH7563-80(Y) 520 129 25
CSH7573-70(Y) 515 120 25
CSH7573-90(Y) 530 132 25
CSH7583-80Y 525 90 25

SB-170-9 7
747
 CSH compressors Weight (kg) Centre of gravity X (mm) Centre of gravity Y (mm)
CSH7583-100(Y) 550 102 25
CSH7593-90Y 530 111 25
CSH7593-110(Y) 560 123 25
CSH7673-70Y 520 120 25
CSH7683-80Y 530 90 25
CSH7693-90Y 535 111 25
CSH8553-80Y 830 103 22
CSH8553-110(Y) 840 115 22
CSH8563-90Y 830 129 22
CSH8563-125(Y) 850 143 22
CSH8573-110Y 840 131 22
CSH8573-140(Y) 860 145 22
CSH8583-125Y 850 98 22
CSH8583-160(Y) 880 108 22
CSH8593-140Y 860 105 22
CSH8593-180(Y) 900 115 22
CSH8673-110Y 850 131 22
CSH8683-125Y 860 98 22
CSH8693-140Y 880 105 22
CSH9553-180(Y) 1280 128 10
CSH9563-160Y 1270 120 10
CSH9563-210(Y) 1300 129 10
CSH9573-180Y 1280 127 10
CSH9573-240(Y) 1310 137 10
CSH9583-210Y 1330 100 10
CSH9583-280(Y) 1360 109 10
CSH9593-240Y 1350 105 10
CSH9593-300(Y) 1380 109 10
CSH95103-280Y 1450 108 10
CSH95103-320(Y) 1480 120 10
CSH95113-320Y 1480 125 10
CSH9663-160Y 1280 120 10
CSH9673-180Y 1290 127 10
CSH9683-210Y 1350 100 10
CSH9693-240Y 1370 105 10
CSH96103-280Y 1450 108 10
CSH96113-320Y 1480 125 10

8 SB-170-9
741
 CSW compressors Weight (kg) Centre of gravity X (mm) Centre of gravity Y (mm)
CSW6583-40Y 360 34 22
CSW6583-50(Y) 365 39 22
CSW6593-50Y 360 42 22
CSW6593-60(Y) 365 46 22
CSW7573-60Y 515 112 25
CSW7573-70(Y) 520 120 25
CSW7583-70Y 525 84 25
CSW7583-80(Y) 530 90 25
CSW7593-80Y 530 92 25
CSW7593-90(Y) 535 111 25
CSW8573-90Y 840 93 22
CSW8573-110(Y) 850 131 22
CSW8583-110Y 850 90 22
CSW8583-125(Y) 860 98 22
CSW8593-125Y 870 103 22
CSW8593-140(Y) 880 105 22
CSW9563-140Y 1270 115 10
CSW9563-160(Y) 1280 120 10
CSW9573-160Y 1260 123 10
CSW9573-180(Y) 1290 127 10
CSW9583-180Y 1320 96 10
CSW9583-210(Y) 1350 100 10
CSW9593-210Y 1360 103 10
CSW9593-240(Y) 1370 105 10
CSW95103-240Y 1430 105 10
CSW95103-280(Y) 1450 108 10
CSW95113-280Y 1450 109 10
CSW95113-320(Y) 1480 125 10
CSW10593-400Y 1900 300 -44
Tab. 2: Weights and centres of gravity of CSH and CSW compressors (without shut-off valves)

4.2 Installing the compressor 4.2.1 Arranging for removal clearances

Every compact semi-hermetic screw compressor is a When installing the compressor in the system, arrange
motor-compressor unit. Therefore, it is only necessary for removal and maintenance clearances of sufficient
to install the whole unit correctly and to connect the size.
electrical system and the pipelines.
• CSW105: provide at least 450 mm for the removal of
Install/mount the compressor horizontally. Take suit- the oil filter!
able measures if the compressor is operated under ex-
treme conditions (e.g. aggressive atmosphere, low out-
4.2.2 Marine application
side temperatures, etc.). Consultation with BITZER is
recommended. With regard to marine applications, defined diagonal
mounting on the longitudinal axis of the ship can be ne-
cessary, see figure 3, page 10.

SB-170-9 9
74(
Mount the compressor in parallel to the longitudinal Installa- Inclination in the Inclination in the
axis of the ship and tion longitudinal direction transversal direction
• either horizontally to the water level static dynamic static dynamic
• or inclined by 10° in the longitudinal direction of the hori- ±5° ±7.5° ±15° ±22.5°
compressor, with the motor downwards zontal
Requirement: During operation, the oil level must re- inclined ±15° ±17.5° ±15° ±22.5°
main in the range of the upper sight glass. This is in- by +10°
dicated in the following figure as a large grey line.
Tab. 3: Maximum inclination angles of the ship

4.2.3 Vibration dampers

22,5° The compressors may be mounted solidly. To reduce
7,5°

5° 15° structure-borne noise however, it is recommended us-

0° 0° ing specially tuned vibration dampers.
5° 15°
7,5°
22,5° NOTICE

17,5°

15°
! Do not mount the compressor solidly on the
heat exchanger!
Risk of damage to the heat exchanger (fatigue
fractures).
+10° 22,5°

15° 15° Mounting vibration dampers

0°
15° Tighten the screws until first deformations signs of the
17,5°
22,5°
upper rubber disc are visible.

Fig. 3: Permitted inclination angles of the ship using the example of

the CSH85

M
15

1 2

Fig. 4: Vibration dampers

Vibration dampers Compressor M

1 CS.9553 .. CS.9573, 2 CS.9553 .. CS.9573, CSK61, CS.65 M10
CSH96: blue CSH96: yellow CS.75, CSH76 M16
CSW10593: yellow CSW10593: yellow
CS.85, CSH86 M16
CS.95, CSH96 M20
CS.105 M20

10 SB-170-9
74)
4.3 Connecting the pipelines When turning or mounting shut-off valves:

WARNING NOTICE
The compressor is under pressure!
Serious injuries are possible.
Depressurize the compressor!
Wear safety goggles!
! Risk of damage to the compressor.
Tighten screws crosswise in at least 2 steps to
the prescribed tightening torque.
Test tightness before commissioning!

When retrofitting the ECO shut-off valve:

NOTICE

! Potential chemical reactions due to air penetra-

tion!
Proceed swiftly and keep shut-off valves closed
until evacuation.
Information
To increase the corrosion protection, it is recom-
mended to coat the surface of the ECO shut-off
valve.

4.3.1 Pipe connections 4.3.3 Pipelines

The pipe connections are suitable for pipes in all com- Use only pipelines and system components which are
mon dimensions in millimetres and inches. Brazed con-
• clean and dry inside (free from slag, swarf, rust and
nections have stepped diameters. The pipe will im-
phosphate coatings) and
merge more or less depending on its dimensions. If ne-
cessary, the bushing may even be cut at the end with • which are delivered with an air-tight seal.
the largest diameter.
Depending on the compressor versions, they are sup-
plied with blanking plates on the pipe connections or
4.3.2 Shut-off valves shut-off valves. These must be removed before per-
forming the strength pressure and tightness tests and
CAUTION commissioning the system.
Depending on the operation mode, the shut-off
valves may become very cold or very hot. Information
Risk of burning or frostbite! The blanking plates are only designed to serve
Wear suitable protective equipment! as a transport protection. They are not suitable
as a separation between different system sec-
tions during the strength pressure test.
NOTICE

! Do not overheat the shut-off valves!

Cool the valve body and the brazing adapter
during and after the brazing operation.
Maximum brazing temperature 700°C! !
NOTICE
For systems with rather long pipelines or for
brazing operations without protective gas:
Install the suction-side cleaning filter (mesh size
For welding, dismount the pipe connections and < 25 μm).
the bushes.
NOTICE

! Risk of compressor damage!

Generously sized filter dryers should be used to
ensure a high degree of dehydration and to
maintain the chemical stability of the circuit.
Make sure to choose a suitable quality (molecu-
lar sieves with specially adapted pore sizes).

Information
Notice for mounting the suction-side cleaning fil-
ter, see manual SH-170.

SB-170-9 11
744
Mount pipelines in such a way that the compressor is Additional connections for evacuation
protected from flooding with oil or liquid refrigerant dur-
For an optimal evacuation capacity, it is recommended
ing standstill. Follow the notes given in SH-170.
to install generously-sized, lockable additional connec-
Optional pipes for economiser (ECO) (not for CSH95), tions on the discharge and suction sides. Sections
see figure 5, page 12 and/or liquid injection (LI), see locked by check valves must have separate connec-
figure 6, page 12 must first be routed upward from the tions.
connection. This avoids oil migration and damage to
the components through hydraulic pressure peaks (see Observe the following for all connections retrofitted on
manual SH-170). the compressor

NOTICE

1
CS.65 .. CS.85,
CSW95:
min. 20 cm
! Risk of refrigerant loss!
Check the thread.
Carefully screw the adapter in and tighten it to
the prescribed tightening torque.
Test tightness before commissioning!

4.4 Oil connection

Fig. 5: Pipe layout of the ECO suction gas line at the compressor

1 Pulsation muffler Pressure gauge connection on the oil valve for

maintenance
ON 110°C The pressure gauge connection on the oil valve for
OFF 100°C
TC maintenance is delivered with a screwing cap
(7/16-20 UNF, tightening torque max. 10 Nm). In case
of any modification, proceed very carefully.

NOTICE

!
min. 20 cm
Risk of refrigerant loss!
Check the thread.
Carefully screw the adapter in and tighten it to
the prescribed tightening torque.
Test tightness before commissioning!
Fig. 6: Pipe layout for liquid injection (LI) with liquid injection valve

4.5 Capacity control (CR) and start unloading (SU)

Information
The connections for economiser (ECO) and/or The standard CS. versions are equipped with a "Dual
liquid injection (LI) are not provided on all com- capacity control" (control with a slider). This allows in-
pressor models, see dimensional drawings. finite as well as 4-stage regulation without any rebuild-
The connections for ECO and LI on the CSK61 ing of the compressor. The only difference in the oper-
compressor are not approved for use. These ating mode is the activation of the solenoid valves.
connections will no longer be available in the
The capacity control of CSW105 compressors is auto-
near future.
matically controlled via the CM-SW-01 compressor
module.
Information
Notice for connecting an external oil cooler, see
Information
manual SH-170.
For detailed descriptions on capacity control
and start unloading as well as their control, see
Information manual SH-170.
For other examples about pipe layout, see
manual SH-170.

12 SB-170-9
74W
4.5.1 Solenoid valves and control sequences CR Y1 Y2 Y3 Y4
Start / Stop
CR1 CR2
(Y1) (Y2) CAP 25%
CAP 50%
CAP 75%
CAP 100%
Tab. 6: 4-stage capacity control (CR)

CAP Cooling capacity

CAP ⇑ Increase cooling capacity
CAP ⇓ Decrease cooling capacity
CR3 CR4 CAP ⇔ Constant cooling capacity
(Y3) (Y4)
Solenoid valve de-energized
Fig. 7: Arrangement of the solenoid valves Solenoid valve energized
Solenoid valve pulsing
CR Y1 Y2 Y3 Y4
Solenoid valve intermittent
Start / Stop
(10 s on / 10 s off)
CAP ⇑
Tab. 7: Legends
CAP ⇓
CAP ⇔ Capacity steps 75%/50%/25% are nominal values. The
real residual capacities depend on the operating condi-
Tab. 4: Infinite capacity control (CR) in the range 100% .. 25%
tions and on the compressor design. The data can be
determined with the BITZER SOFTWARE.
CR Y1 Y2 Y3 Y4
Start / Stop Information
CAP ⇑ In part-load operation, the application ranges
are limited! See manual SH-170 or BITZER
CAP min. 50% ⇓ SOFTWARE.
CAP ⇔
Tab. 5: Infinite capacity control (CR) in the range 100% .. 50%

SB-170-9 13
74ü
4.6 Connections and dimensional drawings CSH6553 .. CSH95113, CSK6151 .. CSK6161

12 3 (LP) 565
1/8-27 NPTF 7/16-20 UNF
504
A 150
126 415 3 (LP) 94
1/8-27 NPTF
550

146
H
215

208

8
60 60 20 132
140 457 305 Ø21
360

6 4 9 4/8 5 275 263

1/8-27 NPTF 1 1/8-18 UNEF 1 1/8-18 UNEF 5/8-18 UNF

SL DL 1 (HP) 2 (HP)
1/8-27 NPTF 1/8-27 NPTF
62
41

14 47 161
M12x16 15 10 13
11
M22x1,5 2x 1 1/4''-12 UNF 1/8-27 NPTF Ø22 (7/8'')
(Valve connection: (Adaptor connection:
Ø12 / 1/2'') Ø12 / 1/2'')

Fig. 8: Dimensional drawing CSH6553-35Y .. CSH6593-60Y, CSK6151 .. CSK6161

A H L
mm mm mm
CSH6553, CSH6563, CSK6151, CSK6161 1107 460 478
CSH6583, CSH6593 1207 469 481
Representation with optional ECO valve (position 13). Legend for connections, see table 8, page 23.

14 SB-170-9
74M
 3 (LP) 555
7/16-20 UNF
A 135
114 J 3 (LP) 108
1/8-27 NPTF
572

69 77
527
511
257

250

10
50 50 33 120 Ø17
D 457 305
360
252 292

6 12 9 5 4/8 4 571
1/8-27 NPTF 1/8-27 NPTF 5/8-18 UNF 1 1/8-18 UNEF 1 1/8-18 UNEF

SL 14 DL 1 (HP) 2 (HP)
M10x12 1/8-27 NPTF 1/8-27 NPTF
33

20

128 277

15 11 10 13
M22x1,5 2x 1 1/4-12 UNF 1/8-27 NPTF Ø22 (7/8'')
(Valve connection: (Adaptor connection:
Ø12 / 1/2'') 2x Ø16 / 5/8'')

Fig. 9: Dimensional drawing CSH7553-50Y .. CSH7593-110(Y)

A D J
mm mm mm
CSH7553, CSH7563, CSH7573, CSH7583-80Y, 1354 262 540
CSH7593-90Y
CSH7583-100(Y), CSH-7593-110(Y) 1385 293 570
Representation with optional ECO valve (position 13). Legend for connections, see table 8, page 23.

SB-170-9 15
74B
 16 3 (LP) 700
1/8-27 NPTF
1540 146
161 585 105
739

643
598
305

305

35
60 60 20 180 Ø17
116 695 400
465
380

6 12 5 9 4/8 4/8
1/4-18 NPTF 1/8-27 NPTF 5/8-18 UNF 1 1/8-18 UNEF 1 1/8-18 UNEF

SL DL 1 (HP) 2 (HP) 13 14
1/8-27 NPTF 1/8-27 NPTF M10x16
40

25

185 455

15 10 11
M22x1,5 1/8-27 NPTF 2x M26x1,5
(Valve connection: (Adaptor connection:
Ø12 / 1/2'') 2x Ø22 / 7/8'')

Fig. 10: Dimensional drawing CSH8553-80Y .. CSH8593-180(Y)

Legend for connections, see table 8, page 23.

16 SB-170-9
7W0
 3 (LP)
A 1/8-27 NPTF
J 95
C

L
355
295

30
70 70 20 225 Ø21
D 793 450
520
F

6 12 5 4/8 9 4/8 B
1/4-18 NPTF 1/8-27 NPTF 5/8-18 UNF 1 1/8-18 UNEF 1 1/8-18 UNEF

SL DL 1 (HP) 2 (HP) 16
7/16-20 UNF 1/8-27 NPTF
20
M

30

I 731

13 15 11 10
M22x1,5 2x M26x1,5 1/8-27 NPTF
(Valve connection: (Adaptor connection:
Ø12 / 1/2'') 2x Ø22 / 7/8'')

Fig. 11: Dimensional drawing CSH9553-180(Y) .. CSH95113-320Y

A B C D F I J L M
mm mm mm mm mm mm mm mm mm
CSH9553 .. CSH9573 1824 717 776 224 417 746 930 744 106
CSH9583-210Y, 1842 717 776 242 417 764 948 751 113
CHS9593-240Y
CSH9583-280(Y), 1869 717 776 269 417 791 975 751 113
CSH9593-300(Y)
CSH95103-280Y 1955 731 796 269 431 791 975 758 113
CSH95103-320(Y), 1975 731 796 289 431 810 995 758 113
CSH95113-320Y

SB-170-9 17
7W7
CSW6583 .. CSW10593, CSH7673 .. CSH96113

12 3 (LP)
1/8-27 NPTF 1/8-27 NPTF
1207 149
126 415 94
550

481
468

43
215

208

8
60 60 20 132
140 457 305 Ø21
360
273

6 4 9 4/8 5 551
1/8-27 NPTF 1 1/8-18 UNEF 1 1/8-18 UNEF 5/8-18 UNF
SL DL 1 (HP) 2 (HP)
1/8-27 NPTF 1/8-27 NPTF
43

62
10

42 179

14 13 17
M12x1,75 Ø22 (7/8'') M22x1,5
(Adaptor connection:
Ø16 / 5/8'')

Fig. 12: Dimensional drawing CSW6583-40Y .. CSW6593-60(Y)

Presentation with optional ECO valve (position 13). Legend for connections, see table 8, page 23.

18 SB-170-9
7W1
 3 (LP) 550
1/8-27 NPTF
1353 135
114 540 108
572

534
513
257

250

10
50 50 33 120 Ø17
261 457 305
360
308 292

6 12 9 5 4/8 4 2 (HP) 616

1/8-27 NPTF 1/8-27 NPTF 5/8-18 UNF 1 1/8-18 UNEF 1 1/8-18 UNEF 1/8-27 NPTF

SL 14 DL 1 (HP)
M10x1,5 1/8-27 NPTF

43
N

O
33

20

13 I1 I2 17
Ø22 (7/8'') M22x1,5
(Adaptor connection:
Ø16 / 5/8'')

Fig. 13: Dimensional drawing CSW7573-60Y .. CSW7593-90(Y), CSH7673-70Y .. CSH7693-90Y

I1 I2 N O
mm mm mm mm
CSW7573, CSH7673 153 258 20 70
CSW7583, CSW7593, CSH7683, CSH7693 157 261 23 70
Representation with optional ECO valve (position 13). Legend for connections, see table 8, page 23.

SB-170-9 19
7W(
 16 3 (LP) 695
7/16-20 UNF
1540 146
161 585 3 (LP) 105
1/8-27 NPTF
739

643
598
305

305

35
60 60 20 180 Ø17
116 695 400
465
380

6 12 5 9 4/8 4/8
1/4-18 NPTF 1/8-27 NPTF 5/8-18 UNF 1 1/8-18 UNEF 1 1/8-18 UNEF

SL DL 1 (HP) 2 (HP) 14
1/8-27 NPTF 1/8-27 NPTF M10x16
N

O
40

25

I1 I2

13 17
Ø28 (1 1/8'') M26x1,5
(Adaptor connection:
Ø22 / 7/8'')

Fig. 14: Dimensional drawing CSW8573-90Y .. CSW8593-140(Y), CSH8673-110Y .. CSH8693-140Y

I1 I2 N O
mm mm mm mm
CSW8573, CSH8673 221 434 0 56
CSW8583, CSW8593, CSH8683, CSH8693 228 432 4 50
Legend for connections, see table 8, page 23.

20 SB-170-9
7W)
 3 (LP)
1/8-27 NPTF
A B
J 95

C
L
355
295

30
70 70 20 225 Ø21
D 793 450
520
F

6 12 5 4/8 9 4/8
1/4-18 NPTF 1/8-27 NPTF 5/8-18 UNF 1 1/8-18 UNEF 1 1/8-18 UNEF

SL DL 1 (HP) 2 (HP) 16
7/16-20 UNF 1/8-27 NPTF
20

70
N
30

I 731

13 17
Ø35 (1 3/8'') M26x1,5
(Adaptor connection:
Ø22 / 7/8'')

Fig. 15: Dimensional drawing CSW9563-140Y .. CSW95113-320(Y), CSH9663-160Y .. CSH96113-320Y

A B C D F I J L N
mm mm mm mm mm mm mm mm mm
CSW9563, CSW9573, 1824 717 776 224 417 41 930 751 118
CSH9663, CSH9673
CSW9583, CSW9593, 1842 717 776 242 417 34 948 751 122
CSH9683, CSH9693
CSW95103-240Y 1927 731 796 242 431 26 948 751 120
CSW95103-280(Y), 1955 731 796 269 431 26 975 751 120
CSW95113-280Y,
CSH96103-280Y
CSW95113-320(Y), 1974 731 796 289 431 26 994 751 120
CSH96113-320Y

SB-170-9 21
7W4
 SL 3a (LP) 22
1/8-27 NPTF 1054
2254 448 94
1448 40

901
678
454
394

30
70 Ø21 452 146
237 1113 522

16 12 5 8 4 2a (HP)
1/8-27 NPTF 5/8-18 UNF 1/8-27 NPTF

23 Vi (+) Vi (-) DL 2 (HP) 1 (HP)

1/8-27 NPTF 1/8-27 NPTF

3 (LP) CR (-) CR (+) 580

1/8-27 NPTF 650

13 17
M48x1,5 M48x1,5

239 138
9 18 6
1/4-18 NPTF

Fig. 16: Dimensional drawing CSW10593-400Y

Legend for connections, see table 8, page 23.

22 SB-170-9
7WW
 Connection positions Connection positions
1 High pressure connection (HP) 23 Slider position indicator
2 Additional high pressure connection (HP) SL Suction gas line
2a Connection for high pressure transmitter DL Discharge gas line
(HP)
Tab. 8: Connection positions
CS.105: connected to the compressor
module Dimensions (if specified) may have tolerances accord-
3 Low pressure connection (LP) ing to EN ISO 13920-B.
3a Connection for low pressure transmitter The legend applies to all CS. compressors and con-
(LP) tains connection positions that do not exist in every
CS.105: connected to the compressor compressor series.
module
4 Oil sight glass
5 Oil valve for maintenance (standard) / con-
5 Electrical connection
nection for oil equalisation (parallel opera-
tion) Compressors and electrical equipment comply with the
6 Oil drain plug (motor body) EU Low Voltage Directive 2014/35/EU.
7 Connection for electro-mechanical oil level Connect mains cables, protective earth conductors and
switch for the replacement of CSH.1 with bridges (if needed) as specified on the labels in the ter-
CSH.3 minal box. Observe EN60204-1, the safety standard
8 Connection for opto-electronic oil level series IEC60364 and national safety regulations.
switch (OLC-D1-S)
CS.105: connected to the compressor NOTICE

9
module
Oil heater with heater sleeve (standard)
CS.105: connected to the compressor
! Risk of short-circuit due to condensation water
in the terminal box!
Use only standardised cable bushings.
When mounting, pay attention to proper sealing.
module
10 Oil pressure connection Additionally earthing the compressor housing
11 Connections for external oil cooler (op-
tional adapter) DANGER
High electrostatic discharge voltage possible.
11a Outlet to the oil cooler
Risk of electric shock!
11b Inlet/return from the oil cooler Also earth the compressor housing!
12 Oil temperature sensor
CS.105: connected to the compressor
module
Connection, see position 16 in the dimensional draw-
13 Connection for economiser (ECO, optional
ings.
shut-off valve, CSH65 and CSH75 with
pulsation muffler)
14 Threaded bore for pipe fixture for ECO or 5.1 Mains connections
LI line When dimensioning motor contactors, feed lines and
15 Connection for liquid injection (LI, optional fuses:
shut-off valve)
• Use the maximum operating current or maximum
16 Earth screw for housing power consumption of the motor as a basis.
17 Connection for oil and gas return (for sys- • Select the contacts according to the operational cat-
tems with flooded evaporator, optional ad- egory AC3.
apter)
18 Oil filter (maintenance connection) • Set the thermal overload relays to the maximum op-
erating current of the compressor.
21 Oil injection valve (internal)
22 Compressor module

SB-170-9 23
7Wü
5.2 Motor versions 5.3 High potential test (insulation strength test)
The compressors were already submitted to a high po-
NOTICE

!
tential test in the factory according to EN12693 or ac-
Risk of compressor failure!
cording to UL984 or UL60335-2-34 for the UL model.
Operate the compressor only in the intended ro-
tation direction!
NOTICE
The compressor series CS.65, CS.75, CS.85, CSH76
and CSH86 and are equipped by default with part-wind-
ing motors ("PW") in Δ/ΔΔ-wiring. Star-delta motors (Y/
! Risk of defect on the insulation and motor fail-
ure!
Never repeat the high potential test in the same
way!
Δ) are also available as an option. For detailed informa-
tion, see manual SH-170.
A repeated high potential test may only be carried out
The CS.95, CSH96 and CSW105 models are generally with max. 1000 V AC.
equipped with star-delta motors (Y/Δ).
5.4 Protection devices
Part-winding motors (PW)
Starting modes: WARNING
Risk of electric shock!
• Part-winding start to reduce the starting current.
Before performing any work in the terminal box
• Direct start. of the compressor: Switch off the main switch
and secure it against being switched on again!
Time delay until switch-on of the 2nd part winding: max.
Close the terminal box of the compressor before
0.5 s!
switching on again!
Make the connections correctly! Wrong electrical con-
nections will lead to opposite fields of rotation or to NOTICE
fields of rotation out of phase and therefore to a motor
lock!
Connect motor terminals on the cover of the terminal
! Potential failure of the protection device and the
motor due to improper connection and/or faulty
operation!
Connect properly according to the schematic
box according to the instructions.
wiring diagrams and check the connections for
Strictly observe the order of the part windings! tight seat.
The cables and terminals of the PTC control cir-
• 1st part winding (contactor K1): connections 1 / 2 / 3.
cuit must not come into contact with the control
• 2nd part winding (contactor K2): connections 7 / 8 / voltage or operating voltage!
9.
• Winding partition 50%/50%. 5.4.1 SE-E1
• Motor contactor selection: This protection device is incorporated as standard in
the terminal box of all HS.53 .. HS.85 compressors and
– 1st contactor (PW 1): 60% of the max. operating
CSH, CSW compressors. In the state of delivery, the
current.
cables for the monitoring of motor and oil temperature,
– 2nd contactor (PW 2): 60% of the max. operating rotation direction and phase failure are connected to
current. the terminal plate. Other connections according to the
wiring diagram in the terminal box, see manual SH-170
Star-delta motor and Technical Information ST-120.
The time delay between switch-on of the compressor Monitoring functions:
and switch-over from star to delta operation shall not
• Temperature monitoring.
exceed 2 s.
Make the connections correctly! • Rotation direction monitoring.
Wrong electrical connections will lead to short-circuit!
• Phase failure monitoring.
Information
Rate the mains contactor and the delta con-
tactor at min. 60% and the star contactor at min.
33% of the max. operating current.

24 SB-170-9
7WM
5.4.2 CM-SW-01 5.4.3 SE-i1
This protection device with extended monitoring func-
Standard for all CSW105 compressors
tions can be used as an option for all HS.53 .. HS.85
The compressor module integrates the entire electronic compressors and CSH and CSW compressors.
periphery of the compressor: It allows monitoring the
Monitoring functions:
essential operating parameters of the compressor: mo-
tor and discharge gas temperature, phase and rotation • Temperature monitoring.
direction monitoring, oil supply and application limits
• Monitoring of the PTC control circuit to detect any
and thus protects the compressor from operation under
short-circuit or line break/sensor failure.
critical conditions. For further information, see Tech-
nical Information ST-150. • Rotation direction monitoring.
• Monitoring of phase failure and asymmetry.
NOTICE

! The compressor module may be damaged or

fail!
Never apply any voltage to the terminals of CN7
to CN12 – not even for test purposes!
• Monitoring of the maximum cycling rate.
For further information, see Technical Information
CT-110.
The voltage applied to the terminals of CN13
must not exceed 10 V! 5.4.4 SE-E2
The voltage applied to terminal 3 of CN14 must
Optional protection device for operation with frequency
not exceed 24 V! Do no apply voltage to the
inverter and soft starter (for a ramp time shorter than
other terminals!
1 s).
The following components are completely installed and • Dimensions and integration in the control identical to
wired in the state of delivery: SE-E1.
• Slider position indicator. • Suitable for all CS. compressors.
• Oil monitoring (OLC-D1). • Monitoring functions are basically identical to those
of SE-E1. However, the SE-E2 monitors phase fail-
• Solenoid valves for capacity control and Vi.
ure during the entire running time of the compressor.
• Discharge gas temperature sensor.
For further information, see Technical Information
• Low pressure and high pressure transmitter. ST-122.
Modification to these components or their wiring is not
required and should not be done without consulting 5.4.5 Monitoring of the oil circuit
BITZER.
• For short circuits without liquid injection (LI) for addi-
The following components are not installed and wired in tional cooling and for small system volume and small
the state of delivery and need to be connected: refrigerant charge: Indirect monitoring with oil tem-
perature sensor (standard)
• Motor temperature monitoring (PTC sensor in motor
winding).
NOTICE
• Phase monitoring (in case of a phase failure or inad-
missibly high phase asymmetry).
The compressor module internally supplies voltage to
! Lack of oil leads to a too high increase in tem-
perature.
Risk of damage to the compressor!
the peripheral devices (solenoid valves, oil monitoring
• For circuits with liquid injection (LI) for additional
device and slider position indicator) and to the terminal
cooling and / or for great system volume as well as
strips CN7 to CN12.
parallel compounding: Monitor oil level directly with
Please refer to the Technical Information ST-150 for in- opto-electronic oil level monitoring (option), see
formation on all connections. chapter Opto-electronic oil level monitoring OLC-D1-
S, page 26. The connection is on the compressor
housing, see chapter Connections and dimensional
drawings, page 14, position 8.

SB-170-9 25
7WB
Opto-electronic oil level monitoring OLC-D1-S 5.4.7 Oil heater
The OLC-D1-S is an opto-electronic proximity sensor The oil heater ensures the lubricity of the oil even after
that monitors the oil level with infrared light. Depending long standstill periods. It prevents increased refrigerant
on the mounting position and electrical connection, the concentration in the oil and therefore reduction of vis-
same unit can be used for monitoring the minimum and cosity.
maximum oil levels.
The oil heater must be operated while the compressor
The monitoring device comprises two parts: a prism is at standstill in case of
unit and an opto-electronic unit.
• outdoor installation of the compressor,
• The prism unit – a glass cone is mounted directly
• long shut-off periods,
into the compressor housing.
• high refrigerant charge,
• The opto-electronic unit is designated as OLC-D1. It
is not directly connected to the refrigerating circuit. It • possible refrigerant condensation in the compressor.
is screwed into the prism unit and integrated in the
Connection according to Technical Information KT-150.
system's control logic. No external control device is
required.
Isolating the oil separator
Delivery in a pre-setup state Operating at low ambient temperatures or with high
temperatures on the high-pressure side during stand-
If the prism unit of the OLC-D1-S has been ordered
still (e.g. for heat pumps) requires additional isolation of
pre-assembled, the compressor will have already been
the oil separator.
tested as a whole in the factory for strength pressure
and tightness. In this case, it will only be necessary to
screw in the opto-electronic unit and to connect it elec-
trically (see Technical Information ST-130). Sub-
6 Commissioning
sequent tightness testing will not be required in this
case. The compressor has been carefully dried, checked for
tightness and filled with a holding charge (N2) before
When retrofitting, both prism and electronic unit must
leaving the factory.
be mounted. For a detailed mounting description,
please see Technical Information ST-130.
DANGER
Risk of explosion!
5.4.6 Safety devices for pressure limiting (HP and LP) Never pressurize the compressor with oxygen
(O2) or other industrial gases!
• These safety devices are required for securing the
compressor's application range in order to avoid un-
acceptable operating conditions.
• Do not connect any safety devices to the mainten- WARNING
ance connection of the shut-off valve! Risk of bursting!
A critical shift of the refrigerant ignition limit is
• Set cut-in and cut-out pressures according to the ap- possible in case of excess pressure.
plication limits and perform a test to exactly check Do not add a refrigerant (e.g. as a leak indic-
them. ator) to the test gas (N2 or air).
Environmental pollution in case of leakage and
when deflating!

NOTICE

! Risk of oil oxidation!

Check the entire system for strength pressure
and tightness, preferably using dried nitrogen
(N2).
When using dried air: Remove the compressor
from the circuit – make sure to keep the shut-off
valves closed.

26 SB-170-9
7ü0
6.1 Checking pressure strength 6.4 Charging refrigerant
Check the refrigerant circuit (assembly) according to Use only permitted refrigerants, see see chapter Ap-
EN378-2 (or other applicable equivalent safety stand- plication ranges, page 5.
ards). The compressor had been already tested in the
factory for strength pressure. A tightness test is there- DANGER
fore sufficient, see chapter Checking tightness, page Risk of bursting of components and pipelines
27. If you still wish to perform a strength pressure test due to hydraulic excess pressure while feeding
for the entire assembly: liquid.
Serious injuries are possible.
DANGER Avoid overcharging the system with refrigerant
Risk of bursting due to excessive pressure! under all circumstances!
The pressure applied during the test must never
exceed the maximum permitted values! WARNING
Test pressure: 1.1-fold of the maximum allow- Risk of bursting due to counterfeit refrigerants!
able pressure (see name plate). Make a distinc- Serious injuries are possible!
tion between the high-pressure and low-pres- Purchase refrigerants only from reputable man-
sure sides! ufacturers and reliable distributors!

NOTICE

!
6.2 Checking tightness
Risk of wet operation during liquid feeding!
Check the refrigerant circuit (assembly) for tightness, Measure out extremely precise quantities!
as a whole or in parts, according to EN378-2 (or other Maintain the discharge gas temperature at least
applicable equivalent safety standards). For this, create 20 K above the condensing temperature.
an excess pressure, preferably using dried nitrogen.
➙ Before charging with refrigerant:
Observe test pressures and safety reference, see
chapter Checking pressure strength, page 27. ➙ Do not switch on the compressor!
➙ Switch on the oil heater.
6.3 Evacuation
➙ Check the oil level in the compressor.
• Switch on the oil heater.
• Fill liquid refrigerant directly into the condenser or re-
• Open all shut-off valves and solenoid valves. ceiver; on systems with flooded evaporator, maybe
directly into the evaporator.
• Use a vacuum pump to evacuate the entire system,
including the compressor, on the suction side and • Blends must be taken out of the charging cylinder as
the high-pressure side. a solid liquid.
With the vacuum pump shut off, a "standing vacuum" • After commissioning, it may be necessary to add re-
lower than 1.5 mbar must be achieved. frigerant: While the compressor is running, charge
with refrigerant on the suction side, preferably at the
• Repeat the operation several times if necessary.
evaporator inlet. Blends must be taken out of the
charging cylinder as a solid liquid.
NOTICE

! Risk of damage to the motor and compressor!

Do not start the compressor while it is in a va-
cuum!
Do not apply any voltage, not even for testing!

SB-170-9 27
7ü7
6.5 Checks prior to compressor start 6.6 Compressor start
• Oil level (between the middle of the lower sight glass
and the upper area of the upper sight glass). 6.6.1 Checking the rotation direction
• During compressor start, oil temperature must be at
NOTICE

!
least 20°C and 20 K above ambient temperature –
Risk of compressor failure!
that means approximately (at least) 15 K at the
Operate the compressor only in the intended ro-
measuring point directly under the oil sight glass.
tation direction!
• Setting and functions of safety and protection
devices. Even if the protection device SE-E1 or the optional pro-
tection device SE-i1 monitors the rotating field, a test is
• Setpoints of the time relays.
recommended:
• Cut-out pressures of the high-pressure and low-pres-
Rotation direction test with integrated suction shut-off
sure switches.
valve:
• Check if the shut-off valves are opened.
• Connect the pressure gauge to the suction shut-off
valve. Close the valve spindle and open again by
In case of compressor replacement
one turn.
Oil is already in the circuit. It may therefore be neces-
• Let the compressor start shortly (approximately 0.5 ..
sary to drain off some oil.
1 s).
NOTICE • Correct rotation direction: Suction pressure drops im-

! In case of larger oil quantities in the refrigerant

circuit: Risk of liquid slugging when the com-
pressor starts!
Maintain the oil level within the marked sight
mediately.
• Incorrect rotation direction: Suction pressure in-
creases or protection device shuts off.
glass area! • Incorrect rotation direction: Change the poles of the
terminals on the common feed line.
When a reciprocating compressor is replaced:
Direction rotation test without suction shut-off valve:
• Completely remove the oil from the system. The new
• Close the solenoid valves on the evaporator and the
oil is not only more viscous. It is an ester oil with dif-
economiser. The pressure changes measured in
ferent chemical and physical properties.
such a case are much lower than with throttled suc-
tion shut-off valve!
NOTICE

! Risk of damage to the compressor!

The new oil has a great cleaning effect in the re-
frigerant circuit.
On the suction side, mount a cleaning filter suit-
• Let the compressor start shortly (approximately 0.5 ..
1 s).
• Correct rotation direction: Suction pressure drops a
bit.
able for bidirectional operation!
Mesh size: 25 µm • Incorrect rotation direction: Suction pressure stays
the same or increases a bit, or protection device
• Mount a filter for bidirectional operation with perfor- shuts off.
ated metal tubes around the inside and outside dia-
• Incorrect rotation direction: Change the poles of the
meter of the filter element.
terminals on the common feed line.
• After several operating hours: Change the oil filters
After the rotation direction test:
and cleaning filters.
• Let the compressor start while opening slowly the
• If needed, repeat the operation, see chapter Oil
suction shut-off valve.
change, page 31.

28 SB-170-9
7ü1
6.6.2 Lubrication/oil level monitoring 6.6.5 Vibrations and frequencies
• Check the lubrication of the compressor directly after Check the system carefully to detect any abnormal vi-
the compressor start. bration, check particularly pipelines and capillary tubes.
In case of strong vibrations, take mechanical meas-
The oil level must be visible in the zone of both sight
ures: e.g. use pipe clamps or install vibration dampers.
glasses.
• Check the oil level repeatedly within the first hours of NOTICE
operation!
During the start phase, oil foam may arise but its level
should decrease at stable operating conditions. Other-
! Risk of burst pipes and leakages on the com-
pressor and system components!
Avoid strong vibrations!
wise high proportions of liquid in the suction gas are
suspected. 6.6.6 Checking the operating data
• Evaporation temperature
NOTICE

! Risk of wet operation!

Maintain the discharge gas temperature well
above the condensing temperature: at least
20 K.
• Suction gas temperature
• Condensing temperature
• Discharge gas temperature
At least 30 K for R407A, R407F and R22.
– min. 20 K above condensing temperature
NOTICE – min. 30 K above condensing temperature for

! Risk of compressor failure due to liquid slug-

ging!
Before adding larger quantities of oil: check the
oil return!
R407C, R407F and R22
– max. 120°C on the outside of the discharge gas
line
• Oil temperature directly under the oil sight glass
6.6.3 Set high pressure and low pressure switches • Cycling rate
(HP + LP)
• Current values
Check exactly the cut-in and cut-out pressure values
• Voltage
according to the operating limits by testing them.
• Prepare data protocol.
6.6.4 Set the condenser pressure Application limits, see BITZER SOFTWARE, manual
SH-170 and brochure SP-171 (CSH) / SP-172 (CSW).
• Set the condenser pressure so that the minimum
pressure difference is reached within 20 s after the
compressor start.
• Avoid quick pressure reduction with finely stepped
pressure control.
Application limits, see BITZER SOFTWARE, manual
SH-170 and brochure SP-171 (CSH) / SP-172 (CSW).

SB-170-9 29
7ü(
6.6.7 Control logic requirements – Ensure sufficiently high suction gas superheat,
while also taking into account the minimum dis-
NOTICE charge gas temperatures.

! Risk of motor failure!

The specified requirements must be ensured by
the control logic!
– Stable operating mode under all operating and
load conditions (also part-load, summer/winter op-
eration).
• Desirable minimum running time: 5 minutes! – Solid liquid at the expansion valve inlet, during
ECO operation already before entering the liquid
• Switching the compressor off:
subcooler.
When using a star-delta motor, shut it off from the
25%-CR stage! • Avoid refrigerant migration from the high-pressure
side to the low-pressure side or into the compressor
• Minimum standstill time:
during long shut-off periods!
– 5 minutes (CSW105: 10 minutes).
– Always maintain oil heater operation when the
This is the time the control slider needs to reach system is at standstill. This is valid for all applica-
the optimal start position. tions.
– 1 minute. When installing the system in zones where the
temperatures are low, it may be necessary to in-
Only if the compressor has been shut off from the
sulate the oil separator. At compressor start, the
25%-CR stage!
oil temperature, that is measured under the oil
– Also observe minimum standstill times during sight glass, should be 15 .. 20 K above the ambi-
maintenance work! ent temperature.
• Maximum cycling rate: – Automatic sequence change for systems with sev-
eral refrigerating circuits (approximately every 2
– CS.65 and CS.75: max. 6 starts per hour.
hours).
– CS.85, CS.95 and CSW105: max. 4 starts per
– Mount an additional check valve in the discharge
hour.
gas line if no temperature and pressure compens-
• Switching time of the motor contactors: ation is reached even after long standstill times.
– Part winding: 0.5 s. – If needed, mount a time and pressure-dependant
controlled pump down system or liquid separators
– Star-delta: 1 to 2 s for CS.65, CS.75 and CS.85.
on the suction side – particularly for high refriger-
– Star-delta: 1.5 to 2 s for CS.95 and CSW105. ant charges and/or when the evaporator may be-
come hotter than the suction gas line or the com-
pressor.
6.6.8 Particular notes on safe compressor and
system operation • For further information about pipe layout, see
manual SH-170.
Analysis show that compressor failures are most often
due to an inadmissible operating mode. This applies
Information
especially to damage resulting from lack of lubrication:
In the case of refrigerants with low isentropic ex-
• Function of the expansion valve – observe the manu- ponent (e.g. R134a), a heat exchanger between
facturer's notes! the suction gas line and the liquid line may have
a positive effect on the system's operating mode
– Position the temperature sensor correctly at the
and coefficient of performance.
suction gas line and fasten it.
Arrange the temperature sensor of the expan-
– When using a liquid suction line heat exchanger: sion valve as described above.
Position the sensor as usual after the evaporator
and not after the heat exchanger.

30 SB-170-9
7ü)
7 Operation The listed oils, (see chapter Application ranges, page
5), are characterised by their high degree of stability.
An oil change is generally not required when appropri-
7.1 Regular tests
ate suction-side fine filters are mounted or used. In
Check the system at regular intervals according to na- case of compressor or motor damage, it is recommen-
tional regulations. Check the following points: ded performing an acid test. If necessary, carry out
cleaning measures: Mount a bidirectional acid retaining
• Operating data, see chapter Compressor start, page
suction line gas filter and change oil. Purge the system
28.
on the highest point of the discharge side and collect
• Oil supply, see chapter Compressor start, page 28. the refrigerant in a recycling cylinder If necessary,
change filter and oil again after several operating hours
• Safety and protection devices and all components
and purge the system.
for compressor monitoring (check valves, discharge
gas temperature sensors, differential oil pressure
Changing the oil
switches, pressure limiters, etc.).
• Tight seat of electrical cable connections and WARNING
screwed joints. The compressor is under pressure!
Serious injuries are possible.
• Screw tightening torques (see SW-100).
Depressurize the compressor!
• Refrigerant charge. Wear safety goggles!
• Tightness.
• Prepare data protocol. • Drain the oil from the compressor and motor hous-
ing. Oil draining positions on the compressor are the
connection positions 5 and 6, see chapter Connec-
7.2 Locking the protection and monitoring devices
tions and dimensional drawings, page 14.
The compressors are equipped with electronic protec-
• Fill in new oil.
tion and monitoring devices, triggering a lock-out in
case of overload or inadmissible operating conditions. • Dispose of waste oil properly.
Determine and remove the cause before performing a
reset! 8.2 Replace oil filter (CSW105)
➙ Prepare a new oil filter.
• Place a flat pan under the oil valve for maintenance
8 Maintenance (5) and the oil filter flange (18).
Observe the manufacturer’s documentation of the com- • Drain oil and dispose of it properly.
ponents used!
• Open the flange of the oil filter and remove it by
pulling it forward.
8.1 Oil change
The integrated oil filter is mounted on the rear side of
the flange.
NOTICE

! Damage to the compressor caused by degraded

ester oil.
Moisture is chemically bound to the ester oil and
cannot be removed by evacuation.
• Unscrew the oil filter from the flange.
• Mount a new oil filter on the flange.
• Replace the O-ring at the flange.
Proceed with extreme care:
• Insert the flange with the new oil filter, the new flat
Any penetration of air into the system and oil
gasket and the new O-ring.
drum must be avoided under all circumstances.
Use only oil drums in their original unopened
state!

SB-170-9 31
7ü4
 NOTICE 9 Decommissioning

! Risk of damage to the compressor.

Tighten screws and nuts only to the prescribed
tightening torque and, if possible, crosswise in
at least 2 steps.
9.1 Standstill
Leave the oil heater switched on until disassembly.
This prevents increased refrigerant concentration in the
• Charge with new oil. oil.
• Test tightness before commissioning.
WARNING
Risk of refrigerant evaporation from the oil.
8.3 Integrated pressure relief valve Increased risk of flammability, depending on the
refrigerant!
The valve is maintenance-free. Its response pressure
Shut-down compressors or used oil may still
difference is 28 bar.
contain rather high amounts of dissolved refri-
However, after repeated venting, it may leak perman- gerant.
ently because of abnormal operating conditions. The Close the shut-off valves on the compressor
consequences are reduced performance and a higher and extract the refrigerant!
discharge gas temperature.
9.2 Dismantling the compressor
8.4 Integrated check valve
WARNING
After being shut off, the compressor runs reverse for a
The compressor is under pressure!
short time (approx. 5 s, until pressure compensation in
Serious injuries are possible.
the oil separator takes place). When the check valve is
Depressurize the compressor!
damaged or clogged, this time extends. The valve must
Wear safety goggles!
then be changed.

WARNING
Close the shut-off valves on the compressor. Extract
The compressor is under pressure!
the refrigerant. Do not deflate the refrigerant, but dis-
Serious injuries are possible.
pose of it properly!
Depressurize the compressor!
Wear safety goggles! Loosen screwed joints or flanges on the compressor
valves. Remove the compressor from the system; use
hoisting equipment if necessary.
Mounting position: in discharge gas outlet flange below
the discharge shut-off valve or pipe connection. Re-
9.3 Disposing of the compressor
placement see maintenance instructions SW-170.
Drain the oil from the compressor. Dispose of waste oil
properly! Have the compressor repaired or dispose of it
properly!
When returning compressors that have been operated
with flammable refrigerant, mark the compressor with
the symbol "Caution flammable gas", as the oil may still
contain refrigerant.

32 SB-170-9
7üW
10 Tightening torques for screwed connections 10.2 Special screwed connections
Mind when mounting or replacing parts:
Sealing plugs without gasket
• Clean threads carefully.
• Gaskets: Size Brass Steel
1/8-27 NPTF 35 .. 40 Nm 15 .. 20 Nm
– Use new gaskets only!
1/4-18 NPTF 50 .. 55 Nm 30 .. 35 Nm
– Do not oil gaskets with metallic support.
3/8-18 NPTF 85 .. 90 Nm 50 .. 55 Nm
– Flat gaskets may be moistened slightly with oil. 1/2-14 NPTF 95 .. 100 Nm 60 .. 65 Nm
• Wrap plugs with sealing tape or coat them with liquid 3/4-14 NPTF 120 .. 125 Nm 80 .. 85 Nm
sealing agent.
• Admissible screwing methods: Sealing screws or plugs with aluminium gasket

– Tighten with calibrated torque spanner to indic- Size

ated torque.
M10 30 Nm
– Tighten with pneumatic impact wrench and M18 x 1,5 60 Nm
retighten with calibrated torque spanner to indic-
ated torque. M20 x 1,5 70 Nm
M22 x 1,5 80 Nm
– Tighten with electronically controlled angled
wrench to indicated torque. M26 x 1,5 110 Nm
M30 x 1,5 120 Nm
• Tolerance range of tightening torques: ±6% of nom-
inal value M48 x 1,5 300 Nm
G1/4 40 Nm
• Tighten flange connections crosswise and in at least
2 steps (50/100%). Alternatively, they may be G1 1/4 180 Nm
tightened in one step with a multi spindle tool.
Sealing screws or plugs with O-ring
10.1 Normal screwed connections
Size
Size Case A Case B 1 1/8-18 UNEF 50 Nm
M5 7 Nm M22 x 1,5 40 Nm
M6 9 Nm 16 Nm M52 x 1,5 100 Nm
M8 23 Nm 40 Nm
Sealing nuts with O-ring
M10 42 Nm 80 Nm
M12 80 Nm 125 Nm Thread AF
M16 150 Nm 220 Nm 3/4-16 UNF 22 50 Nm
M20 220 Nm 220 Nm 1-14 UNS 30 85 Nm
M20 with CS.105 400 Nm 1 1/4-12 UNF 36 105 Nm
Case A: Screws without flat gasket, property class 8.8 1 3/4-12 UN 50 150 Nm
or 10.9 2 1/4-12 UN 65 180 Nm
Case B: Screws with flat gasket or gasket with metallic These sealing nuts are normally used for Rotalock
support, property class 10.9 screwed joints.
AF: width across flats in mm

SB-170-9 33
7üü
Screws for shut-off valves and counter flanges 10.4 Screwed joints of electrical contacts in the
terminal box
Size Case C Case D
M10 50 Nm Size
M12 36 Nm 100 Nm M4 2 Nm
M16 98 Nm 150 Nm M5 5 Nm
M18 136 Nm 200 Nm M6 6 Nm
M20 175 Nm 200 Nm M8 10 Nm
M24 320 Nm M10 20 Nm
M12 40 Nm ①
Case C: Screws of property class 5.6
M16 40 Nm ①
Case D: Screws of property class 8.8
They can be used for welding flanges as well. ①: with thrust washer

10.3 Sight glasses 10.5 Screws inside the compressor

Also mind when mounting or replacing: Set screws at shaft seals

• Tighten sight glasses only with calibrated torque
spanner to indicated torque. Do not use a pneumatic Size
impact wrench. M5 3 .. 5 Nm
• Tighten flanges of sight glasses in several steps to M6 5 .. 9 Nm
indicated torque. M8 10 Nm
• Check sight glass visually in detail before and after
mounting. Pressure relief valve
• Test changed component for tightness.
Size
Sight glasses with sealing flange 3/4-14 NPTF 15 .. 20 Nm
This valve vents from the pressure side (HP) to the
Screw size suction side (LP) inside the compressor if the HP pres-
M8 14 Nm sure exceeds the maximum allowable pressure.
M10 18 Nm

Sight glasses with union nut

Size AF
1 3/4-12 UN 50 150 Nm
2 1/4-12 UN 65 180 Nm
AF: width across flats in mm

Screwed sight glass

Size
1 1/8-18 UNEF 50 Nm

34 SB-170-9
7üM
Notes

N
Notes

N
80440806 // 03.2018

Subject to change
Änderungen vorbehalten
Toutes modifications réservées

BITZER Kühlmaschinenbau GmbH

Eschenbrünnlestraße 15 // 71065 Sindelfingen // Germany
Tel +49 (0)70 31 932-0 // Fax +49 (0)70 31 932-147
bitzer@[Link] // [Link]

Änderungen vorbehalten // Subject to change // Änderungen vorbehalten // Toutes modifications réservées80440806 // 02.2018 7M7
 Appendix

Compressor part list

OPERATING
SPARE LIST
INSTRUCTIONS
PARTS
ERSATZTEILLISTE
BETRIEBSANLEITUNG
LISTE DES PIÈCES
INSTRUCTION DÉTACHÉES
DE SERVICE SE-171-1
SE-160-4
KB-540-3

CSH7553-50Y.. CSH7593-110(Y)
CSH6551-35Y.. CSH6591-60Y
CSW7573-60Y.. CSW7593-90(Y)
SEMI-HERMETIC COMPACT SCREW COMPRESSORS
SEMI-HERMETIC COMPACT
HALBHERMETISCHE SCREW COMPRESSORS
KOMPAKT-SCHRAUBENVERDICHTER
HALBHERMETISCHE KOMPAKT-SCHRAUBENVERDICHTER
COMPRESSEURS À VIS HERMÉTIQUES ACCESSIBLES COMPACTES
COMPRESSEURS À VIS HERMÉtiques accessibles compacts
Wichtige Hinweise für Important recom- Recommendation 
den Benutzer mendations for the importante pour le client
user
Eine ordnungsgemäße Bearbeitung L‘éxécution conforme d‘une commande de
Ihres Ersatzteilauftrages kann nur bei pièces détachées ne peut être faite qu‘avec
An order can only be executed exactly
vollständigen Angaben erfolgen. l‘indication complète des coordonnées.
if a full designation is given.
Bestellbeispiel: Exemple de commande:

Stück Benennung Typ Art.-Nr. Fabrikationsnummer

Quantity Description Type Ref. nr. Serial number
Quantité Désignation Type Réf. no. No. de fabrication

1 Dichtungssatz CSH7553-50 Y 372 833 01 1 078 001 001

Set of gasket
Jeu de joints

Sind bei einem Teil Änderungsstufen In cases where stages of modification S’il s’agit d’une pièce ayant subie des
vermerkt, muß neben der Art.-Nummer are indicated, please give the compres- modifications, veuillez indiquer en dehors
auch die Fabrikationsnummer oder die sor serial number as well as the ref. du numéro de référence de la pièce le
Änderungsstufe angegeben werden. number, without this latest design will numéro de fabrication du compresseur à
Werden keine Angaben gemacht, wird be supplied. réparer. Sans ces coordonnées il vous
die neueste Teileausführung geliefert. sera livré d’office la pièce la plus récente.

Verdichtertypen, die älter als 10 Compressor types older than 10 Les types de compresseurs qui sont
Jahre sind, werden in dieser Liste years are not entered any more in plus âgés que 10 ans ne figurent plus
nicht mehr aufgeführt. this list. dans la liste.

Legende Legend Légende

Artikel-Nr. in Klammern: Ref. no. in brackets: Réf. no. entre paranthèses:

(123 456 78)
nicht mehr lieferbar no more available non plus livrable
nicht mehr lieferbar, aber non plus livrable, mais inter-
no more available, but inter-
(123 456 78)↓ austauschbar durch nächste changeable par le prochain no. de mo-
changeable by next modification step
Änderungsstufe dification

[incl.17,23] enthält Pos. 17 und 23 containing item 17 and 23 inclus no. 17 et 23

 17,23 bereits enthalten in Pos. 17 und 23 already contained in item 17 and 23 déjà contenu dans no. 17 et 23

Pos.-Nr. in Klammern: Item no. in brackets: pos. no. in brackets:

(23)
nicht in der Zeichnung dargestellt not shown in the exploded view ne sont pas indiquées sur l’éclaté

 Fortsetzung der Pos. nächste Seite Item continued next page No. continué la page suivante

2 SE-171-1
Die Tabelle zeigt die in dieser Ersatz- The table shows the types and the abb- Le tableau indique les types et les abbre-
teilliste enthaltenen Typen und die ver- reviations used in the spare part list: viations utilisés dans cette liste de pièces
wendeten Abkürzungen: détachées:

CSH75.. CSH7553-50Y CSW75.. CSW7573-60Y

CSH7553-70(Y) CSW7573-70(Y)
CSH7563-60Y CSW7583-70Y
CSH7563-80(Y) CSW7583-80(Y)
CSH7573-70Y CSW7593-80Y
CSH7573-90(Y) CSW7593-90(Y)
CSH7583-80Y
CSH7583-90Y
CSH7583-100(Y)
CSH7593-90Y
CSH7593-100Y
CSH7593-110(Y)

SE-171-1 3
4
CSH75..
CSW75..

SE-171-1
SE-171-1
CSH75..
CSW75..

5
6
CSH75..
127 157
145 156
126 161 150
131 120 146 155
125 154
124

123 147 152

135 151 170
121 148
136 172
174
175
126 170
175
160

176
125
268
265 130 140
264 165 274 273 199
129
162 164 272 196
195
168 166 194
267
266 167

270
269 197
263

198

189 220
271 225 224
262 223
222
248 221
168 247
246
261

260 220
226 221
278
227
258 260 257
259 228
255
254 205
230 231 256 200
250 254
256 251 250
206
229 251
256
207
208

SE-171-1
 CSW75..

SE-171-1 7
8
CSH7553/63/73
CSW7573
CS.7583/-93 Seite 9
CS.7583/-93 Page 9

SE-171-1
SE-171-1
CSH7583/93
CSW7583/93
CSH7553/-63/-73 Seite 8
CSH7553/-63/-73 Page 8
CSW7573 Seite 8
CSW7573 Page 8

9
10
CSH75..
CSW75..

SE-171-1
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

1 CS.75.. 1 372 833 01 Dichtungssatz

Set of gasket
Jeu de joints
[incl.53,56,75,81,90,124,130,154,160,172,175,181,183
185,211,213,227,231,237,243,245,254,258,260,267,362
373,375,382,401,420,432,457,482]

2 CSH7553-.. 1 302 575 51 Nebenläufer Ø 118

Female rotor
CSH7563-.. 1 302 575 50 Ø 118
Rotor secondaire
CS.7573-.. 1 302 575 49 [incl.13] Ø 118
CS.7583-.. 1 1 (302 575 25) ↓ Nur lieferbar zusammen mit Haupt- Ø 129
läufer Pos. 3
1 2 ca. 12/11 302 575 40 Ø 129
Fabrikationsnummer des Verdich-
ters unbedingt erforderlich [incl.13,20]
CS.7593-.. 1 1 (302 575 26) ↓ Ø 129
Only available as complete
1 2 ca. 12/11 302 575 41 assembly together with item 3 Ø 129
Indication of compressor serial [incl.13,20]
number imperative

Livrable seulement ensemble avec

rotor principal no. 3
Précisez impérativement numéro de
fabrication du compresseur

3 CSH7553-.. 1 302 574 03 Hauptläufer Ø 145

Male rotor
Rotor principal
CSH7563-.. 1 302 574 02 Ø 145
[incl.10]

CS.7573-.. 1 302 574 01 Nur lieferbar zusammen mit Ø 145

Nebenläufer Pos. 2
Fabrikationsnummer des Verdich-
CS.7583-.. 1 1 (302 574 34) ↓ ters unbedingt erforderlich Ø 161
1 2 ca. 12/11 302 574 52 Only available as complete Ø 161
assembly together with item 2 [incl.10,21]
Indication of compressorserial
CS.7593-.. 1 1 (302 574 35) ↓ number iperative Ø 161
1 2 ca. 12/11 302 574 53 Ø 161
Livrable seulement ensembleavec
rotor secondaire no. 2 [incl.10,21]
Précisez impérativement numéro de
fabrication du compresseur

4 CSH7553-50 1 384 001 33 Passfeder A 12 x 8 x 205

CSH7553-70 Parallel key DIN 6885
CSH7563-60 Clavette paralléle
CSH7563-80
CSH7573-70
CSH7583-80
CSW7573-60
CSW7573-70
CSW7583-70
CSW7583-80
CSW7593-80
CSH7573-90 1 384 001 34 A 12 x 8 x 230
CSH7583-90 DIN 6885
CSH7583-100
CSH7593-90
CSH7593-100
CSH7593-110
CSW7593-90

SE-171-1 11
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

5 CSH7553-.. 1 300 315 05 Druckflansch

CSH7563-.. Discharge flange
CSH7573-.. Bride de pression
CSH7583-.. 1 300 322 09
CSH7593-.. 1 300 322 10
CSW7573-.. 1 300 315 04
CSW7583-.. 1 300 322 07 nur auf Anfrage !
only upon request !
CSW7593-.. 1 300 322 08 seulement sur demande !

7 CSH7553-.. 1 1 314 008 31 Öldüse M8

CSH7563-.. Oil orifice
0 2 ca. 01/12 —
CSH7573-.. Orificie d´huile
CSW7573-..

8 CSH7553-.. 1 1 314 008 31 Öldüse M8

CSH7563-.. Oil orifice
0 2 ca. 01/12 —
CSH7573-.. Orificie d´huile
CSW7573-..

9 CSH75.. 2 383 011 11 Zylinderstift Ø 16 m6 x 45

CSW75.. Parallel pin EN ISO 8735
Goupille cylindrique

10 CSH75.. 1 374 100 13 Kolbenring Ø 71 x 3,9

CSW75.. Piston ring
Segment de piston
3

13 CSH75.. 1 374 100 14 Kolbenring Ø 56 x 3

CSW75.. Piston ring
Segment de piston
2

14 CSH75.. 1 386 200 25 Zylinder-Rollenlager Ø 110 x Ø 50 x 40

CSW75.. Cylindrical roller bearing NU 2310 [Link].2
Roulement à aiguilles cylindri-
ques
 18

15 CSH75.. 1 386 200 26 Zylinder-Rollenlager Ø 90 x Ø 40 x 33

CSW75.. Cylindrical roller bearing NU 2308 [Link].2
Roulement à aiguilles cylindri-
ques
 18

16 CSH75.. 2 386 100 11 Schräg-Kugellager Ø 110 x Ø 50 x 27

CSW75.. Angular ball bearing 7310 [Link]
Roulement butée à billes
 18

17 CSH75.. 2 386 100 12 Schräg-Kugellager Ø 90 x Ø 40 x 23

CSW75.. Angular ball bearing 7308 [Link]
Roulement butée à billes
 18

18 CSH75.. 1 386 602 01 Wälzlagersatz komplett Satz = 9 Stück

CSW75.. Set of bearing complete Set = 9 pieces
Jeu de coussinet complet Jeu = 9 pièces
[incl.14,15,16,17,61,62]

20 CSH7553-.. 1 381 902 07 Nutmutter M 40 x 1,5

CSH7563-.. Grooved nut
CSH7573-.. Écrou de réglage
CSH7583-.. 1 1 381 902 07 M 40 x 1,5
CSH7593-..
1 2 ca.12/11 381 921 01 M 40 x 1,5
CSW7583-..
2
CSW7593-..

12 SE-171-1
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

21 CSH7553-.. 1 381 902 06 Nutmutter M 50 x 1,5

CSH7563-.. Grooved nut
CSH7573-.. Écrou de réglage
CSH7583-.. 1 1 381 902 06 M 50 x 1,5
CSH7593-..
1 2 ca.12/11 381 921 02 M 50 x 1,5
CSW7583-..
3
CSW7593-..

23 CSH7553-.. 1 314 077 01 Düse M5

CSH7563-.. Orifice
CSH7573-..
CSW7573-.. — — —
CSH7583-.. 2 314 008 31 M8
CSH7593-..
CSW7583-.. 2 314 008 25 M8
CSW7593-..

24 CS.7583-.. 1 312 907 01 Zwischenring Ø 55 x Ø 40 x 23

CS.7593-.. Intermediate ring
Bague intermédiaire

25 CS.7583-.. 1 312 906 01 Zwischenring Ø 66 x Ø 50 x 27

CS.7593-.. Intermediate ring
Bague intermédiaire

40 CSH7553-50 1 346 635 43 Einbaumotor Ø 257

Built-in-motor
CSH7563-60 1 346 645 43
Moteur incorporé
CSW7573-60
(Standardspannung)
CSH7553-70 1 346 656 43 (Standard voltages)
CSH7573-70 (Voltages standard)
CSW7573-70
CSW7583-70
Part winding
CSH7563-80 1 346 667 43 380...415 V - 3- 50 Hz
CSH7583-80 440...480 V - 3- 60 Hz
CSW7583-80
CSW7593-80
CSH7573-90 1 346 671 43
CSH7583-90
CSH7593-90 Andere Spannungen und Strom-
arten auf Anfrage
CSW7593-90
Other voltages and kinds of current
CSH7583-100 1 346 681 43 on request
CSH7593-100 Des autres voltages et genres de
courant sur demande
CSH7593-110 1 346 691 43

43 CSH75.. 1 384 003 12 Passfeder A 12 x 6 x 185

CSW75.. Parallel key DIN 6885 BL.3
Clavette paralléle

SE-171-1 13
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

44 CSH7553-50 1 380 069 02 Sechskantschraube M 16 x 55

CSH7563-60 Hexagon head screw DIN 931-10.9
CSH7553-70 Vis á tête hexagonale
CSH7573-70
CSH7563-80
CSH7583-80
CSW7573-60
CSW7573-70
CSW7583-70
CSW7583-80
CSW7593-80
CSH7573-90 1 380 069 04 M 16 x 80
CSH7583-90 DIN 931-10.9
CSH7593-90
CSW7593-90
CSH7583-100 1 380 069 10 M 16 x 90
CSH7593-100 ISO 4014-10.9
CSH7593-110 1 380 069 05 M 16 x 100
DIN 931-10.9

46 CSH75.. 1 1 (302 905 03)↓ Sicherungsscheibe

CSW75.. Thrust washer
1 2 ca.01/12 313 205 01
Rondelle de sécurité

48 CSH7553-50 1 311 000 15 Distanzhülse Ø 62 x Ø 48 x 62

Spacer sleeve
CSH7563-60 1 311 000 13 Ø 62 x Ø 48 x 51
Douille d’espacement
CSW7573-60
CSH7553-70 1 311 000 12 Ø 62 x Ø 48 x 19
CSH7573-70
CSW7573-70
CSW7583-70
CSH7563-80 — — —
CSH7573-90
CSH7583-80
CSH7583-90
CSH7583-100
CSH7593-90
CSH7593-100
CSH7593-110
CSW7583-80
CSW7593-80
CSW7593-90

49 CSH7553-.. 1 320 102 02 Abdeckblech Ø 75 x Ø 48

CSH7563-.. covering plate
CSH7573-.. chapeau
CSW7573-..

52 CSH75.. 1 366 114 13 Verschluss-Schraube M 22 x 1,5

CSW75.. Sealing screw DIN 910-5.8
Vis de fermeture

53 CSH75.. 1 382 403 05 Aluminium-Dichtring A 22 x 27 x 1,5

CSW75.. Aluminium gasket ring
Joint annulaire d'aluminium
1

54 CSH75.. 1 383 011 21 Zylinderstift 16 m6 x 40

CSW75.. Parallel pin EN ISO 8733
Goupille cylindrique

14 SE-171-1
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

55 CSH7553-.. 1 361 106 01 Druckentlastungs-Ventil Ø 45,6 x 77,8

CSH7563.. Pressure relief valve
CSH7573-.. Soupape de décharge
CSW7573-..
CSH7583-.. 1 361 106 02 Ø 59,2 x 100
CSH7593-..
CSW7583-..
CSW7593-..

56 CSH7553-.. 1 372 001 10 O-Ring Ø 39 x 3

CSH7563.. O-ring
CSH7573-.. Joint annulaire
CSW7573-.. 1
CSH7583-.. 1 372 021 10 Ø 53 x 3
CSH7593-..
CSW7583-..
CSW7593-..

57 CSH75.. 1 314 021 22 Distanzring Ø 110 x Ø 96 x 27

CSW75.. Spacer ring
Bague d’arrét

58 CSH75.. 1 314 020 15 Deckel Ø 90 x 13

CSW75.. Cover
Couvercle

59 CSH75.. 1 382 242 04 Sprengring Ø 37,8 x 2,3 x 1,5 St

CSW75.. Snap ring
Anneau-ressort

60 CSH75.. 1 314 021 10 Distanzring Ø 68 x Ø 60 x 15

CSW75.. Spacer ring
Bague d’espacement

61 CSH75.. 1 386 200 26 Zylinder-Rollenlager Ø 90 x Ø 40 x 33

CSW75.. Cylindrical roller bearing NU 2308 [Link].2
Roulement à aiguilles cylindri-
ques
 18

62 CSH75.. 2 386 200 18 Zylinder-Rollenlager Ø 110 x Ø 60 x 22

CSW75.. Cylindrical roller bearing NU 212 [Link].2
Roulement à aiguilles cylindri-
ques
 18

64 CSH7553-.. 1 306 946 01 Distanzscheibe Ø 118,8 x 59

Spacer bush
CSH7563-.. 1 306 947 01 Ø 118,8 x 38
Bague d’espacement
CSH7573-.. 1 306 939 01 Ø 118,8 x 8
CSW7573-..
CSH7583-.. 1 306 933 01 Ø 129,8 x 35
CSW7583-..
CSH7593-.. 1 306 932 01 Ø 129,8 x 8
CSW7593-..

65 CSH7553-.. 4 380 343 01 Zylinderschraube mit M 6 x 60

Innensechskant ISO 4762-10.9
Hexsocket cheese head screw
CSH7563-.. 4 380 306 55 Vis à tête cylindrique á six pans M 6 x 40
creux DIN 912-10.9
CSH7573-.. 4 380 312 81 M 6 x 12
CSW7573-.. DIN 6912-10.9
CSH7583-.. 4 380 343 04 M 6 x 35
CSW7583-.. ISO 4762-10.9
CSH7593-.. 4 380 312 81 M 6 x 12
CSW7593-.. DIN 6912-10.9

SE-171-1 15
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

67 CSH75.. 1 360 212 07 Tauchrohr Ø 27 x 147

CSW75.. Dip tube
Tube plongeur

68 CSH75.. 1 382 231 25 Sicherungsring 36 x 1,5

CSW75.. Retaining ring with lugs DIN 472 St
Circlip d’arrêt

69 CSH75.. 1 312 036 01 Sitzring komplett Ø 36 x 8

CSW75.. Ring complete
Bague complet

70 CSH75.. 1 313 000 25 Scheibe Ø 35,8 x Ø 22 x 2

CSW75.. Disk
Disque

71 CSH75.. 1 302 9... Schieber

CSW75.. Slider
Tiroir
 76
nicht einzeln lieferbar !
not separatly deliverable !
ne pent pas livré séparement !

72 CSH75.. 1 384 902 03 Nutenstein 16 x 22 x 20

CSW75.. Sliding block CK 45
Conliseau

73 CSH75.. 1 380 306 52 Zylinderschraube mit M 6 x 25

CSW75.. Innensechskant DIN 912-10.9
Hexsocket cheese head screw
Vis à tête cylindrique á six pans
creux

74 CSH7553-.. 7 380 306 42 Zylinderschraube mit M 12 x 35

CSH7563-.. Innensechskant DIN 912-10.9
CSH7573-.. Hexsocket cheese head screw
CSW7573-.. Vis à tête cylindrique á six pans
creux
CSH7583-.. 5 380 306 42
CSH7593-..
CSW7583-..
CSW7593-..

76 CSH7553-.. 1 300 224 07 Gehäuse mit Schieber

CSH7563-.. Housing with slider
Corps avec tiroir
CSH7573-.. 1 300 224 08 [incl.71]
CSH7583-.. 1 300 243 11
CSH7593-.. 1 300 243 12
CSW7573-.. 1 300 224 09
CSW7583-.. 1 300 243 13 nur auf Anfrage !
CSW7593-.. 1 300 243 14 only upon request !
seulement sur demande !

77 CSH75.. 1 314 020 08 Deckel Ø 134 x 13

CSW75.. Cover
Couvercle

78 CSH75.. 4 380 154 04 Sechskantschraube M 6 x 16

CSW75.. Hexagon head screw DIN 933-10.9
Vis à tête hexagonale

79 CSH75.. 1 382 500 01 Dichtlippe Ø 60 x Ø 75 x 5,5

CSW75.. Lip seal
Joint à lévres

16 SE-171-1
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

81 CSH7583-.. 3 372 021 20 O-Ring Ø 28 x 1,7

CSH7593-.. O-ring
CSW7583-.. Joint annulaire
CSW7593-.. 1

82 CSH7583-.. 2 314 008 31 Düse M8

CSH7593-.. Orifice
CSW7573-.. — —
CSW7583-..
CSW7593-..

89 CSH75.. 1 343 433 00 Bausatz Stromdurchführungs-Platte

CSW75.. Terminal plate kit
Kit de plaque á bornes
[incl.90,91,92,93,95,96,97,453,454,457,466,467,468,
469,470,474,475,476,478,482,490,491,492,493,494]

90 CSH75.. 1 372 421 03 Dichtung 222 x 140 x 1

CSW75.. Gasket
Joint
 1,89,98

91 CSH75.. 1 345 500 10 Stromdurchführungs-Platte 220 x 140 x 50

CSW75.. Terminal plate
Plaque á bornes
 89,98

92 CSH75.. 6 382 002 04 Scheibe B 10,5

CSW75.. Washer DIN 125
Rondelle
 89,98

93 CSH75.. 6 381 109 01 Sechskantmutter M 10

CSW75.. Hexagon nut
Écrou hexagonal
 89,98

94 CSH75.. 1 380 907 01 Gewindebolzen B-M 10 x 80

CSW75.. Threaded bolt DIN 976-verz.
Goupille fileté
 89,98

95 CSH75.. 10 380 306 83 Zylinderschraube mit M 10 x 25

CSW75.. Innensechskant DIN 912-10.9
Hexsocket cheese head screw
Vis à tête cylindrique á six pans
creux
 89,98

96 CSH75.. 2 381 101 56 Sechskantmutter M 10

CSW75.. Hexagon nut DIN 934-verz.
Écrou hexagonal
 89,98

97 CSH75.. 2 311 012 04 Distanzhülse Ø 20 x Ø 10 x 15

CSW75.. Spacer sleeve
Douille d’espacement
 89,98

(98) CSH75.. 1 345 501 06 Stromdurchführungs-Platte komplett

CSW75.. Terminal plate complete
Plaque á bornes compléte
[incl.90,91,92,93,94,95,96,97]

110 CSW75.. 1 366 114 13 Verschluss-Schraube M 22 x 1,5

Sealing screw DIN 910 - 5.8
Vis de fermeture
oder/or/ou
360 128 01 Bausatz Ölrückführung Ø 16
Oil return kit
retour d‘huile, kit de montage
[incl.111,112,114,115]

SE-171-1 17
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

111 CSW75.. 1 366 000 14 Rohranschluss Ø 16

Pipe connection
Raccord de tube
 110

112 CSW75.. 1 372 200 02 Dichtring Ø 19,1 x 1,5

Joint ring
Joint annulaire
 1,110

114 CSW75.. 1 365 210 08 Einschraub-Nippel M 22 x 1,5 x 1“ - 14UNS

Screwed nipple
Nipple á vis
 110

115 CSW75.. 1 382 403 05 Aluminium-Dichtring Ø 22 x Ø 27 x 1,5

Aluminium gasket ring DIN 7603
Joint annulaire d‘aluminium
 1,110

120 CSH75.. 1 361 338 08 Saug-Absperrventil komplett Ø 76 (3 1/8“) DN 80

CSW75.. Suction shut-off valve complete
Vanne d’arrêt à l’aspiration
complète
[inc.121,123,124,125,126,127]

121 CSH75.. 1 375 014 05 Schutzkappe

CSW75.. Protecting cap
Chapeau de protection
 120

123 CSH75.. 1 366 110 02 Verschluss-Stopfen 1 /4“ - 18 NPTF

CSW75.. Sealing plug
Bouchon de fermeture
 120

124 CSH75.. 1 372 303 03 Dichtung Ø 105 x Ø 85 x 2

CSW75.. Gasket
Joint
 1,120

125 CSH75.. 1 365 321 05 Rohr-Anschluss Ø 76 (3 1/8“) St. DN 80

CSW75.. Pipe connection
Raccord de tube
 120

126 CSH75.. 1 367 121 03 Spannplatte 142 x 142

CSW75.. Clamping plate
Plaque de serrage
 120

127 CSH75.. 4 380 111 01 Sechskantschraube M 18 x 70

CSW75.. Hexagon head screw DIN 933-8.8
Vis á tête hexagonale
 120

129 CSH75.. 1 320 507 06 Verschluss-Scheibe Ø 105 x 6

CSW75.. Blanking plate
Rondelle de fermeture

130 CSH75.. 1 372 303 03 Dichtung Ø 105 x 86 x 2

CSW75.. Gasket
Joint
1

131 CSH75.. 4 380 009 54 Sechskantschraube M 16 x 140

CSW75.. Hexagon head screw DIN 931-8.8
Vis á tête hexagonale

135 CSH75.. 4 380 009 57 Sechskantschraube M 16 x 70

CSW75.. Hexagon head screw DIN 933-8.8
Vis á tête hexagonale

18 SE-171-1
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

136 CSH75.. 4 311 009 06 Zentrierstück Ø 40 x Ø 17 x 8

CSW75.. Centering piece
Pièce de centrage

140 CSH75.. 1 369 108 01 Rückschlagventil komplett

CSW75.. Check valve complete
Clapet de retenue complet
[incl. 141,142,143,144]

(141) CSH75.. 1 382 231 23* Sicherungsring Ø 58 x 2

CSW75.. Retaining ring with lugs DIN 472 St
Circlip d’arrèt
 140
*nicht einzeln lieferbar
cannot be delivered separately
pas livrable séparément

(142) CSH75.. 1 312 004 04* Sitzring Ø 57,8

CSW75.. Ring
Bague
 140
*nicht einzeln lieferbar
cannot be delivered separately
pas livrable séparément

(143) CSH75.. 1 325 030 02* Kegeldruckfeder Ø 54

CSW75.. Spring
Ressort
 140
*nicht einzeln lieferbar
cannot be delivered separately
pas livrable séparément

(144) CSH75.. 1 313 103 01* Dichtscheibe

CSW75.. Sealing washer
Joint plat
 140
*nicht einzeln lieferbar
cannot be delivered separately
pas livrable séparément

145 CSH75.. 4 380 109 09 Sechskantschraube M 16 x 55

CSW75.. Hexagon head screw DIN 933-8.8
Vis á tête hexagonale

146 CSH75.. 1 367 121 02 Spannplatte 110 x 110

Clamping plate
CSW75.. 1 367 121 13 Plaque de serrage

147 CSH75.. 1 365 321 03 Rohr-Anschluss Ø 54 ( 2 1/8“) St

Pipe connection
CSW75.. 1 365 321 23 Raccord de tube Ø 64 (2 5/8“) St

148 CSH75.. 1 320 507 02 Verschluss-Scheibe Ø 76 x 5

CSW75.. Blanking plate
Rondelle de fermeture

150 CSH75.. 1 361 338 04 Druck-Absperrventil komplett Ø 54 (2 1/8“) DN 50

Discharge shut-off valve compl.
Vanne d’arrèt au refoulement
CSW75.. 1 361 338 05 complète Ø 64 (2 5/8“) DN 50
[inc.151,152,154,155,156,157]

151 CSH75.. 1 375 014 05 Schutzkappe

CSW75.. Protecting cap
Chapeau de protection
 150

152 CSH75.. 1 366 110 08 Verschluss-Stopfen 1/4“ - 18 NPTF

CSW75.. Sealing plug
Bouchon de fermeture
 150

SE-171-1 19
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

154 CSH75.. 1 372 303 02 Dichtung Ø 75 x Ø 61 x 2

CSW75.. Gasket
Joint
 1,150

155 CSH75.. 1 365 321 03 Rohr-Anschluss Ø 54 ( 2 1/8“) St

Pipe connection
CSW75.. 1 365 321 23 Raccord de tube Ø 64 (2 5/8“) St
 150

156 CSH75.. 1 367 121 02 Spannplatte 110 x 110

Clamping plate
CSW75.. 1 367 121 13
Plaque de serrage
 150

157 CSH75.. 4 380 109 09 Sechskantschraube M 16 x 55

CSW75.. Hexagon head screw DIN 933-8.8
Vis á tête hexagonale
 150

160 CSH75.. 1 372 303 02 Dichtung Ø 75 x Ø 61 x 2

CSW75.. Gasket
Joint
1

161 CSH75.. 4 380 009 58 Sechskantschraube M 16 x 110

CSW75.. Hexagon head screw DIN 933-8.8
Vis á tête hexagonale

162 CSH75.. 1 361 501 01 Schrader-Ventil 1/

8“- 27 NPTF
CSW75.. Schrader valve
Vanne Schrader

164 CSH75.. 1 382 001 57 Scheibe A 17

CSW75.. Washer
Rondelle

165 CSH75.. 1 380 307 08 Zylinderschraube mit M 16 x 25

CSW75.. Innensechskant DIN 912-10.9
Hexsocket cheese head screw
Vis à tête cylindrique á six pans
creux

166 CSH75.. 1 366 100 01 Verschluss-Stopfen 1 /8“-27 NPTF

CSW75.. Sealing plug
Bouchon de fermeture

167 CSH75.. 1 366 100 01 Verschluss-Stopfen 1 /8“-27 NPTF

CSW75.. Sealing plug
Bouchon de fermeture

168 CSH75.. 2 366 100 01 Verschluss-Stopfen 1 /8“-27 NPTF

CSW75.. Sealing plug
Bouchon de fermeture

170 CSH75.. 1 366 114 13 Verschluss-Schraube M 22 x 1,5

Sealing screw DIN 910 - 5.8
oder/or/ou Vis de fermeture
1 361 329 16 ECO-Anschluss mit Ventil Ø 22
ECO connection with valve
Raccord pour ECO avec robinet
[incl.172,174,175,176]
CSW75.. 1 366 114 14 Verschluss-Schraube M 26 x 1,5
Sealing screw DIN 910 - 5.8
oder/or/ou Vis de fermeture
1 361 330 03 ECO-Anschluss mit Ventil Ø 22
ECO connection with valve
Raccord pour ECO avec robinet
[incl.171,172,174,175,176]

20 SE-171-1
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

171 CSW75.. 1 361 321 06 Absperrventil (ECO) Ø 22L (7/8")

Valve (ECO) 1 1/4“ - 12UNF
Robinet (ECO)
[incl. 176]
 170

172 CSH75.. 1 372 200 03 Dichtring Ø 25,4 x 1,5

CSW75.. Joint ring 1 1/4“ PTFE
Joint annulaire
 1,170

174 CSH75.. 1 365 210 05 Einschraub-Nippel M 22 x1,5 x 1/4“ - 12 UNF

Screwed nipple
Nipple á vis
CSW75.. 1 365 210 12 M 26x1,5 x 1 1/4“ -12 UNF
 170

175 CSH75.. 1 382 403 05 Aluminium-Dichtring A 22 x 27 x 1,5

Aluminium gasket ring
Joint annulaire d'aluminium
CSW75.. 1 382 403 04  1,170 A 26 x 31 x 2

176 CSH75.. 1 375 014 01 Schutzkappe 3

/4“ 16 UNF
CSW75.. Protecting cap
Chapeau de protection
 171

184 CSH75.. 1 380 354 06 Gewindestift M6x8

Set screw DIN EN ISO 4027
Vis sans tête
 199

185 CSH75.. 1 372 704 04 Dichtung 91 x 52 x 1,5

Gasket
Joint
 1,199

186 CSH75.. 1 367 015 19 Flansch 91 x 52 x 13

Flange 1
/8“ - 27 NPTF
Bride
 199

187 CSH75.. 1 366 110 01 Verschluss-Stopfen 1/

8 “- 27 NPTF
Sealing plug
Bouchon de fermeture
 198,199

188 CSH75.. 2 380 306 32 Zylinderschraube mit M 10 x 30

Innensechskant (Blindflansch) DIN 912-10.9
Hexsocket cheese head screw
(blind flange)
Vis à tête cylindrique á six pans
creux (bride d'obturation)
 198,199

189 CSH75.. 1 372 932 02 Dichtung 91 x 52 x 1

Gasket
Joint
 1,199

190 CSH75.. 2 382 403 05 Aluminium-Dichtring Ø 22 x Ø 27 x 1,5

Aluminium gasket ring DIN 7603
Joint annulaire d‘aluminium
 1,199

191 CSH75.. 2 365 210 08 Einschraub-Nippel M 22 x 1,5 x 1“ - 14 UNS

Screwed nipple
Nipple á vis
 199

SE-171-1 21
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

192 CSH75.. 2 372 200 02 Dichtring Ø 19,1 x 1,5

Joint ring
Joint annulaire
 1,199

193 CSH75.. 2 366 001 16 Winkelrohranschluss 1 “ - 14 UNS

Pipe connection Ø 16
Raccord de tube
 199

194 CSH75.. 2 380 306 90 Zylinderschraube mit M 10 x 55

Innensechskant DIN 912-10.9
Hexsocket cheese head screw
Vis à tête cylindrique á six pans
creux
 199

195 CSH75.. 1 343 313 07 Spule 230V, 50Hz

Coil
1 343 313 08 Bobine 120V, 60Hz
1 343 313 09  198 240V, 60Hz

196 CSH75.. 1 381 909 10 Spulenbefestigung

Coil fixation
Fixation de bobine
 198

197 CSH75.. 1 389 019 01 Gerätesteckdose komplett

Electr. connector complete
Prise de courant complète
 198

198 CSH75.. 1 367 905 03 Anschlussflansch komplett 230V, 50/60Hz

Pipe connection complete
1 367 905 05 120V, 60Hz
Raccord de tube complet
[incl.187,195,196,197]
 199

199 CSH75.. 1 367 912 05 Bausatz Anschlussflansch für 230V

Ölkühler
1 367 912 09 Pipe connection for oil cooler 120V
complete
Raccord de tube complet pour
refroidisseur d’huile
[incl.189,190,191,192,193
194,198]

200 CSH75.. 1 370 012 06 Bausatz Schwingungsdämpfer 4 Stück

CSW75.. Vibration damper set 4 pieces
Amortisseur devibrations-joi 4 pièces

205 CSH75.. 1 327 309 03 Befestigungsschiene 360 x 50 x 45

CSW75.. Fixing rails
Rails de fixation

206 CSH75.. 2 380 312 71 Zylinderschraube mit M 16 x 25

CSW75.. Innensechskant DIN 912-10.9
Hexsocket cheese head screw
Vis à tête cylindrique á six pans
creux

207 CSH75.. 1 327 302 06 Befestigungsschiene 360 x 50 x 20

CSW75.. Fixing rails
Rails de fixation

208 CSH75.. 2 380 312 71 Zylinderschraube mit M 16 x 25

CSW75.. Innensechskant DIN 912-10.9
Hexsocket cheese head screw
Vis à tête cylindrique á six pans
creux

22 SE-171-1
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

213 CSH75.. 4 372 708 03 Dichtung 91 x 52 x 1

CSW75.. Gasket
Joint
1

214 CSH75.. 4 375 914 01 Verdrehsicherung Ø 27 x 6,5

CSW75.. Torsion lock
Protection antitorsion

215 CSH75.. 4 347 161 01 Magnetventil ( CR )

CSW75.. Solenoid valve
Vanne magnétique

216 CSH75.. 8 380 306 32 Zylinderschraube M 10 x 30

CSW75.. Cheese head screw DIN 912-10.9
Vis à tête cylindrique

217 CSH75.. 4 343 313 01 Spule 230V, 50/60Hz

CSW75.. Coil
4 343 313 02 115V, 60Hz
Bobine
4 343 313 03 [incl.219] 24V, 50/60Hz
4 343 313 05 115V, DC
4 343 313 04 24V, DC
4 343 313 06 48V, DC
4 343 313 10 200V, 50/60Hz

218 CSH75.. 4 381 909 09 Spulenbefestigung

CSW75.. Coil fixation
Fixation de bobine

219 CSH75.. 4 389 019 01 Gerätesteckdose komplett

CSW75.. Electr. connector complete
Prise de courant complète
 217

220 CSH75.. 1 366 114 13 Verschluss-Schraube M 22 x 1,5

Sealing screw DIN 910 - 5.8
oder/or/ou Vis de fermeture
1 361 332 10 Flüssigkeitseinspritzung Ø 12 L
Liquid injection
Injection de liquide
[incl.221,222,223,224]

221 CSH75.. 1 382 403 05 Aluminium-Dichtring Ø 22 x Ø 27 x 1,5

Aluminium gasket ring DIN 7603
Joint annulaire d'aluminium
 1,220

222 CSH75.. 1 1 (365 210-25) ↓ Einschraub-Nippel M 22 x 1,5 x 1“ - 14 UNS

Screwed nipple L=43 mm
Nipple á vis
1 2 ca.04/11 365 210 08 M 22 x 1,5 x 1“ - 14 UNS
 220
L=58 mm

223 CSH75.. 1 372 200 02 Dichtring Ø 19,1 x 1,5

Joint ring
Joint annulaire
 1,220

224 CSH75.. 1 361 321 10 Absperrventil Ø 12 L ; 1“- 14 UNS

Shut-off valve
Vanne d’arrèt
[incl.225]
 220

225 CSH75.. 1 375 014 02 Schutzkappe

Protecting cap
Chapeau de protection
 224

SE-171-1 23
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

226 CSH75-.. 1 314 008 12 Öldüse M8

Oil orifice
CS.7583.. 1 1 314 008 12 M8
Orifice d´huile
CS.7593..
0 2 ca. 01/12 —

227 CSH75.. 1 372 021 20 O-Ring Ø 28 x 1,7

CSW75.. O-ring
Joint annulaire
 1,228

228 CSH75.. 1 345 905 05 Tauchhülse 1 1/8“ - 18 UNEF

CSW75.. Heater sleeve
Tube plongeur

229 CSH75.. 1 375 021 04 Verschluss-Stopfen

CSW75.. Sealing plug
Bouchon de fermeture
 228

230 CSH75.. 1 343 213 07 Ölsumpfheizung 200 W , 230V

CSW75.. Crankase heater
1 343 213 08 Résistance de carter 200 W , 115V
[incl. 232]

231 CSH75.. 1 372 021 14 O-Ring Ø 23 x 1,7

CSW75.. O-ring
Joint annulaire
1

232 CSH75.. 1 389 002 01 Gerätesteckdose komplett

CSW75.. Electr. connector complete
Prise de courant complète
 230

236 CSH75.. 1 347 032 02 Druckgastemperaturfühler NPT 1/8“ (120 ° C)

CSW75.. Discharge gas temperature
sensor
Sonde de température du gaz
de refoulement

240 CSH75.. 1 361 913 01 Ölserviceventil komplett

CSW75.. Oil service valve complete
La vanne de service complet
oder/or/ou [incl. 241,242,243,244,245]
1 366 114 13 Verschluss-Schraube M 22 x 1,5
Sealing screw DIN 910-5.8
Vis de fermeture

241 CSH75.. 1 375 014 01 Schutzkappe

CSW75.. Protecting cap
Chapeau de protection
 242

242 CSH75.. 1 361 322 05 Absperrventil Ø 10 B; 3/4“ -16 UNF

CSW75.. Shut-off valve
Vanne d’arrèt
[incl.241]
 240

243 CSH75.. 1 372 200 01 Dichtring Ø 14,3 x Ø 11,1 x 1,5

CSW75.. Joint ring
Joint annulaire
 1,240

244 CSH75.. 1 365 210 16 Einschraub-Nippel M 22 x 1,5 ; 3/4“ -16 UNF

CSW75.. Screwed nipple
Nipple á vis
 240

245 CSH75.. 1 382 403 05 Aluminium-Dichtring A 22 x Ø 27 x 1,5

CSW75.. Aluminium gasket ring
Joint annulaire d'aluminium
 1,240

24 SE-171-1
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

246 CSH75.. 1 314 036 01 Düse M8

CSW75.. Orifice

247 CSH7553-.. 1 314 008 31 Düse M8

CSH7563-.. Orifice
CSH7573-..
CSW7573-..
CSH7583-.. 1 314 036 01 M8
CSH7593-..
CSW7583-..
CSW7593-..

248 CSH75.. 1 361 501 01 Schrader-Ventil 1/

8 “- 27 NPTF
CSW75.. Schrader valve
Vanne Schrader

250 CSH75.. 1/2 347 962 01 Opto-elektronische Ölniveau- 220V

CSW75.. Überwachung
1/2 347 962 02 115V
Opto-electronic oil level monito-
1/2 347 962 03 ring 24V
Opto-électronique contrôle de
niveau d’huile
[incl.251,254,256]

251 CSH75.. 1/2 347 949 01 Opto-elektronische Einheit 220V

CSW75.. Opto-electronic unit
1/2 347 949 02 115V
Opto-électronique unité
1/2 347 949 04  250 24V

254 CSH75.. 2 372 021 20 O-Ring Ø 28 x 1,7

CSW75.. O-ring
Joint annulaire
 1,250

255 CSH75.. 2 380 306 32 Zylinderschraube mit M 10 x 30

Innensechskant DIN 912-10.9
Hexsocket cheese head screw
Vis à tête cylindrique á six pans
creux

256 CSH75.. 1 361 815 03 Schauglas 1 1/8“-18 UNEF

CSW75.. Sight glass
oder/or/ou Voyant
1/2 361 828 02 Schauglas (Opto-elektronische 1 1/8“-18 UNEF / M 24 x 1
Ölniveau- Überwachung)
Sight glass (Opto-electronic oil
level monitoring)
Voyant (Opto-électronique con-
trôle de niveau d’huile)
 250

257 CSH75.. 1 366 144 01 Verschluss-Stopfen 1 1/8“-18 UNEF

CSW75.. Sealing plug
Bouchon de fermeture

258 CSH75.. 1 372 704 01 Dichtung 91 x 52 x 1

Gasket
Joint
1

259 CSH75.. 1 367 015 01 Blindflansch 91 x 52 x 13

Blank flange
Bride d’obturation

SE-171-1 25
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

260 CSH7553-.. 1 372 316 06 Dichtung Ø 346 x Ø 330 x 1

CSH7563-.. Gasket
CSH7573-.. Joint
CSH7583-.. 1
CSH7593-90
CSW7573-..
CSW7583-..
CSW7593-..
CSH7583-100 2 372 316 06 Ø 346 x Ø 330 x 1
CSH7593-100
CSH7593-110

261 CSH75.. 1 362 013 01 Sauggas-Filter Ø 279 x 120

CSW75.. Suction gas filter
Filtre d’aspiration

262 CSH75.. 1 305 237 01 Gehäusedeckel Ø 346 x 170

CSW75.. Housing cover
Couvercle de corps
[incl. 265,268]

263 CSH7553-.. 10 380 307 04 Zylinderschraube mit M 16 x 160

CSH7563-.. Innensechskant DIN 912-10.9
CSH7573-.. Hexsocket cheese head screw
CSH7583-.. Vis à tête cylindrique á six pans
CSH7593-90 creux
CSW7573-..
CSW7583-..
CSW7593-..
CSH7583-100 10 380 338 02 M 16 x 190
CSH7593-100 ISO 4762-10.9
CSH7593-110

264 CSH7553-.. 1 380 307 02 Zylinderschraube mit M 16 x 35

CSH7563-.. Innensechskant DIN 912-10.9
CSH7573-.. Hexsocket cheese head screw
CSH7583-.. Vis à tête cylindrique á six pans
CSH7593-90 creux
CSW7573-..
CSW7583-..
CSW7593-..
CSH7583-100 1 380 338 01 M 16 x 70
CSH7593-100 ISO 4762-10.9
CSH7593-110

265 CSH75.. 1 1 372 021 20 O - Ring Ø 28 x 1,7

CSW75.. O - ring
0 2 ca.02/12 —
Joint annulaire
 1,262

266 CSH75.. 1 320 354 04 Transportöse 80 x 40 x 10

CSW75.. Ring bolt Ø 24, Ø 17,5
Un anneau de manutention

267 CSH7553-.. 1 380 307 07 Zylinderschraube mit M 16 x 170

CSH7563-.. Innensechskant DIN 912-10.9
CSH7573-.. Hexsocket cheese head screw
CSH7583-.. Vis à tête cylindrique á six pans
CSH7593-90 creux
CSW7573-..
CSW7583-..
CSW7593-..
CSH7583-100 1 380 338 02 M 16 x 200
CSH7593-100 ISO 4762-10.9
CSH7593-110

268 CSH75.. 1 1 380 914 01 Verschluss-Schraube 1 1/8“-18 UNEF

CSW75.. Sealing screw
0 2 ca.02/12 366 144 01 Vis de fermeture
 262

26 SE-171-1
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

269 CSH75.. 1 380 306 41 Zylinderschraube mit M12 x 16

CSW75.. Innensechskant DIN 912-10.9
Hexsocket cheese head screw
Vis à tête cylindrique á six pans
creux

270 CSH75.. 1 382 001 04 Scheibe A 13

CSW75.. Washer DIN 125
Rondelle

271 CSH7553.. 1 380 213 01 Sechskantschraube M10 x 16

CSH7563.. Hexagon head screw DIN 6921-8.8
CSH7573.. Vis á tête hexagonale
CSW7573..

272 CSH75.. 1 382 001 57 Scheibe A17

CSW75.. Washer DIN 125
Rondelle

273 CSH75.. 1 380 307 08 Zylinderschraube mit M 16 x 25

CSW75.. Innensechskant DIN 912-10.9
Hexsocket cheese head screw
Vis à tête cylindrique á six pans
creux

274 CSH75.. 1 380 306 21 Zylinderschraube mit M 10 x 12

CSW75.. Innensechskant DIN 912-10.9
Hexsocket cheese head screw
Vis à tête cylindrique á six pans
creux

278 CSH7583-100 1 312 041 01 Distanzring Ø 346 x Ø 270 x 30

CSH7593-100 Spacer ring
CSH7593-110 Bague d'espacement

300 CSH7553-.. 1 360 609 42 Bausatz Ölleitung

CSH7563-.. Kit for oil line
CSH7573-.. Kit pour conduite d’huile
CSW7573-.. [incl. 302,303]

302 CSH7553-.. 1 366 015 02 Gerade Verschraubung (Körper) XGE8-L 1/4“ NPT
CSH7563-.. Straight screwed joint (body)
CSH7573-.. Vissage en ligne droit (corps)
CSW7573-..  300

303 CSH7553-.. 1 366 017 01 Winkel-Verschraubung(Körper) XWE8-L 1/4“ NPT

CSH7563-.. Angle screwed joint (body)
CSH7573-.. Vissage à vis coudé (corps)
CSW7573-..  300

310 CSH7553-.. 1 360 609 04 Bausatz Ölleitung

CSH7563-.. Kit for oil line
CSH7573-.. Kit pour conduite d’huile
CSW7573-.. [incl. 312,313]

312 CSH7553-.. 1 366 017 02 Winkel-Verschraubung(Körper) XWE8-L 1/4“ NPT

CSH7563-.. Angle screwed joint (body)
CSH7573-.. Vissage à vis coudé (corps)
CSW7573-..  310

313 CSH7553-.. 1 366 015 07 Gerade Verschraubung (Körper) XGE8-L 1/8“ NPT
CSH7563-.. Straight screwed joint (body)
CSH7573-.. Vissage en ligne droit (corps)
CSW7573-..  310

320 CSH7553-.. 1 360 609 03 Bausatz Ölleitung

CSH7563-.. Kit for oil line
CSH7573-.. Kit pour conduite d’huile
CSW7573-.. [incl. 322,323]

SE-171-1 27
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

322 CSH7553-.. 1 366 017 02 Winkel-Verschraubung(Körper) XWE8-LL 1/8“ NPT

CSH7563-.. Angle screwed joint (body)
CSH7573-.. Vissage à vis coudé (corps)
CSW7573-..  320

323 CSH7553-.. 1 366 015 07 Gerade Verschraubung (Körper) XGE8-L 1/8“ NPT
CSH7563-.. Straight screwed joint (body)
CSH7573-.. Vissage en ligne droit (corps)
CSW7573-..  320

330 CSH7553-.. 1 360 609 10 Bausatz Ölleitung

CSH7563-.. Kit for oil line
CSH7573-.. Kit pour conduite d’huile
CSW7573-.. [incl. 332,333]

332 CSH7553-.. 1 366 017 02 Winkel-Verschraubung(Körper) XWE8-LL 1/8“ NPT

CSH7563-.. Angle screwed joint (body)
CSH7573-.. Vissage à vis coudé (corps)
CSW7573-..  330

333 CSH7553-.. 1 366 015 07 Gerade Verschraubung (Körper) XGE8-L 1/8“ NPT
CSH7563-.. Straight screwed joint (body)
CSH7573-.. Vissage en ligne droit (corps)
CSW7573-..  330

340 CSH7553-.. 1 360 609 09 Bausatz Ölleitung

CSH7563-.. Kit for oil line
CSH7573-.. Kit pour conduite d’huile
CSW7573-.. [incl. 342,343]

342 CSH7553-.. 1 366 017 02 Winkel-Verschraubung(Körper) XWE8-LL 1/8“ NPT

CSH7563-.. Angle screwed joint (body)
CSH7573-.. Vissage à vis coudé (corps)
CSW7573-..  340

343 CSH7553-.. 1 366 015 07 Gerade Verschraubung (Körper) XGE8-L 1/8“ NPT
CSH7563-.. Straight screwed joint (body)
CSH7573-.. Vissage en ligne droit (corps)
CSW7573-..  340

350 CSH7553-.. 1 360 609 41 Bausatz Ölleitung

CSH7563-.. Kit for oil line
CSH7573-.. Kit pour conduite d’huile
CSW7573-.. [incl. 351,352]

351 CSH7553-.. 1 366 015 06 Gerade Verschraubung (Körper) XGE10-LL 1/4“ NPT
CSH7563-.. Straight screwed joint (body)
CSH7573-.. Vissage en ligne droit (corps)
CSW7573-..  350

352 CSH7553-.. 1 366 015 06 Gerade Verschraubung (Körper) XGE10-LL 1/4“ NPT
CSH7563-.. Straight screwed joint (body)
CSH7573-.. Vissage en ligne droit (corps)
CSW7573-..  350

355 CSH7553-.. 2 345 917 01 Bausatz Schelle

CSH7563-.. Clip kit
CSH7573-.. Kit agrafe de serrage
CSW7573-..

360 CSH7553-.. 3 380 306 52 Zylinderschraube mit M 6 x 25

CSH7563-.. Innensechskant DIN 912-10.9
CSH7573-.. Hexsocket cheese head screw
CSW7573-.. Vis à tête cylindrique á six pans
creux

361 CSH7553-.. 1 367 359 01 Reglerflansch 81 x 50 x 13

CSH7563-.. Regulator flange
CSH7573-.. Bride le régulateur
CSW7573-..

28 SE-171-1
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

362 CSH7553-.. 1 372 435 06 Dichtung 81 x 50 x 2

Gasket
CSH7563-.. 1 372 435 05 81 x 50 x 2
Joint
CSH7573-.. 1 372 435 04 1 81 x 50 x 2
CSW7573-..

363 CSH7553-.. 3 380 306 37 Zylinderschraube mit M 10 x 105

CSH7563-.. Innensechskant DIN 912-10.9
CSH7573-.. Hexsocket cheese head screw
CSW7573-.. Vis à tête cylindrique á six pans
creux

364 CSH7553-.. 2 383 011 08 Zylinderstift Ø 10 M 6 x 30

CSH7563-.. Parallel pin DIN 7979
CSH7573-.. Goupille cylindrique
CSW7573-..

365 CSH7553-.. 1 380 306 38 Zylinderschraube mit M 10 x 45

CSH7563-.. Innensechskant DIN 912-10.9
CSH7573-.. Hexsocket cheese head screw
CSW7573-.. Vis à tête cylindrique á six pans
creux
CSH7583-.. 5 380 306 32 M 10 x 30
CSH7593-.. DIN 912-10.9
CSW7583-..
CSW7593-..

366 CSH7553-.. 1 380 306 24 Zylinderschraube mit M 10 x 40

CSH7563-.. Innensechskant DIN 912-10.9
CSH7573-.. Hexsocket cheese head screw
CSW7573-.. Vis à tête cylindrique á six pans
creux

367 CSH7553-.. 1 313 049 02 Lagerdeckel Ø 77 x 66

CSH7563-.. Bearing cover
Couvercle de palier
CSH7573-.. 1 313 049 03 Ø 77 x 66
 369
CSW7573-..
CSH7583-.. 1 313 049 01 Ø 100 x 54
CSH7593-..
CSW7583-..
CSW7593-..

368 CSH7553-.. 6 380 306 55 Zylinderschraube mit M 6 x 40

CSH7563-.. Innensechskant DIN 912-10.9
CSH7573-.. Hexsocket cheese head screw
CSW7573-.. Vis à tête cylindrique á six pans
creux
CSH7583-.. 4 380 312 83 M 8 x 20
 369
CSH7593-.. DIN 6912-10.9
CSW7583-..
CSW7593-..

369 CSH7553-.. 1 349 005 09 Kolbenstange komplett [incl.367,368,370,371,372

Piston rod complete 374,381,382]
Tige à piston complet
CSH7563-.. 1 349 005 10 [incl.367,368,370,372,374
381,382]
CSH7573-.. 1 349 005 11 [incl.367,368,370,372,374
CSW7573-.. 381,382]
CSH7583-.. 1 349 005 14 [incl.367,368,370,372,374
CSW7583-.. 375,376,381,382,406,407]
CSH7593-.. 1 349 005 16 [incl.367,368,370,372,374
CSW7593-.. 375,376,381,382,406,407]

SE-171-1 29
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

370 CSH7553-.. 1 314 066 01 Kolbenstange SW 36 x 190

CSH7563-.. Piston rod
CSH7573-.. Tige à piston
CSW7573-..  369
CSH7583-.. 1 314 032 09 SW 36 x 210
CSH7593-..
CSW7583-..
CSW7593-..

371 CSH7553-.. 1 311 033 01 Hülse Ø 77 x 20,6

Sleeve
Douille
 369

372 CSH7553-.. 1 1 (325 000 46)↓ Druckfeder

CSH7563-.. Pressure spring
CSH7573-.. 1 2 325 000 56 Ressort de pression
CSW7573-..  369
CSH7583-.. 1 325 000 56
CSH7593-..
CSW7583-..
CSW7593-..

374 CSH7553-.. 1 314 240 04 Kolben [incl. 375,376]

CSH7563-.. Piston
CSH7573-.. Piston
CSW7573-..  369
CSH7583-.. 1 314 062 01 Ø 103
CSW7583-..
CSH7593-..
CSW7593-..

375 CSH7553-.. 1 372 021 32 O-Ring Ø 78,7 x 5,3

CSH7563-.. O-ring  1,374
CSH7573-.. Joint annulaire
CSW7573-..
CSH7583-.. 1 372 021 33 Ø 88,2 x 5,3
CSH7593-..  1,369
CSW7583-..
CSW7593-..

376 CSH7553-.. 1 312 104 02 Gleitring Ø 95 x 6

CSH7563-.. Sliding ring  374
CSH7573-.. Bague de glissement
CSW7573-..
CSH7583-.. 1 312 104 04 Ø 105 x 6
CSH7593-..  369
CSW7583-..
CSW7593-..

381 CSH7553-.. 1 380 166 11 Sechskantschraube M 16 x 40

CSH7563-.. Hexagon head screw DIN 933-10.9
CSH7573-.. Vis á tête hexagonale
CSW7573-..  369
CSH7583-.. 1 1 (380 159 03)↓ M 16 x 40
CSH7593-.. DIN 933-10.9
CSW7583-.. 1 2 380 166 11
CSW7593-..

382 CSH7553-.. 1 372 321 01 Dichtung

CSH7563-.. Gasket
CSH7573-.. Joint
CSW7573-..  1,369
CSH7583-.. 1 372 361 01
CSH7593-..
CSW7583-..
CSW7593-..

30 SE-171-1
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

383 CSH7553-.. 1 305 907 01 Deckel Ø 118 x 16

CSH7563-.. Cover
CSH7573-.. Couvercle
CSW7573-..
CSH7583-.. 1 305 918 01 Ø 129 x 12
CSH7593-..
CSW7583-..
CSW7593-..

384 CSH75.. 1 365 210 14 Einschraub-Nippel M 22 x 1,5 x 1“-12 UNF

CSW75-.. Screwed nipple
Nipple á vis

385 CSH75.. 1 362 105 01 Ölfilter OC 172

CSW75-.. Oil filter
Filtre d’huille

386 CSH7553-.. 2 380 306 32 Zylinderschraube mit M 10 x 30

CSH7563-.. Innensechskant DIN 912-10.9
CSH7573-.. Hexsocket cheese head screw
CSW7573-.. Vis à tête cylindrique á six pans
creux
CSH7583-.. 3 380 306 32
CSH7593-..
CSW7583-..
CSW7593-..

387 CSH7553-.. 1 360 615 01 Leitung komplett

CSH7563-.. Line complete
CSH7573-.. Conduite complet
CSW7573-..
CSH7583-.. 1 360 615 06
CSH7593-..
CSW7583-..
CSW7593-..

389 CSH7553-.. 1 315 028 07 Distanzschraube M 10 x 95 / M8

CSH7563-.. Spacer screw  410
CSH7573-.. Vis d’espacement
CSW7573-..
CSH7583-.. 1 315 028 09 M 10 x 62
CSH7593-..
CSW7583-..
CSW7593-..

393 CSH7583-.. 1 360 608 31 Leitung

CSH7593-.. Line
CSW7583-.. Conduite
CSW7593-..

400 CSH7553-.. 1 305 528 01 Druckflansch-Deckel [incl. 402]

CSH7563-.. Discharge flange cover
CSH7573-.. Couvercle de pression
CSW7573-..
CSH7583-.. 1 305 919 01 136 x 335
CSH7593-..
CSW7583-..
CSW7593-..

401 CSH7553-.. 1 372 929 01 Dichtung

CSH7563-.. Gasket
CSH7573-.. Joint
CSW7573-.. 1
CSH7583-.. 1 372 349 01
CSW7583-..
CSH7593-..
CSW7593-..

SE-171-1 31
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

404 CSH7553-.. 2 315 028 06 Distanzschraube M 10 x 285 / M8

CSH7563-.. Spacer screw  410
CSH7573-.. Vis d’espacement
CSW7573-..
CSH7583-.. 2 315 028 08 M 10 x 173
CSH7593-..
CSW7583-..
CSW7593-..

406 CSH7583-.. 3 380 312 81 Zylinderschraube mit M 6 x 12

CSH7593-.. Innensechskant DIN 6912-10.9
CSW7583-.. Hexsocket cheese head screw
CSW7593-.. Vis à tête cylindrique á six pans
creux
 369

407 CSH7583-.. 0 1 — Distanzscheibe —

CSW7583-.. Spacer washer
1 2 313 050 01 Rondelle d’espacement Ø 64 x 8
CSH7593-.. 1 313 050 02  369 Ø 64 x 14
CSW7593-..

408 CSH7583-.. 1 380 302 05 Zylinderschraube mit M 12 x 50

CSH7593-.. Innensechskant DIN 912-10.9
CSW7583-.. Hexsocket cheese head screw
CSW7593-.. Vis à tête cylindrique á six pans
creux

410 CSH7553-.. 1 369 205 07 Reparatursatz Demister

CSH7563-.. Repair kit demister
CSH7573-.. Réparation de montage
CSW7573-.. débrouilleur
CSH7583-.. 1 369 205 06
CSH7593-..
CSW7583-..
CSW7593-..

411 CSH7553-.. 1 375 069 04 Hülse Ø 63 x 22

CSH7563-.. Sleeve  400
CSH7573-.. Douille
CSW7573-..
CSH7583-.. 1 375 069 06 Ø 72 x 24
CSH7593-..
CSW7583-..
CSW7593-..

413 CSH7553-.. 3 380 306 01 Zylinderschraube mit M 8 x 12

CSH7563-.. Innensechskant DIN 912-10.9
CSH7573-.. Hexsocket cheese head screw
CSW7573-.. Vis à tête cylindrique á six pans
creux
CSH7583-.. 3 380 056 22 M 10 x 150
CSH7593-.. DIN 931-10.9
CSW7583-..
CSW7593-..

420 CSH75.. 1 372 021 08 O-Ring ID 380,3 x 5,3

CSW75-.. O-ring
Joint annulaire
1

429 CSH75.. 11 380 307 01 Zylinderschraube mit M 16 x 50

CSW75-.. Innensechskant DIN 912-10.9
Hexsocket cheese head screw
Vis à tête cylindrique á six pans
creux

430 CSH75.. 1 300 510 01 Ölabscheidergehäuse

CSW75-.. Oil separator body
Corps separateur d’huile

32 SE-171-1
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

431 CSH75.. 7 380 307 05 Zylinderschraube mit M 16 x 60

CSW75-.. Innensechskant DIN 912-10.9
Hexsocket cheese head screw
Vis à tête cylindrique á six pans
creux

432 CSH75.. 1 372 021 01 O-Ring Ø 65 x 4

CSW75-.. O-ring
Joint annulaire
1

433 CSH75.. 1 315 031 02 Verschluss-Schraube M 52 x 1,5

CSW75.. Sealing screw DIN 908-5.8
Vis de fermeture

450 CSH75.. 1 347 017 10 Schutzgerät SE-E1

CSW75.. Protection device 115..230V, 50/60Hz
Dispositif de protection
oder/or/ou
1 347 017 14 SE-E1
24V, 50/60Hz
1 347 034 01 SE-C1
24V..230V, 50/60Hz
1 1 (347 009 01) ↓ INT69VSY-II
230V, 50/60Hz
1 2 ca.05/11 347 038 01 SE-E2
24V..230V, 50/60Hz/DC
oder/or/ou
1 1 (347 009 02) ↓ INT69VSY-II
115V, 50/60Hz
1 2 ca.05/11 347 038 01 SE-E2
24V..230V, 50/60Hz/DC
oder/or/ou
1 1 (347 009 05) ↓ INT69VSY-II
24V, 50/60Hz
1 2 ca.05/11 347 038 01 SE-E2
24V..230V, 50/60Hz/DC
oder/or/ou
1 1 (347 009 04) ↓ INT69VSY-II
24V, DC
1 2 ca.05/11 347 038 01 SE-E2
24V..230V, 50/60Hz/DC

453 CSH75.. 2 380 513 51 Zylinderschraube mit M 3 x 16

CSW75.. Innensechskant DIN EN ISO 7045-4.8
Hexsocket cheese head screw
Vis à tête cylindrique á six pans
creux
 89

454 CSH75.. 1 345 918 01 Klemmleiste mit Kabel

CSW75.. Strip terminal with cable
Réglette de bornes avec câble
 89

455 CSH75.. 4 380 501 52 Kreuzschlitz-Schraube M 6 x 12

CSW75.. Cross recessed raised head DIN 7985-4.8
screw
Vis à tête bombée

456 CSH75.. 1 324 500 13 Anschlusskasten 360 x 290 x 130

CSW75.. Terminal box
Boîte de raccordement

SE-171-1 33
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

457 CSH75.. 1 372 126 01 Dichtung 222 x 140 x 3

CSW75.. Gasket
Joint
 1,89

460 CSH75.. 1 375 022 15 Verschluss-Stopfen Ø 28 x 12

CSW75.. Sealing plug
Bouchon de fermeture

461 CSH75.. 1 375 022 14 Verschluss-Stopfen Ø 25 x 9,5

CSW75.. Sealing plug
Bouchon de fermeture

462 CSH75.. 1 1 (345 101 04) ↓ Kabelverschraubung

CSW75.. Screwed cable gland
1 2 345 121 02 Passe-câble à vis

463 CSH75.. 1 375 022 13 Verschluss-Stopfen Ø 22 x 10,5

CSW75.. Sealing plug
Bouchon de fermeture

464 CSH75.. 2 345 126 04 Verschluss-Stopfen M 63 x 1,5

CSW75.. Sealing plug
Bouchon de fermeture

465 CSH75.. 2 345 122 04 Sechskantmutter M 63 x 1,5

CSW75.. Hexagon nut
Écrou hexagonale

466 CSH75.. 2 389 007 01 Kerbkabelschuh 6 R/10

CSW75.. Notch-type cable lug Ø 10 x 35 MM2
Cosse de câble à sentir
 89

467 CSH75.. 2 378 049 01 Klebefolie Schutzleiteranschluss

CSW75.. Bonding sheet grounding conductor
Feuille de collage
 89

468 CSH75.. 2 382 002 04 Scheibe B 10,5

CSW75.. Washer DIN 125
Rondelle
 89

469 CSH75.. 2 381 101 56 Sechskantmutter M 10

CSW75.. Hexagon nut DIN 934
Écrou hexagonale
 89

470 CSH75.. 6 375 051 02 Isolierplatte 40 x 39

CSW75.. Insulation plate
Plaque isolate
 89

473 CSH75.. 3 345 007 02 Flachstecker 6,3 x Ø 10,5

CSW75.. Blade terminal
Laguette

474 CSH75.. 6 389 007 01 Kerbkabelschuh 6 R/10

CSW75.. Notch-type cable lug Ø 10 x 35 MM2
Cosse de câble à sentir
 89

475 CSH75.. 6 382 205 03 Federring A 10

CSW75.. Single coil spring washer DIN 127-A2
Rondelle-ressort
 89

476 CSH75.. 6 380 385 07 Zylinderschraube mit M 10 x 16

CSW75.. Innensechskant DIN 912-10.9
Hexsocket cheese head screw
Vis à tête cylindrique á six pans
creux
 89

34 SE-171-1
Pos. Typ Stück Änder ab Baujahr Art. Nr. Benennung
ung Mon./Jahr/Nr.
Item Type Qty. Modifi from model Ref. nr. Description
cation month/year/no.
No. Type Pièce Modifi à partir du modèle Réf. no. Désignation
cation mois/année/no.

478 CSH75.. 1 375 907 01 Isolationsfolie 160 x 164 x 0,3

CSW75.. Insulation foil
Isolant flexible
 89

480 CSH75.. 4 380 501 54 Kreuzschlitz-Schraube M 6 x 16

CSW75.. Cross recessed raised head DIN 7985-4.8
screw
Vis à tête bombée

481 CSH75.. 1 324 910 02 Deckel für Anschlusskasten 361 x 291 x 7

CSW75.. Cover for Terminal box
Couvercle pour boîte de
raccordement

482 CSH75.. 1 372 429 04 Dichtung 360 x 290 x 2

CSW75.. Gasket
Joint
 1,89

484 CSH75.. 4 375 072 01 Scheibe Ø 6,4

CSW75.. Washer
Rondelle
 89

490 CSH75.. 1 382 101 54 Zahnscheibe Ø 6,4

CSW75.. Toothed washer DIN 6797
Rondelle évantail
 89

491 CSH75.. 1 344 006 01 Kabel

CSW75.. Cable
Câble
 89

492 CSH75.. 1 382 002 03 Scheibe A6,4

CSW75.. Washer DIN 125-MS
Rondelle
 89

493 CSH75.. 1 382 150 01 Sicherungsscheibe S6

CSW75.. Thrust washer
Rondelle de sécurité
 89

494 CSH75.. 1 381 301 04 Sechskantmutter M6

CSW75.. Hexagon nut DIN 934
Écrou hexagonale
 89

SE-171-1 35
 BITZER Kühlmaschinenbau GmbH
BITZER Kühlmaschinenbau GmbH
Eschenbrünnlestraße 15 // 7 10 65
Eschenbrünnlestraße 15Sindelfingen // Germany// Germany
// 7 10 65 Sindelfingen
Tel +49 (0)Tel
70 +49
31 9(0)
32-070 //
31Fax +49//
9 32-0 (0)Fax
70 +49
31 9(0)
32-1
7047
31 9 32-1 47
bitzer@[Link] // [Link]
bitzer@[Link] // [Link]

Subject to change // Änderungen

Subject to change //vorbehalten
Änderungen // Toutes modifications
vorbehalten // Toutes modifications réservées // 05.2012
réservées // 80420701 05.2010
80420701
06.2011 // 05.2010
Pump manual
OPERATION AND MAINTENANCE INSTRUCTIONS

DESMI vertical "in-line" centrifugal pump

ESL Monobloc

DESMI Pumping Technology A/S

Tagholm 1, DK-9400 Nørresundby, Denmark

Tel.: +45 96 32 81 11
Fax: +45 98 17 54 99
E-mail: desmi@[Link]
Internet: [Link]

Manual: Language: Revision:

T1515 English K (01/19)

Special pump No. ...............................................

OPERATION AND MAINTENANCE INSTRUCTIONS ............................................................................................ 1
1. PRODUCT DESCRIPTION ............................................................................................................................. 3
1.1 DELIVERY ................................................................................................................................................ 3
2. TECHNICAL DATA ....................................................................................................................................... 3
2.1 EXPLANATION OF THE TYPE NUMBER ............................................................................................ 3
2.2 TECHNICAL DESCRIPTION .................................................................................................................. 4
3. INSTALLATION ........................................................................................................................................... 5
3.1 MOUNTING/FASTENING ....................................................................................................................... 5
3.2 WIRING ..................................................................................................................................................... 6
4. TRANSPORT/STORAGE .............................................................................................................................. 6
5. DISMANTLING ........................................................................................................................................... 7
5.1 DISMANTLING OF ESL25/40/50/80/100-180 ...................................................................................... 8
5.2 DISMANTLING OF ESL40/50/80/100-180N, ESL65-180M .............................................................. 10
5.3 INSPECTION .......................................................................................................................................... 11
6. ASSEMBLING ........................................................................................................................................... 12
6.1 FITTING SEALING RINGS (Not applicable for ESL25-180 and ESL40/50-180N) ........................ 12
6.2 FITTING SHAFT ..................................................................................................................................... 12
6.3 FITTING SHAFT SEAL .......................................................................................................................... 12
6.4 FITTING IMPELLER .............................................................................................................................. 12
6.5 FITTING CASING COVER OR MOTOR BRACKET ......................................................................... 12
6.6 FITTING MOTOR FOR ESL40/50/80/100-180N AND ESL65-180M ............................................... 12
6.7 SHAFT ..................................................................................................................................................... 13
7. FROST PROTECTION ................................................................................................................................. 14
8. START-UP ................................................................................................................................................ 14
8.1 START-UP .............................................................................................................................................. 14
9. SYSTEM BALANCING ................................................................................................................................ 15
10. INSPECTION AND MAINTENANCE............................................................................................................. 16
10.1 DRAINING THE PUMP ....................................................................................................................... 16
11. REPAIRS................................................................................................................................................... 16
11.1 ORDERING SPARE PARTS .............................................................................................................. 16
11.2 REPLACING THE IMPELLER ............................................................................................................ 16
11.3 REPLACING WEAR RINGS ............................................................................................................... 16
11.4 REPLACING SHAFT SEAL (22) ........................................................................................................ 16
11.5 REPLACING BALL BEARINGS IN MOTOR..................................................................................... 17
12. OPERATING DATA .................................................................................................................................... 18
13. EU DECLARATION OF CONFORMITY ......................................................................................................... 19
14. ASSEMBLY DRAWING ESL25-180/-12-COMB. ........................................................................................... 20
15. ASSEMBLY DRAWING ESL40-180/-12-COMB. ........................................................................................... 21
16. ASSEMBLY DRAWING ESL50-180/-12-COMB. ........................................................................................... 22
17. ASSEMBLY DRAWING ESL65-180/-12-COMB. ........................................................................................... 23
18. ASSEMBLY DRAWING ESL80-180/-12 & ESL80-180B/-12 &ESL80-180E/-12 -COMB. ................................. 24
19. ASSEMBLY DRAWING ESL100-180/-12-COMB. ......................................................................................... 25
20. ASSEMBLY DRAWING ESL40/50-18N/-12-COMB ...................................................................................... 26
21. ASSEMBLY DRAWING ESL80/100-180N/-12 & ESL65-180M/-12-COMB .................................................... 27
22. DIMENSIONAL SKETCH ESL ...................................................................................................................... 28
1. PRODUCT DESCRIPTION

These operation and maintenance instructions apply to the DESMI ESL Monobloc pump.

The pump is a single-stage vertical "in-line" centrifugal pump (i.e. horizontal inlet and outlet on
the same line) equipped with stainless steel shaft, mechanical shaft seal, and closed impeller.

The impeller is mounted on the motor shaft at a shaft extension. The pumps are equipped with
a mechanical seal shaft and have holes in the bracket for inspection of leaks.

1.1 DELIVERY
- Check on delivery that the shipment is complete and undamaged.
- Defects and damages, if any, to be reported to the carrier and the supplier
immediately in order that a claim can be advanced.

2. TECHNICAL DATA

The pumps are manufactured in various material combinations which appear from the type
number on the name plate. See below.

2.1 EXPLANATION OF THE TYPE NUMBER

All the ESL pumps are provided with a name plate. The type number indicated on the name
plate is built up as follows:

ESLXXX-YYY-MR-Z

XXX: Pressure branch diameter, YYY: Standard impeller diameter

M: The material combination of the pump.
R: The assembly combination of the pump.
Z: Other variants

M may be the following:

A: Casing and cover : Cast iron+cast iron alloy. Impeller and sealing rings: Bronze
B: Casing and cover : Cast iron + cast iron alloy. Impeller and sealing rings: Stainless
C: All cast iron
D: Casing and shaft seal cover: Bronze. Impeller and sealing rings: Bronze
S: Casing, shaft seal cover, impeller and sealing rings: SAF2507 and stainless steel alloy
E: Special materials
U: Nonmagnetic material

The pumps can be delivered in other material combinations according to agreement with the
supplier.

R may be the following:

02: Monobloc, with bearing in the pump
12: Monobloc, without bearing in the pump
13: Spacer, light bearing housing
14: Spacer, heavy bearing housing
15: Spacer, heavy bearing housing and heavy motor bracket (special motor bracket)
Z may be the following:
i : PN16 flanges
j : PN25 flanges
k : Special flange
l : Other stuffing box
m : BS flanges
n : ANSI flanges
o : Shockproof design
p : Other design
q : JIS flanges

Any use of the pump is to be evaluated on the basis of the materials used in the pump. In case
of doubt, contact the supplier.

Pumps in material combinations A and C are primarily used for fresh water.
Pumps in material combination D are primarily used for seawater.

If the pumps are designed for special purposes the following is to be indicated:

Pump No. :
Pump type :
Application :
Comment :

2.2 TECHNICAL DESCRIPTION

The noise level indicated is the airborne noise including the motor. The noise depends on the
motor type supplied, as the noise from the pump can be calculated as the noise level of the
motor + 2dB(A). The noise level is for pumps with electric motors.

The capacity of the pump appears from the name plate on the pump. If the pump has been
delivered without motor, the pump capacity is to be indicated on the plate when mounting the
motor.

The permissible loads on the flanges appear from the following table. The values apply to
standard pumps in bronze (Rg5) and cast iron
(GG20). As to pumps in SG iron (GGG40), NiAlBz
or stainless steel the values are to be increased by
a factor 1.5.
 DN Forces (N) Torques (Nm)
Piping
F M
mm FY Fz FX My Mz Mx

Horizontal pipeline 25 250 320 250 480 300 150 260 420
at right angles to the 40 400 500 400 750 400 200 300 550
shaft 50 500 600 550 1000 450 250 350 600
Suction and pressure 65 650 840 750 1340 510 310 380 700
flanges above level 80 800 950 850 1500 550 350 400 750
of installation 100 1000 1250 1150 2000 650 400 500 900

In connection with the permissible loads on the flanges the following is to be observed:

2 2
 F   
 calculated     M calculated  2
F  M 
 Max. permissible   Max. permissible 

where index “calc” is the values calculated by the user.

At the same time none of the forces or moments may exceed the indicated figure multiplied
by 1.4.

3. INSTALLATION

3.1 MOUNTING/FASTENING
Insert the pump in the pipeline in the same way as a valve. The pump can be inserted in both
horizontal and vertical pipes, but not in a horizontal pipe if the motor is placed below horizontal
level. The max. loads on the flanges appear from the technical description.

When installing the pump check that it is earthed to avoid an electrical potential in the pump.
 The max. permissible loads on the flanges stated in paragraph 2.2 are to be
observed.

At installations pumping hot or very cold liquids, the operator must be aware that it is
dangerous to touch the pump surface and, consequently, he must take the
necessary safety measures.

3.2 WIRING

Wiring to be carried out by authorised skilled workmen according to the rules and
regulations in force.

4. TRANSPORT/STORAGE

The weights of the pumps in A and D combination (without motor) are stated in the following
table, and the pumps are to be lifted as shown below.

Weight in kg A12 / D12

Pump comb. Incl. base plate
ESL25-180 30/32
ESL40-180N 35/38
ESL40-180 37/40
ESL50-180N 42/44
ESL50-180 41/44
ESL65-180M 63/70
ESL65-180 62/69
ESL80-180N 67/74
ESL80-180 64/71
ESL80-180B 64/71
ESL80-180E 65/73
ESL100-180N 78/87
ESL100-180 76/87

The pump is to be stored in a dry area.

Before shipment the pump is to be fastened securely on pallets or the like.

The pump is to be lifted in the following way:

 The lifting straps must not bear against sharp edges and corners.

5. DISMANTLING
Before dismantling the pump make sure that it has stopped. Empty the pump of
liquid before it is dismantled from the piping system. If the pump has been
pumping dangerous liquids you are to be aware of this and take the necessary
safety measures.
If the pump has been pumping hot liquids, take great care that it is drained before it is
removed from the piping system.
5.1 DISMANTLING OF ESL25/40/50/80/100-180

Before dismantling 1. Remove nut (15) and 2. Remove screw (20) and
stud (14); washer (23);
3. Remove the impeller 4. Remove set screw (10) 5. Remove pointed screw (24),
(7)/(2)/(5) and the key (19) pull casing cover (4) and stop
ring(21) and shaft seal(22) and
motor with shaft apart;

6. Press out the seat (22); 7. If necessary, remove

pointed screw (11) to pull
off the shaft;
5.2 DISMANTLING OF ESL40/50/80/100-180N, ESL65-180M

Before dismantling 1. Remove the flush pipe (29) only 2. Remove nut (15) and stud
forESL40/50-180N, remove venting (14);
plug (5), muff (9) and sleeve (21) for
ESL80/100-180N and ESL65-180M

3. Remove screw (20, 24 in 4. Remove the impeller (2, 5 in 5. Remove shaft seal (22, 522 in
ESL40/50-180N) and washer ESL40/50-180N) and the key (19) ESL40/50-180N) and rear cover
(23, 25 in ESL40/50-180N); (4, 7 in ESL40/50-180N);
 6. Remove set screw 7. Remove motor bracket 8. If necessary, remove
(10, 810 in ESL40/50-180N) (7, 104 in ESL40/50-180N) pointed screw (11, 311 in
ESL40/50-180N) to pull off
the coupling

5.3 INSPECTION
When the pump has been dismantled, check the following parts for wear and damage:

- Sealing ring/impeller: Max. clearance 0.3-0.6 mm measured in radius.

- Shaft seal/shaft seal cover: Check the seat for flatness and cracks.
Check the rubber parts for elasticity.
6. ASSEMBLING
Refer to the reverse process of dismantling.
6.1 FITTING SEALING RINGS (Not applicable for ESL25-180 and ESL40/50-180N)
When fitted the wear ring (17) (not applicable for ESL40-180) is to bear against the
shoulder of the pump casing (1). When fitted the wear ring (16) is to bear against the
shoulder of the casing cover (4).

6.2 FITTING SHAFT

For ESL25/40/50/65/80/100-180, fit the shaft flange (8) (Not applicable for ESL25-180) and
the shaft (6) in the motor, then fit the pointed screw (11).

6.3 FITTING SHAFT SEAL

Before fitting the seat, clean the recess in the shaft seal cover (ESL 25-180) or the motor
bracket or rear cover (ESL 40/50/80/100-180N, ESL65-180M). When fitting the seat, remove
the protective coating without scratching the lapped surface. Dip the outer rubber ring of the
seat into soapy water. Now press the seat into place with the fingers and check that all parts
are correctly imbedded.

If it is necessary to use tools for assembling, then protect the sliding surface of the seat to
prevent it from being scratched or cut. Lubricate the inner surface of the slide ring rubber
bellows with soapy water and push it over the shaft. The use of a conical fitting bush as
shown on the assembly drawing is recommended to avoid that the rubber bellows is cut.

Push the slide ring over the shaft with the hand. If the rubber bellows is tight, use a fitting
tool and take care that the slide ring is not damaged. If the carbon ring is not fixed, it is
important to check that it is fitted correctly, i.e. the chamfered/lapped side is to face the seat.
The carbon ring can be held by a little grease.
When using soapy water on the shaft, the bellows will settle and seat in abt. 15 minutes, and
until then tightness should not be expected. After start, check by viewing the leak hole that
there are no leaks.

6.4 FITTING IMPELLER

Fit the key in the shaft and lead the impeller towards the shoulder of the shaft. Fit the stop
ring (21) before the impeller, (2)/(7)/(5). Take care that the ring at the end of the shaft seal
spring locates in the recess of the impeller. Secure the impeller with washers (23) and a
nut/screw (20, for ESL40/50-180N is 24).

6.5 FITTING CASING COVER OR MOTOR BRACKET

Place the O-ring (3, for ESL40/50-180N is 703) (or gasket in ESL25-180 12) between pump
casing and motor bracket (or casing cover in ESL25-180 12 combination or rear cover in
ESL40/50/80/100-180N and ESL65-180M) in the O-ring groove and hold it with a little
grease. However, check the material of the O-ring first. As standard the material is nitrile,
but it might be EPDM which will be damaged by mineral grease. Use soft soap or silicone
grease for EPDM. Fit and fasten shaft seal cover or motor bracket, mounted with the
electric motor, in the pump casing. Screw the pointed screws back into the shaft seal cover
before tightening. Fit circulation pipe (29) in ESL40/50-180N.

6.6 FITTING MOTOR FOR ESL40/50/80/100-180N AND ESL65-180M

Fit the motor coupling (8, 108 in ESL40/50-180N) to motor shaft and tighten the pointed screw
(11, 311 in ESL40/50-180N) slightly, place motor onto bracket (7, 104 in ESL40/50-180N) and
tighten the set screw (10, 810 in ESL40/50-180).Add 2 shims (301) between motor coupling
(8,108 in ESL40/50-180N) and pump shaft flange (6, 206 in ESL40/50-180N), adjust the
motor coupling to make it resist on the shims to ensure it is at the right axial position. Tighten
the pointed screw (11, 311 in ESL40/50-180) and remove the shims (301). Tighten the set
screw (25, 17 in ESL40/50-180N) to lift up the impeller to a right position.

Regarding the tightening torque of pointed screw (11, 311 in ESL40/50-180N)

Dimension Point Torque Pointed

Motor Size
Screws Screws

71/80 M6 10Nm

90/100/112/132/160 M8 24Nm

6.7 SHAFT
When the pump has been assembled, check that the shaft rotates freely. In case the shaft
has been dismantled in the combination, tap the shaft towards the shaft end of the electric
motor by means of a plastic hammer, and fasten the pointed screws (first the middle screw)
according to the below table. Check that the wobble, measured as close to the shaft end as
possible, is within the limits indicated in the table.

Dimension Point Torque Pointed

Motor Size [Link]
Screws Screws

71 M6 10Nm 70um

80 M6 10Nm 70um

90 M8 24Nm 70um

100/112 M8 24Nm 70um

132 M10 40Nm 70um

160 M12 75Nm 70um

7. FROST PROTECTION

Pumps which are not in operation during frost periods are to be drained to avoid frost
damage. Remove the plug at the bottom to empty the pump. Alternatively, it is possible to
use anti-freeze liquids in normal constructions.

8. START-UP

A centrifugal pump will not function until it has been filled with liquid between the foot
valve and somewhat above the impeller of the pump.
The liquid also serves as coolant for the shaft seal. In order to protect the shaft seal
the pump must not run dry.
ATTENTION

For safety reasons the pump is only allowed to operate against closed discharge valve for a
short time (max. 5 minutes and at a max. temperature of 80°C for standard pumps).
Otherwise there is a risk of damage to the pump and, at worst, of a steam explosion. If the
pump is not monitored, the installation of a safety device is recommended.

8.1 START-UP
Before starting the pump check that:

- the shaft rotates freely without jarring sounds.

- the pump casing and the suction line are filled with liquid.

Start the pump for a moment to check the direction of rotation. If the direction is correct (i.e.
in the direction of the arrow) the pump may be started.

In order to protect the shaft seal the pump must never run dry.
If there is a positive suction lift, open the valve on the suction side of the pump and evacuate
the air through the vent plug (5, 25 in rear cover in ESL40/50-180N). If there is no positive
suction lift, the plant must be equipped with a foot valve or a non-return valve on the suction
side.
Prime the pump while the vent plug (5, 25 in rear cover in ESL40/50-180N) is kept open.
When the pump has been filled with water, and the air has been evacuated, the system
can be started. Check the direction of rotation. If the direction is incorrect interchange 2 of
the power cords. The direction of rotation is indicated by an arrow. Make sure the bearings
are running correctly and that they do not become warm.
9. SYSTEM BALANCING

It is often difficult to calculate a manometric delivery head in advance. It is, however,

decisively important to the quantity of liquid delivered.

A considerably smaller delivery head than expected will increase the quantity of liquid
delivered, causing increased power consumption and perhaps cavitation in pump and piping.
In the pump the impeller may show signs of heavy erosion caused by cavitation (corrosion)
which may at times render an impeller unfit for use in a very short time. Not unusually do
similar erosions occur in pipe bends and valves elsewhere in the piping system.

Therefore, after start-up, it is necessary to check either the quantity of liquid delivered or the
power consumption of the pump e.g. by measuring the current intensity of the connected
motor. Together with a reading of the differential pressure the quantity of water delivered can
be determined against the characteristics of the pump.

Should the pump not function as intended, please proceed according to the fault-finding list.
Bear in mind, though, that the pump was carefully checked and tested at the factory and that
the majority of faults stem from the piping system

FAULT CAUSE REMEDY

The pump has no 1. Wrong direction of rotation Change direction of rotation to

or too low capacity clockwise when viewed from
shaft end (the direction of the
arrow)
2. Piping system choked Clean or replace
3. The pump is choked Clean the pump
4. Suction line leaks Find the leakage, repair the fault,
Pump takes air non-return valve not submerged
5. Suction lift too high Check data sheet Q/H curve and
6. Pump and piping system NPSH or contact DESMI
wrongly dimensioned As 5

The pump uses too 1. Counter-pressure too low Insert orifice plate or check
much power 2. The liquid is heavier valve/Contact DESMI
than water Contact DESMI
3. Foreign body in pump
Dismantle the pump, remove the
4. Electric motor is cause
running on 2 phases Check fuses, cable connection,
and cable

The pump makes 1. Cavitation in pump Suction lift too high/ Suction line
noise wrongly dimensioned/Liquid
temperature too high
10. INSPECTION AND MAINTENANCE

Inspect the shaft seal for leaks at regular intervals.

- Before inspection of a pump without guard check that the pump cannot be started
unintentionally.

- The system is to be without pressure and drained of liquid.

- The repairman must be familiar with the type of liquid which has been pumped as well
as the safety measures he is to take when handling the liquid.

10.1 DRAINING THE PUMP

When the piping system has been drained, note that there is still liquid in the pump. Remove
the liquid by dismantling the pipe plug (18) at the bottom of the pump.

11. REPAIRS

11.1 ORDERING SPARE PARTS

When ordering spare parts please always state pump type, serial No. (appears on the name
plate of the pump), position No. on the assembly drawing and designation on the spare parts
list.

The following parts are exposed to wear: Shaft seal (22,522 in ESL40/50-180N), impeller
(2)/(7)/(5), wear rings (16)and (17) (not including in ESL25-180 and ESL40/50-180N)and the
ball bearings of the motor.

11.2 REPLACING THE IMPELLER

Close the valves on both sides of the pump. Dismantle pipe (29) in ESL40/50-180N and loosen
the nuts (15) and dismantle the top piece from the pump casing. Remove the screw (20, for
ESL40/50-180N is 24) and take off the impeller (2)/(7)/(5),. Fit the new impeller.

11.3 REPLACING WEAR RINGS

(Not applicable for ESL 25-180 and ESL40/50-180N. And ESL40-180 only has a wear
ring in the motor bracket)

When motor and pump have been separated, the wear ring (17) in the pump casing (1) can
be pulled out.
In order to replace the upper wear ring (16) it is necessary first to dismantle the impeller. Press
the new seal rings into place with an even push all over the face of the ring. Normal diameter
difference between seal ring and impeller 0.3-0.4 mm.

11.4 REPLACING SHAFT SEAL (22)

Dismantling as described in paragraph 5.1 or 5.2.

When the impeller has been dismantled, remove the key (19) and then the stop ring (21) (Not
applicable for ESL 25-180 and ESL40/50/80/100-180N, ESL65-180M) which is locked with a
pointed screw. The sealing element itself can now be pulled off the shaft.

Remove the seat ring from the top piece by pressing with a pair of screwdrivers or the like
under the collar off the seat. If the seat cannot be removed, dismantle the top piece from the
motor to permit pressing from the back.
Clean the bore for seat and shaft thoroughly of dirt and rust. Remove persistent coatings, if
any, by grinding the shaft lightly with very fine emery cloth.

Grease the new seat ring and the inserted 0-ring well with glycerine – not oil – and press it
into place in the casing. Check that the seat is fitted correctly by knocking lightly with a piece
of wood. The seat ring is to be treated very carefully to prevent the sliding surface from being
scratched.

It is necessary to use a conical bush as shown below to prevent the rubber bellows from being
damaged during mounting.

Grease the back of the carbon ring with glycerine to ensure that it stays in its correct place
during the mounting. Grease the shaft, the conical bush and the rubber bellows amply with
glycerine.

Press the shaft seal on to the shaft until it resists. Press the driving ring only.

Finally place the stop ring (21) (Not applicable for ESL 25-180 and

ESL40/50-180N) on the shaft and lock it with the pointed screw.

When the pump has been mounted, ventilate the pump casing carefully before putting the
pump into operation.

When the pump has been running for 1-2 min., ventilate it again, after which it can start normal
operation.
Do not forget to check the direction of rotation if there is a risk that the power cords to motor
have been exchanged.

11.5 REPLACING BALL BEARINGS IN MOTOR

The ball bearing in the front bearing of the motor can be replaced without disassembling the
pump.

If the ball bearing in the rear bearing of the motor is to be replaced, it is necessary to
disassemble the pump and dismantle the pump shaft (as described in paragraph 5.1):

Dismantle the top piece from the motor. Remove the pointed screws (11, 311 in ESL40/50-
180N) in the pump shaft (6,206 in ESL40/50-180N). The pump shaft can now be pulled off the
motor shaft.

When assembling the pump again, check the motor shaft for damages in the form of marks,
burrs, or upsetting of the shaft end.

Damages, if any, are to be remedied by means of a file and fine emery cloth. This work has to
be done very carefully, especially on new motors, the shaft ends of which are often damaged
during transport. If this is not done carefully, the throw will be bigger than permitted and/or the
pump shaft will scratch the motor shaft when fitted.

Normally, the pump shaft is to go relatively smoothly on the motor shaft (manually or by means
of light strokes with a plastic hammer).
Tighten the pointed screws (the one in the middle first) in accordance with the torque indicated
in the table and finally check that the throw stays within the indicated limits by means of an
indicator clock.

12. OPERATING DATA

The following working pressures (pressure in piping incl. the pressure increase caused by the
pump) and number of revolutions are allowed in standard pumps.

Max. Max.
working working pressure[bar]
Pump [Link]
pressure[bar] Bronze SG-iron
ESL25-180 /Cast
16iron 30 3600
ESL40-180N 16 30 3600
ESL40-180 16 30 3600
ESL50-180N 16 30 3600
ESL50-180 16 30 3600
ESL65-180M 10 16 3600
ESL65-180 10 16 3600
ESL80-180N 10 16 3600
ESL80-180 10 20 3600
ESL80-180B 10 20 3600
ESL80-180E 10 16 3600
ESL100-180N 10 16 3600
ESL100-180 10 16 3600

The max. working pressure for NiAlBz and stainless steel pumps is 1.5 times max. working
pressure for bronze (RG5).

The above-mentioned max. working pressure is a design value – delivered pumps are
pressure tested according to actual application requirements and actual flange standards.

For instance the above-mentioned max. working pressure is NOT valid for pumps approved
by a classification society. Pumps approved by classification societies have been pressure
tested according to the requirements of these societies, i.e. a test pressure of 1.5 x the
permissible working pressure. The test pressure is stated in the test certificate and stamped
into the discharge flange of the pump.
13. EU DECLARATION OF CONFORMITY

DESMI Pumping Technology A/S, hereby declare that our pumps of the ESL Monobloc type
are manufactured in conformity with the following essential safety and health requirements in
the COUNCIL DIRECTIVE 2006/42/EC on machines, Annex 1.

The following harmonized standards have been used:

EN/ISO 13857:2008 Safety of machinery. Safety distances to prevent

danger zones being reached by the upper limbs
EN 809 + A1 Pumps and pump units for liquids – Common
safety requirements
EN/ISO12162+A1:2009 Liquid pumps – Safety requirements – Procedure
for hydrostatic testing
EN 60204-1:2006 Safety of machinery – Electrical equipment of
machines (item 4, General requirements)
Ecodesign Directive (2009/125/EC) Water pumps:
Commission Regulation No 547/2012.
Applies only to water pumps marked with the
minimum efficiency
index MEI. See pump nameplate.

Pumps delivered by us connected with prime movers are CE-marked and comply with the
above requirements.

Pumps delivered by us without prime movers (as partly completed machinery) must only be
used when the prime mover and the connection between prime mover and pump comply with
the above requirements.

Nørresundby, November 17 2014

Henrik Mørkholt Sørensen

Managing Director

DESMI Pumping Technology A/S

Tagholm 1
9400 Nørresundby
14. ASSEMBLY DRAWING ESL25-180/-12-COMB.

1 Pump casing
2 Impeller
02 Plug
3 Gasket
4 Motor bracket
5 Vent plug
6 Shaft
10 Set screw
11 Pointed screw
14 Stud
15 Nut
19 Key
20 Nut
Mechanical
22
shaft seal
23 Washer
25 Cover
26 Plug
27 Washer
28 Guard
96 Manometer
97 Nipple
98 Sleeve
100 Base plate
200 Screw
15. ASSEMBLY DRAWING ESL40-180/-12-COMB.

1 Pump casing
2 Plug
3 O-ring
4 Casing cover
5 Vent plug
6 Shaft
7 Impeller
8 Shaft flange
10 Set screw
11 Pointed screw
14 Stud
15 Nut
16 Wear ring
18 Plug
19 Key
20 Screw
21 Stop ring
Mechanical
22
shaft seal
23 Washer
24 Pointed screw
51 Base plate
52 Screw
96 Manometer
97 Nipple
98 Sleeve
16. ASSEMBLY DRAWING ESL50-180/-12-COMB.

1 Pump casing
2 Plug
3 O-ring
4 Casing cover
5 Vent plug
6 Shaft
7 Impeller
8 Shaft flange
10 Set screw
11 Pointed screw
14 Stud
15 Nut
16 Wear ring
17 Wear ring
18 Plug
19 Key
20 Screw
21 Stop ring
Mechanical
22
shaft seal
23 Washer
24 Pointed screw
51 Base plate
52 Screw
96 Manometer
97 Nipple
98 Sleeve
17. ASSEMBLY DRAWING ESL65-180/-12-COMB.

1 Pump casing
2 Plug
3 O-ring
4 Casing cover
5 Vent plug
6 Shaft
7 Impeller
8 Shaft flange
10 Set screw
11 Pointed screw
14 Stud
15 Nut
16 Wear ring
17 Wear ring
18 Plug
19 Key
20 Screw
21 Stop ring
Mechanical
22
shaft seal
23 Washer
24 Pointed screw
96 Manometer
97 Nipple
98 Sleeve
100 Base plate
200 Screw
18. ASSEMBLY DRAWING ESL80-180/-12 & ESL80-180B/-12 &ESL80-180E/-12 -COMB.

1 Pump casing
2 Plug
3 O-ring
4 Casing cover
5 Vent plug
6 Shaft
7 Impeller
8 Shaft flange
10 Set screw
11 Pointed screw
14 Stud
15 Nut
16 Wear ring
17 Wear ring
18 Plug
19 Key
20 Screw
21 Stop ring
Mechanical
22
shaft seal
23 Washer
24 Pointed screw
96 Manometer
97 Nipple
98 Sleeve
100 Base plate
200 Screw
19. ASSEMBLY DRAWING ESL100-180/-12-COMB.

1 Pump casing
2 Plug
3 O-ring
4 Casing cover
5 Vent plug
6 Shaft
7 Impeller
8 Shaft flange
10 Set screw
11 Pointed screw
14 Stud
15 Nut
16 Wear ring
17 Wear ring
18 Plug
19 Key
20 Screw
21 Stop ring
Mechanical
22
shaft seal
23 Washer
24 Pointed screw
96 Manometer
97 Nipple
98 Sleeve
100 Base plate
200 Screw
[Link] DRAWING ESL40/50-18N/-12-COMB

1 Pump casing
5 Impeller
7 Rear cover
14 Stud
15 Nut
16 Washer
17 Set screw
18 Plug
19 Key
23 Washer
24 Screw
25 Plug
26 Nipple
28 Nipple
29 Pipe
51 Base plate
52 Screw
96 Manometer
97 Nipple
98 Sleeve
104 Motor bracket
108 Motor coupling
206 Shaft W. Flange
311 Pointed screw
522 Shaft seal
703 O-ring
810 Set screw
811 BH-Screw
812 Guard
[Link] DRAWING ESL80/100-180N/-12 & ESL65-180M/-12-COMB

1 Pump casing
2 Impeller
3 O-ring
4 Rear cover
5 Venting plug
6 Shaft W. Flange
7 Motor bracket
8 Motor coupling
9 Muff
10 Set screw
11 Pointed screw
14 Stud
15 Nut
16 Wear ring
17 Wear ring
18 Plug
19 Key
20 Set screw
21 Sleeve
22 Shaft seal
23 Washer
24 Washer
25 Set screw
96 Manometer
97 Nipple
98 Sleeve
100 Base plate
200 Screw
201 Inter. flange
202 Set screw
811 BH-Screw
812 Guard
 [Link] SKETCH ESL

D DA DB DC H HA HB HF I J K KA KB L LA LB N x M
Type TN Flange Max. Max. Min. Max. Max.
mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm

1"
1 ESL25- 180 10 25 115 68 85 754 644 110 60 240 275 220 110 110 300 150 150 4xø14
25 mm

1½"
2 ESL40-180N 10 40 150 90 110 878 778 100 60 285 320 244 116 128 360 180 180 4xø18
40 mm

1½"
3 ESL40- 180 10 40 150 90 110 960 840 120 60 285 320 253 118 135 350 175 175 4xø18
40 mm

4 2"
ESL50-180N 10 50 165 102 125 878 780 98 60 285 320 260 123 137 400 200 200 4xø18
50 mm

2"
5 ESL50- 180 10 50 165 102 125 935 830 105 60 285 320 267 145 122 400 200 200 4xø18
50 mm

2½"
6 ESL65- 180 10 65 185 122 145 878 828 155 100 285 320 295 137 158 440 220 220 4xø18
65 mm

7 2½"
ESL65- 180M 10 65 185 122 145 878 828 155 100 285 320 295 137 158 440 220 220 4xø18
65 mm

3"
8 ESL80- 180 10 80 200 138 160 966 830 136 120 285 320 320 150 170 480 240 240 8xø18
80 mm

9 3"
ESL80- 180N 10 80 200 138 160 966 830 136 120 285 320 320 150 170 480 240 240 8xø18
80 mm

10 3"
ESL80- 180B 10 80 200 138 160 966 830 136 120 285 320 320 150 170 480 240 240 8xø18
80 mm

11 3"
ESL80- 180E 10 80 200 138 160 990 830 160 120 285 320 310 140 170 480 240 240 8xø18
80 mm

12 4”
ESL100- 180 10 100mm 100 220 158 180 1003 833 170 140 285 320 350 160 190 540 270 270 8xø18

13 4”
ESL100- 180N 10 100mm 100 220 158 180 1003 833 170 140 285 320 350 160 190 540 270 270 8xø18

Table with thread sizes of manometer, drain and vent plug hole (if any) on the next page.
 Type Manometer Drain Air vent

1 ESL25-180 1/4” 1/8” 1/8”

2 ESL40-180N 1/4” 3/8” 1/4”

3 ESL40-180 1/4” 3/8” 1/8”

4 ESL50-180N 1/4” 3/8” 1/4”

5 ESL50-180 1/4” 3/8” 1/8”

6 ESL65-180 1/4” 3/8” 1/8”

7 ESL65-180M 1/4” 3/8” 1/8”

8 ESL80-180 1/4” 3/8” 1/8”

9 ESL80-180N 1/4” 3/8” 1/8”

10 ESL80-180B 1/4” 3/8” 1/8”

11 ESL80-180E 1/4” 3/8” 1/8”

12 ESL100-180 1/4” 3/8” 1/8”

13 ESL100-180N 1/4” 3/8” 1/8”

Troubleshooting manual

M
 Troubleshooting Manual

Contents

1. System
2. Compressor
3. Condenser
4. Power/control panel
 1. System

NO. PROBLEM POSSIBLE CAUSE SUGGESTED CORRECTION

1. SUCTION FILTER (BAG) CLOGGING. 1. CHECK ANY FILTERS' CLOGGING IN THE AC REF PIPE LINE.
SUCTION PRESSURE 2. CLOSE POSITION OF SHUT OFF VALVES. 2. CHECK REFRIGERANT LEVEL IN CONDENSER AND STOP VALVE OPENING STATUS.
1-1
LOW TRIP 3. MALFUCTIONING OF EXP. V/V OR SOL. V/V. 3. CHECK EXPANSION VALVE AND EVR SOLENOID VALVE IF WORKING PROPERLY.
4. LOW HEAT LOAD CONDITION 4. CHECK CHILLED WATER TEMPERATURE IS LOWER THAN COOLING STOP SET POINT.

1. ENSURE THAT THE EQUIPMENT IS STARTING FOLLOWING THE DESIRED CHILLED WATER SPEC AND
INLET TEMP.
1. LOW FLOW RATE OF COOLING WATER.
2. CHECK CONDENSER’S COOLING WATER PRESSURE AND TEMPERATURE.
DISCHARGE PRESSURE 2. HIGH TEMPERATURE OF COOLING WATER.
1-2 3. PUMP DOWN THE PLANT, WAIT FOR 20MINUTES. OPEN THE PURGE LINE TO RELEASE INCONSIBLE
HIGH TRIP 3. OVERCHARGE OF REFRIGERANT GAS IN SYSTEM.
GASES IN THE CONDENSER.
4. INCONDENSABLE GAS IN SYSTEM.
4. CHECK THE LEVEL OF REFRIGERANT IN THE CONDENSER IF EXCESSIVE.
5. CHECK FOR PRESENCE OF NOISE. MEASURE TEMPERATURE OF DIFFERENT PARTS FOR COMPARISON.
1. IF COMPRESSOR OIL IS LOWER THAN 1. KEEP AT LEAST 1/2 COMPRESSOR OIL LEVEL OF SIGHT GLASS.
OIL PRESS SIGHT GLASS LEVEL. 2. CHECK THE COMPRESSOR OIL PUMP STATE.
1-3
LOW TRIP 2. FAULT OF COMPRESSOR OIL PUMP. 3. CHECK THE OIL PRESSURE TRANSMITTER.
3. FAULT OF OIL PRESSURE TRANSMITTER. 4. CHECK CONNECTION BETWEEN OIL PRESSURE TRANSMITTER AND CABLE.
1. LOW HEAT EXCHANGE FROM THE COOLER.
1. CHECK CHILLED WATER'S TEMPERATUER INLET AND OUTLET IS ATTAINED.
SUCTION TEMP 2. EXCESSIVE LOW SET POINT
1-4 2. CHECK EEV EXPANSION VALVE IF WORKING NORMALLY.
LOW TRIP FROM THE CONTROL KIT.
3. CHECK IF MGO & CHILLER CONTROL 3WAY VALVE IS OPERATING NORMALLY.
3. LIQUID HAMMERING ON THE COMPRESSOR.
1. CHEC COMPRESSOR’S SUC & DISH VAVLE PLATE FOR DAMAGE. AFTER PUMPING DOWN, CHECK IF
SUC AND DISCH WILL EQUALIZE QUICKLY.
1. DAMAGE ON VALVE PLATE.
2. IF COMP STOP, CHECK SUCT AND DISCH EQUALIZE QUICKLY. OPEN THE COPMRESSOR TO CHECK
1-5 DISCHARGE TEMP 2. INTERNAL LEAKAGE FROM BY-PASS VALVE.
FOR DAMAGED PARTS.
HIGH TRIP 3. LOW LOAD OPERATING OF COMPRESSOR.
3. CHECK IF TEMP OF COMP SUCTION IS HIGH.
4. CHECK CONDENSING TEMPERATURE.
1. OVERHEAT THE COMPRESSOR.
OIL TEMP
1-6 2. MALFUNCTIONING OF THE OIL COOLER OR 1. CHECK DISCHARGE TEMP AND SUCTION TEMP.
HIGH TRIP
LIQUID INJECTION SYSTEM.
1. IF CHILLED WATER OUTLET TEMPERATURE IS LOWER THAN SETTING VALUE,
1-7 COOLING STOP ALARM 1. LOW HEAT LOAD CONDITION THE COMPRESSOR WILL BE STOPPED.
2. CHECK CHILLED WATER OUTLET TEMPERATURE.

1. PUMP STOP. 1. CHECK IF CHILLED WATER PUMP IS RUNNING.

1-8 PUMP ALARM 2. BURNT & LOW INSULATION OF CHILLED WATER 2. CHECK THE MOTOR STATE. (INSULATION RESISTANCE)
PUMP MOTOR COIL 3. CHECK CONNECTION BETWEEN MOTOR AND POWER PANEL

PSP
 COOLING WATER PRESS 1. PUMP STOP. 1. CHECK IF COOLING WATER PUMP IS RUNNING.
1-9
LOW TRIP 2. PRESSURE S/W SETTING. 2. CHECK IF COOLING WATER PRESSURE S/W IS NORMAL AND ADJUST PRESSURE SET VALUES.
1. WATER CONTAMINATION ON MOTOR SIDE.
MOTOR LOW 1. CHECK MOTOR’S JUNCTION BOX IF MOISTURE ENTERED.
1-10 2. EXCESSIVE LIQUID FLOW
INSULATION 2. CHECK FOR ANY ICE FORMATION AROUND THE MOTOR DUE TO LOW TEMP OF THE CASING.
INTO THE COMPRESSOR.
1. CHECK IF POWER IS SUPPLIED AND NORMAL.
2. CHECK CABLE CONNECTION.
1. WIRING FAULT OR LOOSE.
1-11 PLC MODULE FAULT 3. CHECK THE WIRING CONNECTION IF ACCORDING TO DRAWING.
2. POWER SUPPLY FAIL.
4. CHECK IF THE FAULT WILL DISAPPEAR AFTER TURNING OFF AND ON THE PLC.
5. IF AFTER CHECKING THE ABOVE, PLC MAY NEED TO BE REPLACED.
1. CHECK CABLE CONNECTION BETWEEN PLC MODULE.
1. WIRING FAULT OR LOOSE.
1-12 HMI FAULT 2. AFTER REWIRING, TURN OFF AND ON THE PLC, CHECK THE STATUS.
2. POWER SUPPLY FAIL.
3. IF AFTER PERFORMING ABOVE AND PROBLEM PERSIST, REPLACE THE MODULE.
1. CHECK IF ALL SENSORS ARE NORMAL.
2. CHECK CONNECTION BETWEEN SENSOR AND TERMINAL CABLE.
3. CHECK WIRING OF SENSOR IS WIRED IF CORRECT.
1. SENSOR CABLE BROKEN OR LOOSE.
1-13 SENSOR FAULT 4. CHECK POWER (440V/380V, OTHERS) AND CABLE OF SENSORS FOR OUTPUT SIGNAL.
2. SENSOR ELEMENT BROKEN.
: NOISE IN THE CABLES COULD CAUSE ALARMS, CHECK CABLE ARRANGEMENT.
5. CHECK IF POWER IS PRESENT.
: CHECK PANEL COMPONENTS FOR BURNT SUCH AS FUSES AND CABLES.

ORP
 2. Compressor

NO. PROBLEM POSSIBLE CAUSE SUGGESTED CORRECTION

1. LIQUID REFRIGERANT REACHING THE COMPRESSOR AND MIXING WITH OIL COULD CAUSE
INSUFFICIENT LUBRICATION AND DAMAGE TO THE MAIN BEARING.

2. THE SETTING OF THE PLANT SHOULD BE ACCORDING TO THE MANUAL TO AVOID ABNORMAL
OPERATIONOF THE SYSTEM. DURING LONG IDLE OR STOP PERIOD OF THE COMPRESSOR,
LIQUID REFRIGERANT MAY ENTER THE COMPRESSOR SUCTION LINE. SUCTION VALVE MUST BE
ADJUSTED FOR PREVENTION.
1. LACK OF PRE-LUBRICATING ON SHAFT SEAL.
MAIN BEARING
2-1 2. LIQUID HAMMERING ON COMPRESSOR. 3. THE FOLLOWING MUST BE CHECKED TO PREVENT LIQUID IN THE COMPRESSOR'S SUCTION.
DAMAGE
3. MATERIAL FAULT.
1) THERMOSTAT – CHECK TEMP. SETTING
2) CHECK EXPANSION VALVE STATUS AND SETTING
3) PUMPING DOWN SHOULD BE DONE WHEN SHUTTING DOWN THE PLANT.

4. CHECK THE OIL LEVEL IN THE SIGHT GLASS. THIS SHOULD BE MORE THAN 1/3 OF THE SIGHT GLASS.
IN ADDITION, HIGH DISCHARGE GAS TEMPERATURE AND OIL TEMPERATURE SHOULD BE CHECKED.
LIQUID INJECTION LINE SHOULD BE ADJUSTED TO MAINTAIN 65C AND BELOW DISCHARGE GAS
1. COMPRESSOR SAFETY VALVE HAS A LEAK IF DISCHARGE AND SUCTION PRESSURE EQUALIZE
2-2 PRESSURE EQUALIZING 1. INTERNAL LEAKAGE ON SAFETY VALVE.
QUICKLY EVEN AFTER REPLAING THE VALVE PLATE.

1. VISUAL CHECK COMP. OIL CHAMBER and SIGHT GLASS

2. CHECK ELECT. EXP. VALVE SETTING
3. CHECK COMP. CONTROLLER SETTING
4. CHECK CAPACITY SOL. VALVE SETTINGS (CAPACITY OPEN/CLOSE).
5. CHECK EVAPORATOR STATUS
6. CHECK C.W TEMPERATURE (SEA WATER 32’C/SEA WATER REG. VALVE STATUS)
2-3 OIL FOAMING 1. LIQUID HAMMERING.
7. COMP. RUNNING CURRENT DISPLAY IN COMPARISON TO CLAMP METER MEASUREMENT.
8. CHECK TEMPERATURE OF OIL RETURN PIPE.
9. CHECK INTERNALS OF OIL RETURN BLOCK.
10. AFTER CHECKING THE RUNNING COMP AMP DISPLAY AND INSTRUMENT AMP,
THE COMP. UNLOADING FRAME AND CYLINDER SHOULD BE CHECKED.
11. CHECK COMP’S INTERNALS, SUCTION AND DISCHARGE RING PLATE FOR DAMAGE.

PSR
 PLEASE CHECK IF THERE'S OIL FOAMING IN COMPRESSOR SIGHT GLASS.
OIL FOAMING IS CAUSED BY LIQUID REFRIGERANT REACHING THE COMPRESSOR AND MIXING WITH
OIL. WRONG ADJUSTMENT OR MALFUCTIONING EXPANSION VALVES ARE MAINLY THE CAUSE OF THIS
PROBLEM. VERIFY IF THE NOISE OCCURS WHEN THERE'S OIL FOAMING.

1. CHECK THE PLANT'S VIBRATION AND SHIP'S VIBRATION DURING BERTHING..

2. CHECK COMP. BED BOLT AND MOTOR BED BOLT TIGHTNESS.
3. CHECK CHAMBER OIL COLOR AND OIL LEVEL.
4. CHECK IF FREON TYPE AND OIL TYPE IS MATCHED ACCORDING THE SPECIFICATION.
5. CHECK C.W SIDE HAMMERING.
2-4 VIBRATION / NOISE 1. INTERNAL DAMAGE OF COMPRESSOR. 6. CHECK SUCTION, DISCHARGE, OIL TEMPERATURE.
7. CHECK CAPACITY AND AMPERE WITH CLAMP AMMETER.
8. INTERNAL INSPECTION
1) CHECK DISCHARGE VALVE RING PLATE DAMAGE.
2) CHECK LINER PARTS SUCTION RING PLATE DAMAGE.
3) CHECK UNLOADING FRAME PARTS FOR DAMAGE.
4) CHECK UNLOADING CYLINDER.
5) CHECK CHAMBER INTERNALS, OIL SUCTION FILTER & OIL FILTER.
6) CHECK HALF BEARING PARTS and PISTON PIN.
7) CHECK OIL PUMP PARTS.
8) INPECTION COMPRESSOR PARTS SUCTION AND DISCHARGE VALVE INTERNALS.
DIFF OIL PRESS HIGH TRIP
2-5 1. CLOGGING OF OIL FILTER IN THE COMPRESSOR SIDE. 1. CHANGE THE OIL FILTER IN THE COMPRESSOR SIDE.
DIFF OIL PRESS HIGH WARNING

2-6 OIL SEP TEMP LOW TRIP 1. FAULT OF COMPRESSOR OIL HEATER 1. CHECK CONNECTION BETWEEN OIL TEMPERATURE SENSOR, OIL HEATER AND CABLE.

2-7 OIL FILTER S/W WARNING 1. CLOGGING OF OIL FILTER IN THE COMPRESSOR SIDE. 1. CHANGE THE OIL FILTER IN THE COMPRESSOR SIDE.
1. CHECK THE COMPRESSOR ROTATION
2-8 OIL STOP S/W TRIP 1. COMPRESSOR ROTATION 2. CHECK THE OIL STOP SWITCH SENSOR STATE
3. CHECK CONNECTION BETWEEN OIL STOP SENOSR
1. CHECK THE OIL RETURN LINE STATE
1. CLOGGING OF OIL RETRUN LINE.
2-9 OIL SUPPLY S/W TRIP 2. CHECK THE OIL SUPPLY SWITCH SENSOR STATE
2. FAULT THE OIL SUPPLY SWITCH.
3. CHECK CONNECTION BETWEEN OIL SUPPLY SENOSR
1. IF COMPRESSOR OIL IS LOWER THEN SIGHT GLASS LEVEL. 1. KEEP AT LEAST 1/2 COMPRESSOR OIL LEVEL OF SIGHT GLASS.
2-10 OIL LEVEL S/W TRIP
2. FAULT OF COMPRESSOR OIL LEVEL SWITCH 2. CHECK CONNECTION BETWEEN OIL LEVEL SWITCH.
1. FAULT OF MOTOR PROTECTION SENSOR. 1. CHECK THE MOTOR STATE. ( INSULATION RESISTANCE )
2-11 MOTOR PROTECTION TRIP
2. BURNT & LOW INSULATION OF FAN MOTOR COIL 2. CHECK CONNECTION BETWEEN MOTOR AND POWER PANEL.

ORR
 3. Condenser

NO. PROBLEM POSSIBLE CAUSE SUGGESTED CORRECTION

1. CHECK IF HIGH PRESSURE EXIST IN A/C COMPRESSOR.
2. CHECK IF THE LEVEL OF REFRIGERANT IN THE CONDENSER IS HIGH
1. HIGH TEMPERATURE OF COOLING WATER. 3. SEPARATE THE SAFETY VALVE TO THE PURGE LINE PERFORM LEAK TEST BY LEAK DETECTOR OR
3-1 SAFETY VALVE LEAKAGE 2. LOW FLOW RATE OF COOLING WATER. BY BUBBLE TEST.
3. NON-CONDENSIBLE GAS INSIDE CONDENSER 4. CHECK THE CONNECTION OF SAFETY VALVE ON THE CONDENSER BY BUBBLE WATER AND LEAKAGE
DETECTOR BECAUSE SOMETIMES THE THREAD OF THAT BECOMES WEEK.
5. USE THE PURGE VALVE ON THE CONDENSER TO DISCHARGE THE NON-CONDENSIBLE GAS.
1. CHECK IF THE CONDENSER COOLING WATER LINES ARE OPEN
2. AFTER CHECKING THE STATUS OF THE LT LINE PUMP, ALSO CHECK THE PRESSURE THROUGHT
THE GUAGE.
CONDENSER COOLING
1. HIGH TEMPERATURE OF COOLING WATER. 3. CHECK IF COOLING WATER IS FLOWING THROUGH THE DRAIN VALVE.
3-2 WATER TEMP HIGH,
2. LOW FLOW RATE OF COOLING WATER. 4. CHECK CONDENSER COOLING WATER INLET TEMPERATURE IS NOT HIGH.
HIGH PRESSURE TRIP
5. CHECK INLET AND OUTLET VALVE OF THE CONDENSER IF SUSPECTING MALFUNCTION .
6. CHECK/CLEAN CONDENSER COVER AND CONDENSER TUBE CONTAMINANTS IN THE CONDENSER
REDUCES EFFICIENCY OF HEAT EXCHANGE.
1. POLLUTED DRIER FILTER MAKES PRESSURE DROP, LOW EFFICIENCY OF HEAT EXCAHGE THAT MAKES
DAMAGE OF COMPRESSOR BY LIQUID. SO, FILTER SOULD BE CHANGED REGULARLY.
2. OPEN THE BYPASS VALVE WHEN REPLACING THE DRIER CORE. CLOSE THE ISOLATION VALVE
DRYER FILTER 1. WATER CONTAMINATION. OF THE FILTER DRIER THEN OPEN THE BYPASS VALVE.
3-3
CLOGGED 2. EXCEED OF MAINTENANCE PERIOD. 3. WHEN REPLACING FILRE DRIER CORE, ALSO CHECK THE GASKET IF STILL USABLE. REPLACE IF
NECESSARY AND CHECK FOR LEAKAGE AFTER CLOSING.
4. IF OUTLET OF DRYER FREEZE, THIS MAY BE DUE TO CLOGGING OF THE WIRE SCREEN.
IN THE CASE, THE DRYER SHALL BE CLEANED AND DRIED.
COOLING WATER PRESS 1. CHECK IF COOLING WATER PUMP IS RUNNING.
3-4 1. LOW FLOW RATE OF COOLING WATER.
LOW TRIP 2. CHECK IF COOLING WATER PRESSURE S/W IS NORMAL AND ADJUST PRESSURE SET VALUES.

PST
Maintenance manual
 Maintenance Manual

Contents

1. Chiller Unit
2. Panel
 1. Chiller Unit

Interval
No Item Task Description
Inspection Replacement

1.1 External inspection and leakage check. Visual check any leakage during routine UMA

Visual check oil level in the oil separator

1.2 Check oil level in the oil separator.
and crank chamber
Compressor
1.3 Check operating pressure and temperature. Visual check operating condition of compressor. Daily
Common
Visual check any vibration or noise
1.4 Check for unusual vibration or noise.
from the compressor with motor.
Should be recorded operating condition
1.5 Record operating date in the log book.
for the unit in log book or check sheet.
Leak rate of the shaft seal should be checked
by compressor manual. If the leak rate increased
1.6 Shaft seal 10,000h 20,000 / 40,000h
than normal leak limit, should be checked
or replace the shaft seal with new one.

1.7 Pressure relief valve Refer to compressor maintenance instruction. 100,000h

1.8 Check valve Refer to compressor maintenance instruction. 5,000h 20,000 / 40,000h

1.9 Oil solenoid valve Refer to compressor maintenance instruction. 5,000h 100,000h
Screw
Compressor
1.10 Oil stop valve Refer to compressor maintenance instruction. 5,000h Occurring leakage

1.11 Oil flow switch Refer to compressor maintenance instruction. 5,000h 100,000h

1.12 Oil filter Refer to compressor maintenance instruction. 5,000h

1.13 Roller bearing Refer to compressor maintenance instruction. 10,000h 40,000 / 50,000h

Check normal energizing on the coil and motor

1.14 Capacity Solenoid Valve Every 3 month
ampere with compressor's load.

1.15 Refrigerant Level Visual check refrigerant level to check any leakage. Every day

Check any clogging or damage on filter mats

1.16 Filter Drier Every 3 month Every 6 month
and change if need.
Condenser
Visual check any crack and check any flash gas
1.17 Drier Sight Glass
in the condenser.

1.18 Check Valve with gland Check any leakage from the gland. Every month

1.19 Stop Valve with gland Check any leakage from the gland.

1.20 Tubes Check normal working condition.

1.21 Evaporator Freezing Check any freezing through. Every month

1.22 Corrosion Check any corrosion

Check normal working voltage and opening

1.23 Expansion Valve Electric Every month
with superheat controller set values.
Correct q'ty of grease should be put
1.24 Grease maintenance Every month
by specified interval.
Visual check any loosen or damage on cable
1.25 Cable
with lugs and terminal.

1.26 Pump Connector Visual check any corrosion and fixing condition. Every 6 month

Measure the phase resistance and megger

1.27 Ground (Phase resistance & insulation)
insulation by periodically.

1.28 Bearing Visual check any abnormal sound and noise. Every year

1.29 Switch Check wiring connection and function test.

1.30 Dial Gauge Check any leakage and normal fixing status.
Sensor Every month
1.31 Pressure Transmitter Check the cable connection.

Check the cable connection and measure the

1.32 Temperature Sensor
resistance of the sensor.

ORV
 2. Power/control Panel

Interval
No Item Task Description
Inspection Replacement
Check normal working condition (Green Lamp)
2.1 PLC
and connection on modules.

2.2 Touch Screen Check any abnormal indicating condition or color.

Periodically check wiring connection

2.3 Panel MCCB / Contactor / OCR (EOCR) Every 3 month
and tips' condition.
Visual check any loosen or damage on cable
2.4 Cable
with lugs and terminal.
Compare the indicated position
2.5 Ampere meter
with actual current measured by clamp meter.

2.6 Terminal Board Visual check any corrosion and fixing condition.
Junction Box Every 3 month
Visual check any loosen or damage on cable
2.7 Cable
with lugs and terminal.

OSM
1.1 Condenser cleaning

Before condenser cleaning, pump-down must be carried out.

Cooling water must be drained from condenser.

The condenser should be cleaned every six months.

1) Unscrew the bolt on end cover from tube plate.

2) Remove the end cover.

3) Cleaning the internal tube using the soft brush.

4) Refer to below figure;

1.2 Corrosion plug replace

Before corrosion plug replacement, pump-down must be carried out.

Cooling water must be drained from condenser.

Corrosion plugs should be checked or replaced every three months.

1) Unscrew the bolt on anode cap from end cover.

2) Remove the anode cap.

3) Remove the corrosion plug and o-ring from end cover.

4) Install new corrosion plug and o-ring to end cover.

5) Place anode cap.

6) Install screw to end cover.

7) Refer to below figure;